增材制造复杂流道水冷电机壳体对驱动电机持续功率影响的研究

目的 提高量产铸造电机壳体的换热效率，确保电机在高功率持续工作状态下不会过热，从而提高电机的持续功率。方法 基于增材思维对电机水冷壳体的流道进行优化，改变流道形状以增大流道表面积、消除流道涡流并减小流道与内壁的间距。通过仿真分析，不断优化迭代得到最佳的流道设计方案。运用选区激光熔化（SLM）增材技术及相应的后处理工艺，制造出复杂流道结构的电机壳体。结果 采用SLM增材技术制造的AlSi10Mg铝合金壳体在x、xz、z 3个方向上的屈服强度均大于230 MPa，即使在较小壁厚的条件下，壳体强度仍满足设计要求。采用该壳体后，电机的持续功率从原量产电机的45 kW提升到50.7 kW，且仍能连续稳定运行45 min，同时电机温度未超过130℃。微观组织检测和工业CT测试结果显示，SLM电机壳体结构致密，未见气孔夹杂。该增材制造壳体的质量为6.95 kg，与量产电机壳体相比，减重约19%。结论 通过增材制造技术设计制造的电机壳体整体性能良好，可以有效提高换热效率以及电机的持续功率，并实现了电机的减重。

Influence of Additive Manufacturing Complex Flow Channel Water-cooled Housing on Continuous Rating of Drive Motor

The work aims to increase heat transfer efficiency of the housing and ensure that the motor will not overheat under higher-power continuous operating conditions, so as to improve the continuous rating of the electric motor. In this study, the flow channel of a water-cooled housing was optimized by AM thinking, which changed the shape of the flow channel to increase surface area, eliminate turbulence, and reduce wall thickness. Through simulation analysis, continuous optimization and iteration, the optimal channel scheme was obtained. Finally, the complex channel structure of the motor housing was manufactured with selective laser melting (SLM) additive technology and corresponding post-processing techniques. The results indicated that the AlSi10Mg aluminum alloy housing manufactured with SLM additive manufacturing technology exhibited yield strength greater than 230 MPa in the x, xz, and z directions. Even with a smaller wall thickness, the housing''s strength still met the design requirements. Additionally, the motor with AM housing operated continuously for 45 min under stable conditions, with the continuous power output increasing from 45 kW (for the original mass-produced motor) to 50.7 kW, while keeping the motor temperature below 130 ℃. Microstructure testing and industrial CT testing showed that the structure of the SLM motor housing was compact and there was no gas pore or inclusion. Furthermore, the additive manufactured housing weighed 6.95 kg, representing a weight reduction of approximately 19% compared with the mass-produced motor housing. In conclusion, the motor housing designed and manufactured with additive manufacturing technology exhibits excellent overall performance, effectively improving heat transfer efficiency, increasing the motor''s continuous power output, and achieving weight reduction.