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Introduction of company AionaCast
The company does not have an
- wn production facility, we did set
up collaborations with partners who
- wn adequate production
presentation of an innovation RoBoC = Roll Bond Core - - PowerPoint PPT Presentation
presentation of an innovation RoBoC = Roll Bond Core - - PowerPoint PPT Presentation
presentation of an innovation RoBoC = Roll Bond Core www.aionacast.com info@aionacast.com Introduction of company AionaCast INTRODUCTION AionaCast Consulting GmbH Vaihingen an is located in the South of der Enz Germany. ST A TUS QUO
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Share of new vehicle sold, percent
EV breakthrough scenario
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Quelle Bild: McKinsey & Company, Reboost Report, A comprehensive view on the changing powertrain component market and how suppliers can succeed
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION China EU US RoW
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E - engines
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Quelle Bild: https://www.springerprofessional.de/automobil---motoren/elektromotor/bosch-elektromotor-32-kilogramm-leicht-und- mit-geringem-volumen/6585368
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION All new traction e-engine housings for electric driven passenger cars and trucks are liquid cooled.
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Uniform cooling
Creating innovation…
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION
It should present the following features:
No assembly process, just
- ne casting for the housing,
potentially including other features such as a gear box, etc. Suitable for high volume production -cheap- Flexible layout of the cooling channels No risk of leakage Scalable in length and diameter Weight reduction Low pressure drop The problem we would like to solve is:
How to offer a production process for the cooling channels, which is at the same time easier, cheaper and of a higher quality?
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Our idea, which is already patent pending
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We insert a light metal sheet package, which already includes all cooling channels and connectors, in a die for gravity or low pressure die casting and we recast it with aluminum. What makes this innovation really stand out, is the
perfect combination of a standard casting process with the common roll- bonding production method
used for the light metal sheet package! Hence the innovation is named
RoBoC
(Roll Bond Core) ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION PCT/EP2017/000304
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Realization
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Manufacturing of a Roll bond, ready to be inserted ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION
1.
Rolling Inflation Forming Pressurized Air Screen Printing Oven Oven Quenching Cutting Brushing
Quelle Bild: Muhr und Bender KG (MUBEA)
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Realization
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Manufacturing of a Roll bond, ready to be inserted Inserting the light metal sheet package in the die Closing of the die
2. 5. 6. 4.
Filling the die with molten metal and cooling of the RoBoC from inside during filling → Avoiding fuse of the RoBoC Solidification Taking out the casting of the die ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION
1. 3.
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Design options
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Single Side Inflated with the help of different aluminum material grades Two Side Inflated
- r
Geometric tolerances are similar to the standard sand core process The thickness of each sheet is approximately 0,5 to 2,5 mm Stable up to a burst pressure of 60 bar ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION
Implementation
Example of a design (Helix) for the inserted metal sheet
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION
Implementation
Example of a design for the inserted metal sheet, temperature spreading
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION
Implementation
Example of a design for the inserted metal sheet, cross-section
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Implementation (proof of concept)
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION Cut e-engine housing
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Implementation (proof of concept)
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION E-engine housing with connectors
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Implementation (proof of concept)
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION E-engine housing with connectors
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Result
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION The result is a smooth embedded metal sheet with the shapes for the cooling channels integrated in the casting.
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Implementation
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION Generation 1
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Cost advantages
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION One piece of casting, no additional machinery or assembly process necessary - means simplification of the process Elimination of non value-added operations highly complex sand core production necessity to remove the sand core machining and associated closing of the core prints Shorter cycle times for the casting process in reason of cooling from inside during casting Much less CNC machining Elimination of the flow rate and leak pressure test after casting / assembly Less casting scrap
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Technical advantages
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION High stability of the housing, compared to a 2 shell design and therefore less weight and less required installation space Cooling of the channels during pouring and solidification of the molten metal, means better mechanical properties of the casting weight reduction of up to 1 kg no risk for leakage and residual dirt parallel channels are possible Split of the requirement for mechanical stability and tightness
The process is also suitable for battery housings, power unit housings, junction boxes and other similar applications
Helix-Cooling design could reduce the size of the total engine in reason
- f higher cooling efficiency
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Offer
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ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER INTRODUCTION
We can offer business cases …
a.
delivery of ready for assembly e-engine housings (with partner)
b.
licenses rights of the patent pending
c.
shares in a company AionaCast Engineering
d.
… get in touch with us!
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