Continental Engineering Companies UK (CES) are a number one automotive design consultancy and engineering companies supplier for electrical motors, inverters, PDUs and DCDCs. CES push boundaries, maximising energy density, minimising packaging quantity and element lots. Clients at all times have very aggressive goal weights requiring extremely environment friendly cooling methods. That is the place progressive packaging options grow to be important in offering engineering options and assembly prospects’ necessities.
In CES’ newest undertaking, the necessities to combine into the car energy practice had been such that the one approach to obtain a design answer was to mix the motor and inverter, using a novel cooling structure. This design meant that delicate inside castings with skinny partitions can be required and thus CES began trying on the newest casting strategies and the companies that Sylatech present.
Sylatech was eager to display that its clear sheet reappraisal of sand-casting methodology may provide new alternatives for element design and was keen to satisfy the difficult goal of an ultra-lightweight motor-inverter housing with skinny solid wall thicknesses which are nonetheless machinable.
A 3D idea was designed which then went by means of the usual CES pc simulations and analyses primarily based on buyer necessities. As enhancements and efficiencies had been made, the housing design went by means of a number of iterations. As a part of this design loop, Sylatech carried out their casting simulations and had been in a position to suggestions to CES in a constructive design loop as a accomplished design was finalised.
Sylatech proposed a 100% (Voxeljet) sand printed answer to make sure design flexibility was as free as doable all through the undertaking life cycle. Having supported with casting Design for Manufacture, the corporate set about calculating and modelling a runner system with a relentless fill charge of 0.5m/sec. Commonplace options equivalent to a pouring basin and stopper, constrained sprue and runners, vortex traps (to seize the forefront of oxide-rich aluminium) had been shortly established, adopted by extra nuanced additions equivalent to 60PPI filters on all gates flowing into the mould cavity. Velocity, temperature, gate stream stress and dendrite arm spacing simulations had been then modelled with Sylatech’s FLOW3D CAST software program.
Sylatech’s casting new product introduction (NPI) engineer favours this digital method to sample design. FLOW 3D allows exact understanding of how the metallic flows within the runner system and cavity. The selection of casting solely with sand printed moulds yields important design freedom however the draw back is that it leaves no room for error. Any casting defects would end in costly re-prints. It’s due to this fact crucial that the NPI course of locations such a powerful emphasis on fill calculation and simulation verification. Thus, a complete of twenty-two iterations of runner system had been accomplished earlier than a last design freeze was agreed.
CES’ capability to make use of CFD, FEA and Thermal computational evaluation software program along side Sylatech’s casting evaluation software program was integral to the design course of to satisfy necessities, ‘proper first time’ and shortened deadlines. It’s crucial to have the ability to design, analyze/simulate, and experiment nearly in order that the completed design can meet the targets in actual world testing.
Complimentary to the software program analyses is the usage of non-destructive testing (NDT) on the pre-machined solid half. Radiography is right for expedited integrity checks, offering reside, nonetheless and video imaging which may be considered in actual time earlier than greenlighting the machining course of.
The ultimate housing design achieved round 64% weight saving from preliminary design to last product and is roughly 47% underneath the coolant stress drop requirement, but meets stress, vibration and fatigue targets. Early communication, cross celebration adoption of analytical strategies for design, manufacture and testing and on-going efficient collaboration had been essential to reaching these goals.
