Customer Case Study
Transcription
Customer Case Study
Customer Case Study Automotive Facts Challenge Design and production of a function-integrated cooling water jacket, that dissipates heat directly at the electric motor creating it. Solution Additive Manufacturing of different test components from polyamide as well as of the final component with integrated cooling channels using the EOS M 290. Results •Functional: Integration of cooling and transmission/ wheel mounts in a single component •Lightweight: 16% weight reduction improves performance •Effective: Increase in cooling performance by 37% compared to the previous season‘s car Victorious: The cooling jackets for the electric motors were produced with Additive Manufacturing and played a key role in ensuring that the race car performed well enough in the long-distance tests to secure the GreenTeam 2nd place in the overall ranking for the Formula Student Germany (courtesy of GreenTeam, Stuttgart University). Leading the Pack – Race Car with Water-Cooled Electric Motors Brings Students a Place on the Podium Improved Cooling Thanks to Aluminum Jacket with Internal Helix-Structure Produced with Additive Manufacturing “Rallying has confirmed my presumption that a car with just two-wheel drive is nothing more than Short profile an emergency solution.” These words of racing legend Walter Röhrl also reflect the belief of the The GreenTeam is a registered GreenTeam, one of two Formula Student teams at the University of Stuttgart. For their racing car for association and one of two the 2013/2014 season the young engineers chose a four-wheel drive design with electric motors Formula Student teams at the positioned close to each of the wheels. There are 52 students that make up the team, which applies University of Stuttgart. It was innovative technology not only to powering the vehicle, but also to its manufacture. Central formed in 2009 and is made up components of the cooling system were produced using Additive Manufacturing, supported by EOS. of students from the universities of Stuttgart and Hohenheim, Stuttgart Media University and The Challenge performance of an electric motor. build-up. “The water cooling the FOM Hochschule. While the aims of the student This allows motors to be smaller, didn‘t function perfectly,” says racing series Formula Student leading to important weight Dominik Schäfer, a member of the Further Information Electric (FSE) are broadly savings. team working on the power train. www.greenteam-stuttgart.de educational, success is ultimately “It became clear that we had to measured in lap times and Alongside the benefits of trans- take a closer look at the engine victories. Electric engines provide ferable engine power, contem- cooling concept.” What they found extremely high torque and porary vehicle electronics allow was that the high temperatures thereby offer a very interesting each wheel to be configured were predominantly caused by drive option. An additional individually, ensuring the best heat transfer and convection. “The advantage is that they are respective traction. Such a design, reason for this lay in the geometry relatively small in size. Because of however, also has its disadvan of the water channels. Hotspots the high power density of electric tages. One of these is the limited had formed in areas with low motors, the selection and design possibility of heat dissipation due water flow velocity,” continues of the cooling concept has a big to relatively little available space. Schäfer. The design options were influence on the performance and In addition, the motors release nonetheless limited – on the one efficiency of the engine. Optimal heat in close proximity to the hand because of the lack of cooling can lead to a significant braking system. In short, the space, and on the other, as improvement in the long-term temperature build-up and the a result of the limitations of the limited solutions to the problem manufacturing process itself. represent a significant challenge Thanks to this complex aluminum component, cooling performance was increased by 37% . This achievement was the result of optimized coolant flow and improved heat dissipation (courtesy of EOS GmbH). wherein the basic choice is still Solution between air and water cooling. Once again it was Additive During the 2012/2013 season the Manufacturing that pointed the GreenTeam opted for water cooling way toward a solution. One and the concept proved to be reason for this is the high degree highly promising. of flexibility offered in the construction of any geometric Nonetheless, the previous year‘s form. Another is the ability to car had to battle with heat produce small series of components both quickly and economically. (only one is required for each draining of water were also built crashing into the back of you at The process made it possible for wheel). Thankfully EOS were on in to the design. The result was thirty when you‘re at a red light.“ the GreenTeam to produce three hand to help. that the young engineers were able Perhaps the young engineers to reduce the weight by 16% shared the racing legend‘s thoughts different forms for the cooling unit and to not only test them in “Production turned out to be compared to the previous year – as they set a new world record simulation, but actually manu- both fast and simple,” explains a decisive factor in achieving on the track. facture them from the polyamide Schäfer. “The transfer of the greater speed and in the endurance PA2200. The aim was to achieve design data also took place tests that are such a key part of sufficient cooling at a minimum without any problems.” The EOS the FSE. The final weight was just water pump throughput rate. M 290 was used to build the 370 g. Even more important was A larger pump could, of course, component, layer by layer, from the improvement in the cooling: increase the pressure and flow a fine metal powder by means of performance rose by 37% over velocity of the water, thereby a high precision laser. The metal the 2012/2013 season. improving cooling. However, this used, the EOS Aluminum AlSi10Mg, would in turn require more energy is particularly well suited to the Nikolai Zaepernick is responsible results, including 2nd place in and a corresponding increase in task at hand because it unites for Strategy and Business the overall standings for the the weight of the battery or of high mechanical and thermal Development at EOS. Alongside Formula Student Germany and the pump itself. The best way to durability with light weight, the direct advantages brought by 1st place at the Formula overcome this trade-off was making it ideal for applications the technology he also has an eye Student China. Our car simply through perfecting the geometry on the race track. In very little on its future potential. “Experts performed extremely well. The of the cooling channels. time the racing team was able to predict a big future for electro- four-wheel drive with wheel- benefit from the advantages of mobility. Wheel-hub electric motors hub motors proved the right Schäfer tested different varia- the helix geometry, conceived by in road vehicles bring similar choice in terms of performance, tions in the form of the cooling Schäfer, which had proved its challenges to those faced in this and the cooling water jacket jacket using software for what worth over other honeycomb and racing series. It is good to know produced through Additive is known as Computational meander structures. that intelligent minds have already Manufacturing was shown to been successfully working around be the ideal way of attaining the issues that arise in this area.” the required heat dissipation. Fluid Dynamics (CFD). The final “In the 2013/2014 season our team achieved outstanding component looked like a cup. Results The integrated cooling coils are In addition to built-in cooling channels on the interior wall, channels, the finished component Back on the track, the advantages the build-up of heat compared comparable to a coarse thread. had the further advantage that are there for all to see. The to last year and EOS technology This becomes a watertight the cooling jacket was integrated GreenTeam broke the world record made a great contribution to cooling pipe when the electrical with both the transmission flange in a drag racing competition for this achievement.“ motor is slid into the cup in the and the wheel mounts. Besides the the Formula Student Germany form of a cylinder. It is not a advantages of part consolidation, (FSG)! The race car covered the Dominik Schäfer, Member of simple task to construct such a the total weight was reduced and 75 m distance in just 3.36 sec. the power train working group complex component with the the final assembly was less com- Walter Röhrl once summed up the with GreenTeam, Stuttgart necessary precision and such plicated due to fewer individual acceleration of his Audi Quattro University limited production quantities parts. Brackets for the intake and S1 as follows: “It‘s like someone We were successful in reducing EOS GmbH Electro Optical Systems Corporate Headquarters Robert-Stirling-Ring 1 82152 Krailling/Munich Germany Phone +49 89 893 36-0 Fax +49 89 893 36-285 Further EOS Offices EOS France Phone +33 437 49 76 76 EOS India Phone +91 44 39 64 80 00 EOS Italy Phone +39 02 33 40 16 59 EOS Korea Phone +82 32 552 82 31 EOS Nordic & Baltic Phone +46 31 760 46 40 EOS of North America Phone +1 248 306 01 43 EOS Singapore Phone +65 6430 05 50 EOS Greater China Phone + 86 21 602307 00 EOS UK Phone +44 1926 62 31 07 www.eos.info • [email protected] Think the impossible. You can get it. Status 03/2015. Technical data subject to change without notice. EOS is certified according to ISO 9001.