Motor housing

Project Summary

The customer’s new-generation servo motor originally adopted cast iron housing, which was heavy and poor in heat dissipation, leading to excessive temperature rise during long-time operation. Standard die-cast aluminum housings on market had unreasonable cooling rib layout and poor inner bore roundness, causing uneven stator fitting clearance, vibration and noise. We adopted A380 die-cast aluminum alloy, optimized integrated vertical external cooling rib structure, matched with CNC precision boring, datum milling, sandblasting & passivation. The finished housing greatly improves heat dissipation, ensures high coaxiality of inner bore, realizing mass production of low-temperature-rise, low-noise and lightweight motors for long-cycle industrial operation.

2.3 Core Pain Points

1. Cast iron housing has low thermal conductivity, causing overheating under full load and shorter coil service life; heavy weight increases equipment load
2. Standard aluminum housings have sparse uneven cooling ribs with insufficient heat dissipation area, failing servo motor temperature standard
3. Large deformation of casting blank inner bore leads to unqualified roundness & coaxiality after ordinary boring, causing eccentric vibration & noise after stator assembly
4. Poor mold exhaust causes abundant inner wall pores, paint leakage during dipping process and high defective rate

3.1 Material Selection

A380 high-pressure die-cast aluminum alloy features excellent melt fluidity for integrated complex cooling rib forming. Its thermal conductivity far exceeds cast iron, with balanced strength for motor assembly & vibration resistance and obvious lightweight advantage. Stable machinability after casting meets long-term industrial anti-corrosion demands.

3.2 Structure & Mold Optimization

1. Extended & dense vertical external cooling ribs expand heat exchange area to rapidly dissipate motor heat and limit temperature rise
2. Integrated forming of flange base & terminal box cavity eliminates secondary welding, improving integral rigidity and unified datum
3. Circular vacuum exhaust system on mold with multi-point exhaust along inner bore & rib roots eliminates inner pores & shrinkage porosity
4. Uniform CNC machining allowance & optimized positioning datum realize one-clamping boring & flange milling to guarantee coaxiality

3.3 Core Process

Process Route: A380 aluminum melting → high-pressure vacuum integrated die casting → vibratory gate & burr removal → CNC inner bore boring, flange milling & tapping → sandblasting & passivation anti-corrosion → full CMM dimension inspection & packaging