Energy supply housing

Different housings are used to protect electronic components, such as battery systems or power electronics, from external environmental influences and to attach the components to the interior in order to ensure that they function properly during vehicle operation. The requirements for the housing depend on the electronic system and drive concept. Different materials and manufacturing processes are currently used.

FEATURES

• Unstable, thin-walled components (susceptible to vibration)
• Construction as a cast tub or as a frame construction made of hollow profiles
• Partly low-silicon aluminium
• Large area (2 x 3 m)
• Mainly drilling and milling operations and threading
• Accuracy and surface requirements for cable bushing and cooling
  connections

Extruded profile

Extruded profile

Due to the increasing size of the battery, modular concepts for different performance classes and ranges are used. For this reason, extruded aluminium profiles are welded to form a housing.

MACHINING REQUIREMENTS

• Thin material with several layers
• Drilling: Vibrations and burr formation. Ring formation on the tool → Helix milling/orbital drilling prevents burrs and rings
• Milling: Thin material tends to vibrate → Fewer vibrations through optimised
  cutting edge geometry

Die-cast housing

Druckgussgehäuse

Für die Unterbringung der Leistungselektronik oder kleinere Batteriesysteme für Hybridfahrzeuge werden meist Druckgussgehäuse aus Aluminium verwendet. Die komplexen Gehäusestrukturen werden mit integrierten Kühlkanälen ausgeführt.

ZERSPANUNGSANFORDERUNGEN

• Fräsen von Dichtflächen (teilweise spezielle Oberflächenanforderungen)
• Fräsen von Aufnahmeflächen für Elektronik und Batteriezellen bei langer Werkzeugauskragung​​​​​​​
• Bohren von Kernlöchern (> 50 Bohrungen pro Bauteil)

Werkzeugübersicht