W 型铸铝水冷机座压铸新工艺
发布时间：2020-07-20 14:07
<p style="margin-top: 0px; margin-bottom: 0px; padding: 0px; max-width: 100%; clear: both; min-height: 1em; color: rgb(51, 51, 51); font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; font-size: 17px; letter-spacing: 0.544px; text-align: justify; white-space: normal; background-color: rgb(255, 255, 255); line-height: 1.75em; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;">本文介绍了一种环保能源牵引电机及发电机定子机座的制造方法。通过压铸模具的设计，在内筒体 上铸出 W 型水道 和 W 型阴槽及焊缝保护法兰；在外筒体上铸出 W 型阳槽，内外筒体压力铸造；然后在压力状 态下通过 W 型导向，对内外筒体进行预热压装；最后内外筒体进行组焊制成电机定子水冷机座。本工艺结构巧 妙，工序简单，防漏水、窜水，结构可靠。</span></p><p style="margin-top: 0px; margin-bottom: 0px; padding: 0px; max-width: 100%; clear: both; min-height: 1em; color: rgb(51, 51, 51); font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; font-size: 17px; letter-spacing: 0.544px; text-align: justify; white-space: normal; background-color: rgb(255, 255, 255); line-height: 1.75em; box-sizing: border-box !important; overflow-wrap: break-word !important;"><br/></p><p style="margin-top: 0px; margin-bottom: 0px; padding: 0px; max-width: 100%; clear: both; min-height: 1em; color: rgb(51, 51, 51); font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; font-size: 17px; letter-spacing: 0.544px; text-align: justify; white-space: normal; background-color: rgb(255, 255, 255); line-height: 1.75em; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;">随着动车动力包、电动汽车、地铁电机制造技 术的迅速发展，铸铝水冷机座结构在电机制造中广 泛应用。绿色环保能源电动汽车电机，高速动车动 力包发电机，机场大巴电机，轨道用城市交通永磁 牵引电机大多是采用铸铝水冷机座。 水冷铸造机座散热效果良好是满足电机制造 的关键，其主要制造过程包括金属熔炼技术、成型技术、装配技术、加工技术等几个方面。铸铝水冷机 座的结构是否合理、质量的优劣、直接影响该类电 机运行可靠性、劳动生产率及经济效益。应用结构 合理铸铝水冷机座结构，可以提高该类电机机座的运行可靠性，缩短了制造周期，节省了制造成本，提 高劳动生产率及经济效益。</span></p><p><br/></p><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; color: rgb(123, 12, 0);"><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 18px;">一、 水冷机座目前生产技术状况</span></strong></span><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 18px;"> </span></strong></section><p></p><section><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 18px;"><br/></span></strong></section><section><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;">1.1 工艺方法</span></strong><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;"></span></section><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;"> 国内外电机同行业中铸铝水冷机座制造方式 有：整体进行砂型铸造，分体砂型铸造，挤压成型等 方式。整体铸造工艺流程是：模具芯盒制造 - 砂型 砂芯制作 - 合金熔炼 - 合箱 - 浇注 - 清理 - 成品。 分体铸造工艺流程是：模具芯盒制造 - 砂型砂芯制 作 - 合金熔炼 - 合箱 - 浇注 - 清理 - 加工 - 焊接 - 组装形成机座毛坯。挤压成型工艺流程是：模具制 造 - 铸铝熔炼 - 浇注铝锭 - 高压挤压成型 - 焊接 - 机座毛坯。</span></section><section><br/></section><section><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;">1.2 传统工艺方法存在的不足</span></strong><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;"></span></section><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;">整体铸造铸铝水冷机座，存在问题是机座成品 率低，制造周期长，最大难题是水道砂芯清理困难， 水道砂芯固定困难；分体砂铸铸铝水冷机座结构，存在的问题是制作过程繁琐，周期过长，质量难于控 制，且需要对内外筒体预加工，且需端面封焊，加工 后容易漏水；挤压成型铸铝水冷机座结构：受压力机 吨位限制，大型机座无法实现，且也存在封焊焊缝需 要加工有漏水风险，往往由于焊接质量问题造成机 座漏水而影响机座性能，甚至造成电机的报废。</span></section><section><br/></section><section><br/></section><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; color: rgb(123, 12, 0);"><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; font-size: 18px; box-sizing: border-box !important; overflow-wrap: break-word !important;">二、 新工艺方法构思与目标</span></strong></span></section><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;"><br/>通过分析传统工艺方法存在的不足，提出一种新工艺，其特点包括：1）内、外高压一次成型铸造。2）冷却通道结构特征在内、外筒体一次成型。3）省去了机座冷却水道加工难度大、加工时间 长的工序。4）将焊缝控制在法兰内侧，焊缝不得加工，解决了机座在焊接过程出现的打压漏水问题。5）在水道壁处设置定位和防窜水结构，提高机 座的可靠性。6）过盈热套成型。</span></section><p></p><p><br/></p><p style="text-align: center;"><img src="https://www.luliaohui.com/uploads/home/article/5efd7b716838c.png"/></p><section><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; color: rgb(123, 12, 0);"><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; font-size: 18px; box-sizing: border-box !important; overflow-wrap: break-word !important;">三、 新工艺具体实施过程 </span></strong></span></section><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; color: rgb(123, 12, 0);"><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; font-size: 18px; box-sizing: border-box !important; overflow-wrap: break-word !important;"><br/></span></strong></span></section></section><p style="margin-top: 0px; margin-bottom: 0px; padding: 0px; max-width: 100%; clear: both; min-height: 1em; color: rgb(51, 51, 51); font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; font-size: 17px; letter-spacing: 0.544px; text-align: justify; white-space: normal; background-color: rgb(255, 255, 255); box-sizing: border-box !important; overflow-wrap: break-word !important;"><br/></p><p></p><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;"> 压铸新工艺的流程是：模具制造 - 合金熔炼 - 压铸 - 热套 - 焊接 - 机座毛坯。通过压铸方法将内 外筒水道铸造成型，不需进行加工。充分利用压铸的特点，速度快、表面光洁度高， 采用压铸工艺方法，压铸成外筒体、内筒体。在内筒 体上铸出 W 型水道结构和导向 W 槽见图 2；外筒 体铸出导向与锁紧结构，内外筒体同时进行预热， 然后将内外筒体进行热套如图 3</span></section><p></p><p><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;"><br/></span></p><p style="text-align: center;"><img src="https://www.luliaohui.com/uploads/home/article/5efd7b8b18d90.png"/></p><p><span style="color: rgb(51, 51, 51); font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; letter-spacing: 0.544px; text-align: justify; background-color: rgb(255, 255, 255);">封口焊接成机座 毛坯如图 4 所示。新工艺优点是：1）内外筒体直接 通过压铸成型，不进行加工水道。2）外筒体带内法 兰、内筒体带外法兰对焊缝进行保护。3）内外筒体 进行预热进行过盈热套。4）设置导向和锁紧装置保 证机座可靠性。</span></p><p style="text-align: center;"><span style="color: rgb(51, 51, 51); font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; letter-spacing: 0.544px; text-align: justify; background-color: rgb(255, 255, 255);"><img src="https://www.luliaohui.com/uploads/home/article/5efd7bb5b8653.png"/></span></p><p><br/></p><section><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 18px; color: rgb(123, 12, 0);">四、结 论</span></strong></section><p></p><section><strong style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 18px; color: rgb(123, 12, 0);"><br/></span></strong></section><section><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; overflow-wrap: break-word !important; font-size: 16px;">W 型水冷机座生产新工艺在国内专业电机制 造行业尚属先例，在吸收国内外铸铝机座制造技术 基础上，结合铸件结构，采用特殊工艺方法，在实现 W 型铸铝水冷机座制造过程中，充分发挥压力铸造 特点，采用预热过盈装套，巧妙设置焊缝保护、防漏 水结构，实现 W 型铸铝水冷机座制造。缩短产品研 制周期，降低电机制作难度、劳动强度，简化电机关 键件制造流程，提高制造运行可靠性，有效控制电 机制造成本。</span></section><p></p><p><span style="color: rgb(51, 51, 51); font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; letter-spacing: 0.544px; text-align: justify; background-color: rgb(255, 255, 255);"><br/></span><br/></p>
