Entraînements électriques

Exigences d'usinage et caractéristiques des différents types de carters

Carters de moteur électrique hautement intégrés

高度集成壳体 电机壳体

描述: 高度集成的复杂外壳，带定子安装座．表遮箱壳体等多合一壳体，功能复合，节约
装配成本，紧凑式设计，这值得加工更加复杂．

特征

• 定子直接安装在壳体内或定子安装座／玲却外壳
• 定子孔以及台阶和平面作为功能表面
• 转子的轴承孔与定子孔同轴，集成在壳体内
• 通过定位销货定位面对第二轴承定心定位，第二轴承孔必须是同轴的
• 轴承孔集成在壳体内，要求商同心庄和定位精庄
• 冷却管道部分集成在壳体内
• 复杂的锢合金预铸壳体

加工需求

• 量杂的轮廓设计，多台阶〈切削力
  大，切削量大〉
• 混合加工〈切屑分离〉
• 不连续切削
• 15°剖·倒角（长周可能和大的径向力）

桶型壳体 电机壳体

桶型壳体 电机壳体

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

Mecanizado fino de carcasas de motor para accionamientos eléctricos

En el último paso, el orificio del estátor se mecaniza con una precisión de unos pocos μm utilizando una herramienta de taladrado de precisión, que también está diseñado como un diseño soldado. Para alcanzar la más alta precisión, las placas de corte de PCD pueden pasar por un ajuste fino. La herramienta está equipada con guías de apoyo para un apoyo óptimo en el taladro.

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.

Zerspanungslösungen für...

Basic

Prototypenlösung mit Standardwerkzeugen

• Hohe Flexibilität
• System zum Vor- und Fertigbearbeiten
• Modularer Aufbau
• Standardprogramm ab Ø 87 - 1000mm 
• Feinbohrkurzklemmhalter im µm-Bereich justierbar
• Einfaches Handling

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

• ModulBore

  Boring head with bridge module

  • Pre- and finish machining system
  • Modular construction
  • ISO cartridges

Finish machining

• ModulBore

  high level of flexibility during boring and fine boring

  • Pre- and finish machining system
  • Modular construction
  • Standard range from ø 87 mm – 1000 mm
  • Fine boring cartridge adjustable in the µm range
  • Easy to handle

Performance

Series solution with HSK-63 / HSK-100

Process-safe solution with adapted performance and requirement spectrum

• Three-stage process (pre-, semi-finish and finish machining)
• Particularly light tools
• Large components on compact machines
• Optimal solution for small and medium quantities

Vorbearbeitung

• Helixfräser

  mit ISO-Wendeschneidplatten

  • Beschichtete ISO-Wendeschneidplatten aus Hartmetall oder PKD-bestückte Schneidplatten
  • Reduzierte Schnittkräfte
  • Standardprodukt
  • HSK-Verlängerung für verschiedene Bearbeitungstiefen

• PKD-Formfräser

  Konturbearbeitung im Bohrungsgrund

  • Gelötete Schneiden
  • Spezielle Konturen möglich
  • Optional mit HSK-Verlängerungen einsetzbar

Semi-Finish-Bearbeitung

• Präzisions-Aufbohrwerkzeug

  mit ISO-Wendeschneidplatten

  • Werkzeugform auf Magazinwechsler angepasst
  • Beschichtete ISO-Wendeschneidplatten aus Hartmetall oder PKD-bestückte Schneidplatten

• Präzisions-Aufbohrwerkzeug

  ein- oder mehrstufig

  • ISO-Kurzklemmhalter
  • PKD-bestückte ISO-Schneidplatten
  • Grundkörper aus Aluminium

• Präzisions-Aufbohrwerkzeug

  ein- oder mehrstufig

  • ISO-Kurzklemmhalter
  • PKD-bestückte ISO-Schneidplatten
  • Grundkörper aus Aluminium

Fertigbearbeitung

• Feinbohrwerkzeug

  mit Führungsleisten

  • PKD-bestückte Schneidplatten
  • Feinjustierbar
  • Führungsleisten aus PKD
  • Werkzeugform auf Magazinwechsler angepasst

• Feinbohrwerkzeug

  in Leichtbauweise aus Stahl

  • PKD-bestückte Schneidplatten
  • Cermet Schneidplatten für die Bearbeitung von Lagerbuchsen aus Stahl
  • Feinjustierbar und temperaturstabil
  • Führungsleistentechnologie mit EA-System

Expert

Serienlösung mit HSK 100

Hochproduktiv für große Durchmesser

• Dreistufiger Prozess (Vor-, Semi-Finish-, und Fertigbearbeitung)
• Große Bearbeitungsdurchmesser > 220 mm
• Höchste Performance und Präzision
• Idealer Prozess für hohe Stückzahlen und kurze Taktzeiten

Vorbearbeitung

• ISO-Aufbohrwerkzeug

  in Aluminiumbauweise

  • PKD-bestückte Schneidplatten
  • ISO-Kurzklemmhalter
  • Ein- oder mehrstufig ausgeführt

Semi-Finish-Bearbeitung

• Präzisions-Aufbohwerkzeug

  in Aluminiumbauweise

  • PKD-bestückte Schneidplatten
  • Ausführung als Schweißkonstruktion oder mit Grundkörper aus Aluminium

Fertigbearbeitung

• 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