EV Battery Housing Machining: A 3-Hnub Rapid Prototyping Case Study

Yog tias koj xauj, koj yuav nquag ntsib qhov txawv ntawm qhov kev npau suav phem no: "Ib tus neeg muag khoom tau cog lus rau 3-hnub hloov pauv. Peb lub lis piam tom qab, kuv pom tias cov khoom sib tsoo ntawm lub tshuab thiab cov cuab yeej tawg. Zero kev sib txuas lus kom txog rau thaum lub sijhawm dhau mus, ua rau peb tsis muaj dab tsi los kuaj."

Rau hardware engineers thiab procurement managers nrhiavhluav taws xob tsheb qhov chaw, nrawm R & D iterations txhais tau hais tias cuam tshuam nrog cov sij hawm ua haujlwm siab heev. Kev ncua sij hawm tau txais cov qauv kuaj lub cev feem ntau txhais tau tias cov neeg ua lag luam poob qis lossis ncua cov khoom lag luam tawm mus.

Cov ntaub ntawv kawm engineering no qhia meej tias Xiamen Dazao Machinery yuav ua li cas-ib ISO9001: 2015 thiab IATF16949: 2016 tau lees paub kev cai qhov chaw Hoobkas hauv Suav teb- ua tiav txoj haujlwm tiavEV roj teeb vaj tsev machiningnyob rau hauv lub qhov rais 72-teev nruj heev. Los ntawm kev siv5-axis CNC tshuabthiab 24-teev synchronized engineering workflow, peb tau ua siab ntevceev prototyping aluminiumCheebtsam yam tsis muaj kev cuam tshuam cov qauv kev ncaj ncees lossis geometric dimensioning thiab kam rau ua (GD&T) cov cai.

Qhov Kev Sib Tw 72-teev: Vim li cas Standard Factories Fail ntawm Fais Tsheb Qhov Chaw

Tus neeg siv khoom, ib qho kev pib EV, yuav tsum muaj kev ua haujlwm, tag nrho - nplai txhuas roj teeb enclosure qauv los ua cov dej ntsuas kub thiab ntsuas dej. Cov ntaub ntawv ntsuam xyuas yog qhov yuav tsum tau ua ua ntej rau qhov yuav los tom ntej Series B nyiaj puag ncig tau teem sijhawm 96 teev tom qab.

Cov khw muag khoom siv tshuab txheem feem ntau xav tau ob hnub tsuas yog los ntawm qhov loj 6000-series aluminium billet, ua raws li plaub mus rau tsib hnub ntxiv rau kev ntxhib los mos, kev ntxhov siab, thiab ua tiav. Peb hnub kawg - hnub kawg yog lej ua tsis tau yam tsis muaj kev faib tshuab ua ntej thiab kev ua kom zoo dua ntawm CAM toolpaths.

Project Specifications & Engineering Requirements:

Dazao's 3-Hnub Execution Plan rau Rapid Prototyping Aluminium

Txhawm rau ua kom tau raws li 72-teev lub sijhawm nyuaj, Dazao Machinery hla dhau cov txheej txheem tsim ua ntu zus thiab ua raws li cov txheej txheem kev tsim vaj huam sib luag.

Hnub 1: Al6061 Material Allocation & Concurrent CAM Programming

Tsis pub dhau 60 feeb ntawm PO tiam, peb qhov kev hloov pauv hloov tau yooj yim ntau lawm kab raws tu qauv tau qhib. Es tsis txhob tos rau cov neeg muag khoom khoom sab nraud, peb rub lub 850mm x 620mm Al6061-T6 thaiv ncaj qha los ntawm peb cov khoom siv raw khoom tsis zoo. Tib lub sijhawm, peb cov kws tsim khoom tsim khoom tau pib Mastercam programming, ua qhov tseem ceeb ntawm txoj kev roughing kom lub tshuab tuaj yeem pib txiav thaum txoj kev ua tiav tseem raug suav.

Hnub 2: 24/7 5-Axis CNC Milling & Deep Cavity Optimization

Peb faib lub siab -rigidity 5-axis CNC machining chaw nruab nrog 20,000 RPM spindle. Kev khiav hauj lwm nruj 24- teev sijhawm ua haujlwm, hnub ua haujlwm tau tswj hwm qhov hnyav hnyav hnyav- tshem tawm txog li 80% ntawm cov khoom siv. Hmo ntuj ua haujlwm seamlessly coj mus rau ib nrab ua tiav thiab ua tiav, siv 70-bar los ntawm-spindle coolant (TSC) kom tshem tawm cov chips los ntawm cov kua dej sib sib zog nqus thiab tiv thaiv kev txiav.

Hnub 3: CMM Tolerancing & Expedited Global Shipping

Los ntawm teev 60, ib feem tau tawm ntawm lub tshuab. Nws tam sim ntawd nkag mus rau hauv peb qhov kev nyab xeeb- tswj chaw soj ntsuam. Siv lub HexagonCoordinate Measuring Machine (CMM), peb soj ntsuam IP67 sealing grooves thiab mounting tus thawj qhov chaw los xyuas qhov ± 0.02mm kam rau ua. Ua raws li kev ceev ceev ultrasonic tu thiab tshuaj lom neeg hloov txheej txheej (RoHS raws), lub thawv ntim tau ruaj khov thiab xa tawm los ntawm kev thauj khoom huab cua thoob ntiaj teb nrawm.

3 Cov Pitfalls zais hauv EV roj teeb vaj tsev Machining (Thiab peb cov kev daws teeb meem DFM)

Ntau tus neeg muag khoom thov kom muab kev hloov pauv sai los ntawm kev nce tus nqi pub. Txawm li cas los xij, nruj machining ntawm loj hluav taws xob tsheb qhov chaw qhia cov neeg kho tshuab loj thiab thermal txaus ntshai. Ntawm no yog yuav ua li cas peb pab neeg engineering tau txo peb qhov feem ntau ua rau kev ua tsis tiav.

Pitfall 1: Tswj Thermal Warping nyob rau hauv nyias-Wall Enclosures

Standard Factory Approach: Txhawm rau txuag lub sijhawm, cov khw muag khoom txheem khiav siab - pub roughing thiab tam sim ntawd hloov mus ua kom tiav. Thaum qhov loj 850mm yog unclamped los ntawm lub vise, lub internal stresses nyob rau hauv lub ceev prototyping txhuas tso, ua rau lub 2.5 hli nyias phab ntsa warp los ntawm mus txog rau 1.5mm, rendering IP67 foob tsis muaj txiaj ntsig.

Txoj Kev Dazao: Peb tau npaj ib qho kev suav "Roughing - Stress Relief - Finishing" voj voog. Tom qab tshem tawm 80% ntawm cov khoom siv, peb txhob txwm nres lub tshuab, unclamped tag nrho ib feem, thiab tso cai rau nws so rau 2 teev kom ib txwm tso tawm sab hauv kev ntxhov siab. Peb mam li rov-clamped nws siv tswj, qis-torque nqus fixtures rau qhov kawg 0.5mm tiav. Qhov no ua kom lub hauv paus loj loj tuav lub tiaj tiaj ntawm 0.05mm tshaj 800mm.

Pitfall 2: Tshem Tawm Cov Cuab Yeej Sib Tham hauv Cov Cuab Yeej Cuab Yeej

Standard Factory Approach: Cov neeg ua haujlwm thauj khoom 3D qauv raws nraim li tau muab. Thaum machining cov ces kaum sib sib zog nqus ntawm cov cua txias, cov txheej txheem kawg mills raug kev txom nyem los ntawm overhang loj (L / D piv> 5), ua rau muaj kev vibration heev, lub cuab yeej tawg, thiab qhov chaw gouged. Lub tshuab nres, kev cai ntev - ncav cuag cov cuab yeej raug xaj, thiab qhov project yuav ncua ib lub lis piam.

Txoj Kev Dazao: Lub sijhawm thawj teev ntawm kev hais tawm, peb cov kws ua haujlwm tau khiav cov cuab yeej simulations txhawm rau txheeb xyuas kev sib tsoo thiab kev pheej hmoo sib tham. Peb tam sim xa tus neeg siv khoom aTsim rau Manufacturing (DFM)markup. Peb tau txheeb xyuas tias 5 hli sab hauv kaum sab xis ntawm qhov tob ntawm 60 hli yuav ua rau muaj kev sib tham. Peb tau hais kom hloov kho qhov tsis yog - radii tseem ceeb rau 8mm, tso cai rau peb siv cov tuab tuab, txheej txheem nruj kawg zeb. Tus neeg siv tau pom zoo qhov kev hloov pauv hauv 10 feeb, tshem tawm qhov tsis ua haujlwm tseem ceeb ua ntej lub spindle txawm pib.

Pitfall 3: Kev daws "Lub Sijhawm Zone Black Hole" rau Kev Muag Khoom Thoob Ntiaj Teb

Qhov Kev Tsis Txaus Siab: "Qhov phem tshaj plaws ntawm kev xa cov khoom ceev mus rau cov neeg muag khoom Asian yog qhov sib txawv ntawm 12-teev lub sijhawm. Yog tias lub tshuab tswb nrov thaum lawv ua haujlwm hmo ntuj, qhov project zaum tuag txog kuv tag kis."

Txoj Kev Dazao: Raws li cov chaw tsim khoom muaj kev paub dhau los thiab cov neeg xa khoom thoob ntiaj teb, peb xa daim duab ntxoov ntxoo ua haujlwm raws li lub sijhawm tseem ceeb- cov qauv tsim nyog. Peb cov kev ua haujlwm hmo ntuj tsis yog cov neeg ua haujlwm ua haujlwm xwb. Peb tso cai kom muaj kev paub lus Askiv zoo- hais lus Tus Thawj Saib Xyuas Haujlwm (PM) thiab Tus Kws Tsim Khoom Tsim Khoom hauv pem teb. Thaum US- pab pawg neeg tsim khoom tsim tawm hnub 2, lawv tsis tau txais kev ceeb toom yuam kev ntawm lub tshuab. Hloov chaw, lawv pom email uas muaj nruab nrab - cov duab ua haujlwm thiab cov ntaub ntawv CMM ua ntej rau theem roughing.

Xaus:Vim li cas Dazao yog Koj Lub Tuam Txhab Tuam Txhab Tuam Txhab Tuam Txhab rau EV Cheebtsam?

Kev ua kom tiav sai prototyping txhuas tej yaam num rau lub automotive sector yuav tsum tau ntau tshaj li ceev ceev tshuab cuab yeej. Nws xav kom muaj kev nkag siab zoo ntawm metallurgy, active DFM kev cuam tshuam, thiab cov txheej txheem tswj xyuas nruj raws li kev caiIATF16949 tus qauv.

Thaum cuam tshuam nrog siab -stakes hluav taws xob tsheb qhov chaw, xaiv cov chaw tsim khoom hauv Suav teb yog hais txog kev tiv thaiv koj lub sijhawm R&D thiab koj cov peev nyiaj engineering. Xiamen Dazao Machinery muab qhov tseeb - qauv kev ua siab ntev rau lub sijhawm, nrog kev sib txuas lus pob tshab ntawm txhua theem ntawm kev tsim khoom.