Acionamentos eletrificados

Exigências da usinagem e características dos diferentes tipos de carcaça

Carcaça altamente integrada

Carcaça dos motores elétricos altamente integrados

Descrição: Carcaça altamente integrada e complexa com montagem de estator, montagem de transmissão e conexão para a potência eletrônica. A alta integração funcional economiza custos de montagem. Design compacto. Consequentemente, a carcaça fundida é muito complexa. 

CARACTERÍSTICAS 

• Estator incorporado diretamente na carcaça ou através de um suporte do estator / camisa de resfriamento 
• Furo do estator com estágios e superfícies planas como superfícies funcionais 
• Um furo do rolamento do rotor é integrado coaxialmente ao furo do estator na carcaça 
• Posicionamento da segunda tampa do rolamento por meio de pinos-guia ou superfícies de encaixe; o segundo furo do rolamento deve ser coaxial 
• Furos do rolamento dos estágios de transmissão integrados na carcaça; é necessária alta concentricidade e precisão de posição 
• Os canais de refrigeração são parcialmente integrados na carcaça 
• Carcaça complexa de alumínio fundido 

EXIGÊNCIAS DA USINAGEM 

• Elaborar uma série de contorno com vários níveis de diâmetro (→ altas forças de corte e grande taxa de remoção) 
• Usinagem mista (→ separação/remoção de cavacos) 
• Cortes interrompidos (→ contato, circuito de refrigeração) 
• Chanfros de entrada planos de 15° a 30° (→ formação de evacuação dos cavacos e altas forças radiais) 

Carcaça em forma de panela

Carcaça do motor elétrico em forma de panela

Descrição: Para reduzir a complexidade, em particular para implementar uma construção mais simples da camisa de resfriamento, são usados carcaças ou suportes de estator em forma de panela ou de sino. 

CARACTERÍSTICAS 

• Como uma carcaça intermediária para integração no sistema completo 
• Furo do estator com estágios e superfícies planas como superfícies funcionais 
• Um furo do rolamento do rotor integrado na carcaça coaxialmente ao furo do estator 
• Posicionamento por meio de superfícies de encaixe na superfície externa 
• Canais de refrigeração como nervuras do lado de fora 
• Parede fina, propenso a vibração 
• Problemático em termos de tensão 

EXIGÊNCIAS DA USINAGEM 

• Peças com paredes extremamente finas (→ corresponde à espessura da parede) 
• As nervuras de refrigeração externas devem ser usinadas 
• Forma de panela ou sino (→ promove vibrações, conceitos especiais de fixação e amortecimento de vibração) 
• Chanfros de entrada planos de 15° a 30° (→ formação de evacuação dos cavacos e altas forças radiais) 

Carcaça tubular

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.

Machining solutions for...

Basic

Solution de prototype avec outils de base

• Flexibilité élevée
• Système pour les travaux de pré-usinage et d'usinage final
• Structure modulaire
• Programme standard à partir de ø 87 mm – 1 000 mm
• Supports de serrage courts à alésage fin réglables dans la plage µm
• Maniement simple

Ébauche

• Fraises hélicoïdales

  avec plaquettes amovibles ISO 

  • Plaquettes de découpage amovibles ISO avec revêtement carbure ou plaquettes de coupe à insert en PCD 
  • Réduction des efforts de coupe 
  • Produit standard 
  • Extension HSK pour différentes profondeurs d'usinage 

• ModulBore

  Tête de forage avec module de pontage 

  • Système pour les travaux de pré-usinage et d'usinage final 
  • Structure modulaire 
  • Porte-outils courts ISO 

Pré-usinage et usinage final

• ModulBore

  flexibilité élevée en forage et alésage de précision 

  • Système pour les travaux de pré-usinage et d'usinage final 
  • Structure modulaire 
  • Programme standard à partir de ø 87 mm – 1 000 mm 
  • Supports de serrage courts pour alésage fin réglables au µm 
  • Manipulation simple 

Performance

Solution de série avec HSK-63 / HSK-100

Solution fiable avec un spectre de puissance et d'exigences adapté

• Processus en trois étapes (pré-usinage, semi-finition et usinage final)
• Outils particulièrement légers
• Composants volumineux sur machines compactes
• Solution optimale pour petites et moyennes quantités

Ébauche

• Fraises hélicoïdales

  avec plaquettes amovibles ISO 

  • Plaquettes de découpage amovibles ISO avec revêtement carbure ou plaquettes de coupe à insert en PCD 
  • Réduction des efforts de coupe 
  • Produit standard 
  • Extension HSK pour différentes profondeurs d'usinage 

• Fraise de forme PCD

  Usinage des contours dans un perçage fond plat 

  • Arêtes de coupe brasées 
  • Profils spéciaux possibles 
  • Avec prolongateurs HSK en option 

Semi-finition

• Outil d'alésage de précision

  avec plaquettes amovibles ISO 

  • Forme d'outil adaptée au système de changement de chargeur 
  • Plaquettes de découpage amovibles ISO avec revêtement carbure ou plaquettes de coupe à insert en PCD 

• Outil d'alésage de précision

  un ou plusieurs étages 

  • Porte-outils courts ISO 
  • Plaquettes de découpage ISO à insert en PCD 
  • Corps de base en aluminium 

• Precision boring tool

  single-stage or multi-stage

  • ISO cartridges
  • PCD-tipped ISO indexable inserts
  • Tool body made of aluminium

Finish machining

• Fine boring tool

  with guide pads

  • PCD-tipped indexable inserts
  • Finely adjustable
  • Guide pads made of PCD
  • Tool shape adapted to magazine changer

• Fine boring tool

  in lightweight construction made of steel

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

Expert

Series solution with HSK 100

Highly productive for large diameters

• Three-stage process (pre-, semi-finish and finish machining)
• Large machining diameters > 220 mm
• Highest performance and precision
• Ideal process for high volumes and short cycle times

Pre-machining

• ISO boring tool

  aluminium construction

  • PCD-tipped indexable inserts
  • ISO cartridges
  • Single or multi-stage design

Semi-finish-machining

• Precision boring tool

  Aluminium construction

  • PCD-tipped indexable inserts 
  • Design as welded construction or with tool body made of aluminium

Finish machining

• 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