Plastic components offer a cost-effective, space-efficient solution, allowing Original Equipment Manufacturers (OEMs) to meet the integrated cooling demands of high-torque electric motors. These components are supported by machine-based process monitoring, ensuring every step of manufacturing and assembly is executed accurately and reliably.
Customer Challenge/Requirements
Managing the high temperatures that frequently develop in high-torque electric motors remains a constant challenge for automotive manufacturers. During demanding activities like towing or rapid acceleration, the motor heats up significantly, making integrated cooling through continuous hydraulic fluid application to the stator essential. OEMs rely on dependable cooling systems to meet these demands, safeguarding motors and transaxles from overheating.
Design Requirements
To cool the lubricating fluid within the electric motor, hydraulic fluid continuously circulates through manifolds and cooling distribution systems. Given that these systems are installed inside the front and rear wheel transaxles, size is a critical consideration, as there is minimal extra space available. Integrating these cooling components into the transaxle system presents a significant challenge. Furthermore, traditional vibratory welding methods may not be suitable due to the contamination risks associated with the confined spaces.
In addition to meeting engineering specifications, the components used must perform effectively in fully automated assembly environments, with proper checks and balances to ensure they are manufactured and designed correctly to adhere to stringent quality standards.
Solution
Parker Chomerics addressed these customer needs with a cost-effective, space-efficient plastic solution supported by machine-based process monitoring to ensure proper assembly.
Understanding the constraints of tight spaces, Parker Chomerics designed parts that feature an innovative all-plastic cooling system specifically engineered for compactness. By transitioning from traditional metal components to plastic, customers could achieve a weight reduction of 83g while gaining enhanced functionality and design flexibility, including integrated sealing flanges, molded compression limiters, and built-in fluid drain holes.
One significant distinction between these plastic parts and previously used materials is their method of assembly: they are laser welded. Laser welding accommodates space constraints by allowing chemically resistant parts to fit into tight cavities, be compressed, and then securely welded in place. Additionally, laser welding is one of the few techniques that can accomplish this without generating debris. In contrast, vibration and ultrasonic welding methods can produce plastic particles, which can be problematic in applications requiring high cleanliness. Recent engineering advancements have streamlined the laser welding process, utilizing a single laser that moves along a designated weld path, reducing costs by minimizing the need for extensive equipment and custom fixtures.
Furthermore, Parker Chomerics automates the insert molding of compression limiters, effectively eliminating creep under bolt-tightening compression, which can otherwise lead to screws loosening over time.
To fully leverage these engineering innovations, Parker Chomerics has embedded quality and consistency into the manufacturing process from the outset. All molding machines are equipped with machine-based process monitoring to ensure each process parameter is maintained correctly at every stage. A series of sensors and cameras verify that each step, from loading the plate to welding, is completed accurately and that all parts are properly aligned before allowing the workcell system to proceed to the next step. Additionally, the system conducts leak tests on all components to ensure proper sealing before operators can remove and pack the parts. As a result, the finished products are validated as correctly molded and pressure-tested. This level of error-proofing in highly automated assembly processes enables us to guarantee zero defects.
Results
With engineering innovation and error-proof manufacturing, automotive manufacturers can be confident in their use of high-quality, high-performance electric motors. Parker Chomerics boasts an industry-leading quality record with its automotive partners and receives annual awards from OEMs for meeting and exceeding their quality standards. This low-cost, space-efficient plastic solution from Parker Chomerics addresses product cooling requirements while minimizing the risk of defects.
