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3D Printed Electric Motor Casing Redesign design presentation
- 1. Design for Additive Manufacturing Challenge 2016 23 March 2016 Cassidy Silbernagel Redesigned Electric Motor Casing
- 2. 2 Creating an electric Honda CR 125 motorbike Original gasoline motor specs Torque: 28 Nm @ 11000 rpm Power: 30 kW @ 11500 rpm New electric motor specs Torque: 40 Nm @ 6000 rpm Power: 15 kW @ 6000 rpm
- 4. 4 Thin wall integrated cooling channels
- 5. 5 Minimized Supports – 45 degree angles
- 6. 6 Motivations Show what Additive Manufacturing can do Multi-functional parts Light weight Enhanced cooling Eliminate parts It can do it today!
- 7. Thank you!
Editor's Notes
- Hello, my name is Cassidy Silbernagel and I’d like to thank you for this opportunity.
- A few years ago, I had the opportunity to participate in converting a Motorbike from gasoline to electric. [Click] Once you remove all the parts that are no longer needed, you have quite a bit more room to fit an electric motor. Two things we didn’t want to remove were the [Click] Crankcase pictured here, and the liquid cooling system. [Click] This new motor was designed to fit in an alu-min-ium cylinder within the crankcase. The space between the alu-min-ium cylinder and the crankcase was attached to the existing cooling system and coolant flowed between the two. [Click] This new motor has much more torque than the original even though it has less power. But cooling was still an issue due to poor fluid control within the crankcase. [Click to next slide] Bike Image: http://www.vitalmx.com/forums/MotoRelated,20/CR125-2010-The-Real-Deal,905161 Motor Image: http://www.mxbonz.com/CR8001BK.jpg Casing Images: Myself Specs: http://www.motorbikes.be/en/Honda_CR_125_R_2003.aspx
- For this competition, I wanted to redesign the casing while keeping the shaft and other internal parts the same. [Click] Additive manufacturing allows the casing to not be cylindrical, which helps prevent internal components from rotating. I’ve also added a beveled channel along the length of the casing to allow for proper alignment and ease of assembly. [Click] The overall casing is comprised of two halves, which are identical. They sandwich the existing motor components together using through nuts and bolts, eliminating the need for threaded holes. This concept takes 8 different parts and merges them into one. [Click] O-ring grooves have been added for the bearings. Normally, bearings need a tight fit with high tolerances, higher than what metal additive manufacturing can achieve. This tightness prevents the outer part of the bearing from rotating. However, this tightness can also be achieved with o-rings. O-rings are normally used when a steel bearing is placed in an alu-min-ium case. As the case heats up, the alu-min-ium expands more than the steel bearing which causes looseness if an o-ring is not used. Thus o-rings can compensate for the as built tolerances of an additively manufactured case when is it made from stainless steel. [Click] The resulting design has all of the features that the electric motor needs within a single part. [Click to next slide]
- On the back of the casing are a number of holes. The three elongated wire pass-through holes take the wires out from the center of the motor. These holes make it easy to work with wires. Because if they are too tight or have sharp edges they would cut or nick the insulation off the wires which I’ve learned from experience can cause electrical problems later on. [Click] Near the top are the cooling inlet and outlet which can be hooked into the existing cooling system. [Click] These cooling channels are thin curved walls which are impossible to make with any other manufacturing process. In the middle of the cooling channel are angled cross pins. These increase the cooling ability of the liquid and improves motor performance. These pins could also be lattice structures. Despite the motor looking thick, the majority of this perceived volume is empty and is utilized by the cooling channels. Very little space is wasted in the design, as nearly every part has been optimized for one function or another. [Click] The front of the casing has been optimized and patterned after the output of the Inspire software provided for this competition in order to minimize weight while maintaining strength and stiffness. [Click to next slide]
- In order to aid in additive manufacturing, 45 degree angles have been incorporated in a number of areas in order to minimize support structures needed for overhanging parts. This can be seen on the interior of the casing, where the electric motor parts reside [Click] In the cutouts on the front of the casing, [Click] And even the angle of the interior cooling pins. [Click to next slide]
- So why did I do this? Well, I want to win, but [[Click]] what I really want to do is show what additive manufacturing can do. That we can take existing designs, and make them better. We can incorporate multiple features [[Click]] for alignment, cooling, wire management and assembly all in the same part [[Click]] without sacrificing weight. We can make these features better [[Click]] like incorporating pins or lattices in a cooling channel or [[Click]] by eliminating parts altogether. I believe that additive manufacturing is the future and I not only want to show the world what it can do,[[Click]] but that it can be accomplished today. [Click to next slide]