Casting Study: Cover Plate e-drive

Major Selection Criteria: Complex Shape, Dimensional Precision, Mechanical Properties, Net Shape, Thermal Conductivity
Alloy: Zamak 5 (ZL5, ZL0410, ZnAI4Cu1, alloy 5)
Application Field: Electrical/Electronics
Application Size: >250 g
Surface Finish: As-Cast
Casting Technique: Pressure Die Casting
Source: DYNACAST Osterreich GmbH

ima01This part is used in a drive system as a special shield to guarantee good air ventilation in addition to perfect cooling of the system. Reasons for choosing zinc alloy include the complex tool design; requirement to cast the part to size; ability to forego using expensive machining; excellent process control; and dimensional requirements (flatness 0.2, concentricity 0.1, diameter of 40 M8).

 Applications of this part include: tooling appliances, fans, pumps, vacuum pumps, textile machines, printing apparatuses, lifting and handling devices, conveyer belts and within mobile applications, axillary and traction drives such as automotive electric bikes and electric fun cars for instance.

Technical details about the drive system:

  • Part weight: 687g
  • Dimension: 150 x 137 x 36 mm
  • Cavity: 1
  • Casting: FRECH 125to plus trimming
  • Technology: Integrated drive system motor
  • Power Range: 60 W up to 150 kW
  • Speed Range: Up to 40 000 RPM
  • Voltage Range:12 up to 450 VDC
  • Frame Size: Custom
  • Cooling Types: Air cooled, medium cooled