Integrated Housing Cover Forming via Separation and Axial Relocation
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Solution Overview
Problem
Existing methods for manufacturing electric motor housings with integrated covers and stator/control electronics compartments are costly due to separate production and assembly of individual parts, and die-casting results in high expenses.
Innovation Solution
A method involving the monolithic production of a housing precursor with the cover integrated at one end of the housing wall, followed by separation and positioning within the housing wall, allowing for assembly in a single production facility using conventional forming processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the housing is manufactured using a die-casting process to produce a complex housing with integrated cover, then the housing structure complexity is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The housing manufacturing process is segmented into two main phases: first producing a preliminary stage housing with the cover formed at one end, then separating the cover from the housing wall and positioning it at the predetermined location. This segmentation allows conventional forming processes to be used instead of expensive die-casting while achieving the complex integrated structure.
Solution Approach 2:
The cover is formed in advance as an integral part of the housing wall at one end during the preliminary stage housing production. This preliminary action eliminates the need for separate cover production and positioning steps, reducing manufacturing complexity and cost while maintaining the integrated structure benefit.
2Adaptability or versatility
If individual parts (housing wall and cover) are manufactured separately using deep-drawing process and then assembled, then the manufacturing flexibility is improved, but the production cost increases due to separate tools and fixtures
Solution Approach 1:
The production of the housing wall and cover is merged into a single operation where the cover is formed as an integral part of the preliminary stage housing. This merging eliminates the need for separate tools and fixtures for cover production and assembly, reducing production costs while maintaining the flexibility to position the cover at the predetermined location.
Solution Approach 2:
The cover is preliminarily formed in its final position relative to the housing wall during the preliminary stage housing production. This preliminary positioning action eliminates subsequent positioning steps and reduces the need for separate assembly fixtures, thereby reducing production costs while maintaining manufacturing flexibility.
3Adaptability or versatility
If the cover is positioned at the predetermined position within the housing wall, then the functional separation of stator and control electronics is improved, but the manufacturing process complexity increases
Solution Approach 1:
The manufacturing process is segmented into preliminary stage production followed by cover separation and positioning. This segmentation allows the cover to be formed in its final functional position during preliminary production, achieving functional separation while managing manufacturing complexity through structured process steps.
Solution Approach 2:
The cover is preliminarily formed at the predetermined position within the housing wall during preliminary stage production. This preliminary positioning ensures the correct functional separation of stator and control electronics compartments while simplifying the overall manufacturing process by eliminating subsequent complex positioning operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces manufacturing time and costs by integrating cover formation with the housing wall, enabling efficient assembly and positioning without additional positioning steps, thus lowering overall production expenses.
Implementation Method 1
manufactured from a single blank in a forming device
Implementation Method 2
separating the cover from the housing wall
Implementation Method 3
displacing it relative to the housing wall in the direction of the longitudinal axis from the one longitudinal end into the predetermined position
Implementation Method 4
joining the cover to the housing wall in the predetermined position
Data Source
Figure 1
Figure 2~2A
Figure 3
AI summary
A method for producing a housing (10) which has a sleeve-shaped housing wall (14), extending about a longitudinal axis (12) of the housing (10), and a cover (16), which is arranged on the inner face of the housing wall (14) at a predetermined position between longitudinal ends (18, 20) of the housing wall (14) and transverse to the longitudinal axis (12), comprises: making available a preliminary form (28) of the housing (10), in which the cover (16) is formed integrally with the housing wall (14) and is arranged on one of the longitudinal ends (18, 20) of the housing wall (14), separating the cover (16) from the housing wall (14), and moving the cover (16) relative to the housing wall (14) in the direction of the longitudinal axis (12) from one longitudinal end (18) to the predetermined position. A device for carrying out the method is also described.