Cooling Element Removal Protrusion for Cast Housing
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Solution Overview
Problem
Manual removal of cooling elements from demoulded cast parts is inefficient and prone to errors, especially in the production of light metal alloy housings for electric motors, where low porosity and high strength are critical for reliable cooling and mechanical properties.
Innovation Solution
A device with a gripping mechanism using removal protrusions attached to the cooling elements, allowing for automated removal and centring, enabling the use of a stationary removal apparatus to move relative to a cast part or vice versa, with detachable connections for easy maintenance and simultaneous removal of multiple elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual removal of cooling elements is used, then device complexity is reduced, but productivity decreases and manufacturing precision deteriorates
Solution Approach 1:
The cooling element itself provides the gripping function through its own removal protrusion, eliminating the need for complex external gripping mechanisms. The protrusion on the cooling element engages directly with the gripping means, allowing the cooling element to essentially remove itself through the automated apparatus.
Solution Approach 2:
The removal protrusion is separated from the main cooling element body, allowing for independent optimization of the gripping interface. This segmentation enables the protrusion to be specifically designed for engagement with the gripping means while the cooling element body maintains its cooling function.
2Manufacturing precision
If automated removal with centring is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The gripping means serves multiple functions: it grips the removal protrusion for automated removal, provides centring of the cooling element, and enables consistent positioning for subsequent reuse or reintegration. This multi-functionality reduces the need for separate centring and positioning mechanisms.
Solution Approach 2:
The removal protrusion acts as an intermediary element between the cooling element and the gripping means. This protrusion transfers the gripping force and enables the centring action, serving as a mediator that simplifies the overall positioning system.
3Ease of repair
If detachable connection is used for removal protrusion, then ease of repair improves, but strength decreases
Solution Approach 1:
The removal protrusion is designed as a separate, detachable component from the cooling element body. This segmentation allows the protrusion to be easily replaced if damaged, while the connection strength is maintained through robust attachment methods such as welding or mechanical fastening of the protrusion to the cooling element.
Data Source
AI summary
The invention relates to a device for removing at least one cooling element from an at least partially demoulded cast part, in particular from a cast housing for an electric motor formed from a light metal alloy, which has an apparatus for removing the at least one cooling element. Furthermore, the invention relates to a method for removing at least one cooling element from an at least partially demoulded cast part, a method for introducing at least one cooling element into a mould core of a cast part mould, a cooling element, and a cast part.