電気駆動

さまざまなハウジングタイプの機械加工条件&特性

高度に統合されたハウジング

Highly integrated electric motor housing

Description: Highly integrated, complex housing with stator mount, transmission mount and connection for the power electronics. High functional integration saves assembly costs. Compact design. Complex cast housing as a result.

FEATURES

• Stator incorporated directly in the housing or via a stator carrier / cooling jacket
• Stator bore with stages and flat surfaces as functional surfaces
• A bearing bore of the rotor is integrated coaxially with the stator bore in the housing
• Positioning of the second bearing cover via dowel pins or fitting surfaces; second bearing bore must be coaxial
• Bearing bores of transmission stages integrated in the housing; high concentricity and positional accuracy are required
• Cooling channels partially integrated in the housing
• Complex cast aluminium housing

MACHINING REQUIREMENTS

• Elaborate contour trains with several diameter levels ( high cutting forces and large machining volume)
• Mixed processing (-> chip separation / removal)
• Interrupted cuts (-> contacting, cooling circuit)
• 15°-30° flat lead-in chamfers (-> flow chip formation and high radial forces)

Pot-shaped housing

Pot-shaped electric motor housing

Description: To reduce the complexity, in particular to implement a simpler construction of the cooling jacket, pot-shaped or bell-shaped housings or stator supports are used.

FEATURES

• As an intermediate housing for integration in the overall system
• Stator bore with stages and flat surfaces as functional surfaces
• A bearing bore of the rotor is integrated coaxially with the stator bore in the housing
• Positioning via fitting surfaces on the outer surface
• Cooling channels as ribs on the outside
• Thin-walled, susceptible to vibration
• Tension problematic

MACHINING REQUIREMENTS

• Extremely thin-walled parts (-> ap corresponds to wall strength)
• Outer cooling ribs must be machined
• Pot or bell shape (-> promotes vibrations, special clamping concepts and vibration dampers)
• 15°-30° flat lead-in chamfers (-> flow chip formation and high radial forces)

Tubular housing

Tubular electric motor housing

Description: The simplest design of motor housings is tubular. The length of the housing and thus the electrical machine can be varied comparatively easily for different powers. As a result, the installation effort increases due to the low level of functional integration.

FEATURES

• No rotor bearing bores integrated in the housing
• Two bearing covers to hold the rotor
• Positioning of the two bearing covers over fitting surfaces for coaxiality of the bearing points
• Minimal complexity
• Practically rotationally symmetrical
• Thin-walled, susceptible to vibration
• Tension problematic

MACHINING REQUIREMENTS

• More stable components usually with an internal cooling structure
• Extruded profiles also possible (AlSi1 -> flow chips)
• Without clamping straps (-> special clamping concepts)
• Partly with fits on both sides in IT6 tolerance

Hybrid housing

Hybrid transmission housing and hybrid module/intermediate housing

Description: Integration of the electrical machine into the existing transmission architecture using disk-shaped hybrid modules or intermediate housing. Space neutral structures are also implemented with partially pot-shaped housings as slide-in parts.

FEATURES

Hybrid module/intermediate housing

• Mainly incorporation of the stator
• No rotor bearing with disc shape
• Rotor bearing integrated with pot shape

Hybrid transmission housing

• Extreme length-diameter ratios
• Thin-walled, susceptible to vibration
• Elaborate contour trains
• Interrupted cut

MACHINING REQUIREMENTS

Hybrid transmission housing

• IT6 tolerance
• High demands on coaxiality and stage dimensions
• Restricted maximum weight and moment of tilt

Pre-machining

Pre-machining

The use of an ISO boring tool is particularly suitable for pre-machining. This method allows high cutting speeds and feed rates to remove material quickly and economically. Under specific conditions, for example with precisely pre-cast parts and corresponding machine conditions, the first roughing operation can be omitted.

Semi-finishing

Semi-finishing

During semi-finish machining, the complex contour train of the electric motor housing is prepared. This is done in such a way that the complete contour with chamfers and radial transitions are produced in the required quality during finish machining. This step allows the housing to be shaped optimally. Depending on spindle power and stock removal, it may be necessary to split the semi-finish machining into two steps.

Finishing

Finishing

In the final step, the stator drilling is precisely machined with a fine boring tool that has finely adjustable indexable blades and guide pads.

External Machining stator housing

External machining of stator housings for electric motors is a demanding task. These housings, which often come in tubular or pot-shaped designs, are crucial for the efficiency of the electric motor. Several challenges have to be overcome during the process. The thin-walled aluminium housings with integrated ribs for the cooling circuit require the highest precision in terms of diameter accuracy, shape and position tolerances. The concentricity between different diameters is of huge importance.

加工ソリューション...

Basic

標準ツールによるプロトタイプソリューション

• 高い柔軟性
• 前加工および仕上げ加工用システム
• モジュール構造
• 標準プログラム Ø87-1000mmから
• ミクロン精度で調整可能なファインボーリングショートクランプホルダー
• 容易な取り扱い

粗加工

• ヘリカルミル

  ISOインサート付き 

  • コーティングされた超硬製のPCDインサートまたはPCDインサート 
  • 切削抵抗の軽減 
  • 標準製品 
  • 様々な加工深さに対応するHSKエクステンション 

• ModulBore

  ブリッジモジュール付きドリルヘッド 

  • 粗加工および仕上げ加工用システム 
  • モジュール構造 
  • ISOショートクランプホルダー

粗加工および仕上げ加工

• ModulBore

  ボーリングやファインボーリング時の高い柔軟性 

  • 粗加工および仕上げ加工用システム 
  • モジュール構造 
  • 標準プログラムø87mm–1000mmから 
  • ミクロン精度で調整可能なファインボーリングショートクランプホルダー 
  • 容易な取り扱い 

Performance

HSK-63/HSK-100による生産ソリューション

適合した性能と要件範囲を備えたプロセス信頼性の高いソリューション

• 3段階のプロセス (前加工、中仕上げ加工、仕上げ加工)
• 特に軽量な工具
• コンパクトな機械で大型部品を加工
• ロット・中ロットに最適なソリューション

Pre-machining

• Helix milling cutter

  with ISO indexable inserts

  • Coated ISO indexable inserts made of carbide or PCD-tipped indexable inserts
  • Reduced cutting forces
  • Standard product
  • HSK extension for different machining depths

• PCD form cutter

  contour machining the bottom of the bore

  • Brazed cutting edge
  • Special contours possible
  • Can optionally be used with HSK extensions

Semi-finish-machining

• プレジションボーリングツール

  ISOインサート付き 

  • マガジンチェンジャーに適合した工具形状 
  • コーティングされた超硬製のPCDインサートまたはPCDインサート 

• プレジションボーリングツール

  一段式または多段式 

  • ISOショートクランプホルダー 
  • PCDロウ付けISOインサート 
  • アルミニウム製のツール本体

• プレジションボーリングツール

  一段式または多段式 

  • ISOショートクランプホルダー 
  • PCDロウ付けISOインサート 
  • アルミニウム製のツール本体 

仕上げ加工

• ファインボーリング工具

  ガイドパッド付き 

  • PCDインサート 
  • 微調整可能 
  • PCDガイドパッド 
  • マガジンチェンジャーに適合した工具形状 

• ファインボーリング工具

  スチール製軽量構造 

  • PCDインサート 
  • スチール製ベアリングレースの加工用サーメットインサート 
  • 微調整可能で、温度の高い安定性 
  • EAシステム付きガイドパッド技術 

Expert

HSK100による生産ソリューション

大径向けの高い生産性

• 3段階のプロセス (前加工、中仕上げ加工、仕上げ加工)
• 大きな加工径 > 220 mm
• 最高の性能と精度
• 量産加工と短いサイクルタイムに最適なプロセス

前加工

• ISOガンボーリング工具

  アルミニウム構造 

  • PCDインサート 
  • ISOショートクランプホルダー 
  • 一段または多段の仕様 

中仕上げ加工

• 精密ガンボーリング工具

  アルミニウム構造 

  • PCDインサート 
  • 溶接構造またはアルミニウム製のボディマテリアルの仕様 

仕上げ加工

• Fine boring tool

  in lightweight construction

  • PCD-tipped indexable inserts
  • Cermet indexable inserts for machining of steel bearing bushes
  • Finely adjustable and temperature stable
  • Guide pad technology

• Actuating tool

  for u-axis-systems

  • Suitable for machining of housing variants
  • To compensate for insert wear