Ceramic Helical Coil Mold With Extractable Core for Series Casting
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Solution Overview
Problem
Existing methods for producing cast Cu coils or Cu alloy coils are not suitable for series production in permanent molds, leading to lower power or torque density in electrical machines due to suboptimal filling of installation space and heat dissipation issues.
Innovation Solution
A casting mold system using a ceramic die and core puller in a permanent mold design, allowing for the production of helical cast bodies like coils or spirals, with the core puller moving in multiple directions for demolding and ceramic materials used to prevent thermal damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lost molds (investment casting or lost foam process) are used to produce cast Cu coils, then the production of cast metal coils is enabled, but the service life of the molds is limited and productivity is reduced
Solution Approach 1:
The mold system is segmented into a permanent outer die and a removable inner mold core. The die serves as a reusable permanent component that establishes the outer contour, while the mold core defines the inner hollow space and can be extracted. This segmentation allows the permanent die to be reused across multiple production cycles, significantly improving mold service life and productivity compared to traditional lost mold processes.
Solution Approach 2:
The mold core is designed to be extractable from the cast body after solidification. By taking out the inner mold core, the hollow interior of the coil is formed, and the permanent die can be reused for the next casting cycle. This extraction mechanism enables series production with permanent molds, resolving the contradiction between mold durability and productivity.
2Volume of moving object
If conventional winding methods are used to produce coils, then the installation space can be filled, but the power or torque density is reduced due to suboptimal space utilization
Solution Approach 1:
The invention changes the geometric parameters of the coil by using a conical or pyramidal die contour instead of conventional cylindrical winding. This parameter change allows the coil to better fit the available installation space, optimizing the volume utilization and thereby increasing power or torque density without compromising electrical performance.
3Volume of moving object
If complex coils are manually produced to improve fill level, then the installation space utilization is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention replaces the complex manual winding process with a simplified casting process. Instead of manually winding conductors to achieve optimal fill levels, the cast coil is formed directly in the permanent mold with the desired geometry, achieving both high fill level and ease of manufacture through automated casting operations.
4Shape
If wire windings are stacked from inside to outside, then the coil structure is formed, but heat dissipation is adversely affected resulting in greater heating
Solution Approach 1:
The invention changes the structural parameters of the coil by forming it as a cast body with a conical or pyramidal contour instead of conventional stacked windings. This geometric transformation improves heat dissipation characteristics while maintaining the necessary coil structure for electrical functionality, thereby reducing operating temperature.
Data Source
AI summary
The invention relates to a casting mould for producing helical cast bodies (1), in particular coils, springs or spirals, having a mould (10) in the form of a permanent mould which determines the outer contour of the helical body and consists of a ceramic material or is coated by a ceramic material; a supporting tool (8), which supports the mould (10) from outside; and a mould core (12), which defines the continuous opening within the helical body (1) and consists of a ceramic material or is coated by a ceramic material, the mould core being formed in particular as a core puller.