CPT International 4/2019

Die-cast aluminum
coil with seven turns
and a conductor
height of approx.
1.5 millimeters
(Photo: Fraunhofer
IFAM).
increased from 32 to 60 percent. At the
same time, there was a weight saving of
10 percent. The torque increased by 30
percent. Due to the better thermal
behavior of the coils, the continuous
power at operating temperature increased
by almost 20 percent. The aluminum
coil can deliver the resulting
heat better to the laminated core and
thus to the environment. This results in
an improved continuous performance,
since the coils only reach the permissible
continuous operating temperature
at higher currents.
Even more advantageous were the
measurement results for a laminated
core optimized on the cast coils in another
modified pedelec motor. At lower
weight, the torque increased by almost
80 percent and the continuous power
by 25 percent compared to the original
engine. Design changes can further
increase the performance of aluminum
coil motors.
Thanks to many years of development
work on cast coils at the Fraunhofer
IFAM, it is now possible to cover a
wide variety of application scenarios.
For use in high-performance machines,
copper coils of the highest quality can
be produced by precision casting. For
use in mass production, as required for
example in the manufacture of steering
motors or refrigeration and air conditioning
systems, the die casting process is
particularly suitable. In order to optimize
the production in die casting and
to further reduce the manufacturing
costs, a next development step is the
automated post-processing of the cast
coils. Large quantities in low cycle times
can then be manufactured in every die
casting foundry.
www.ifam.fraunhofer.de/en.html
Photo: Fraunhofer IFAM
FRAUNHOFER IGCV
New center for foundry technology
Photo: Sebastian Kissel
Since 2016, the Fraunhofer Institute for
Foundry, Composite and Processing
Technology IGCV has been researching
innovative foundry topics in Garching
near Munich, Germany. In future, the
scientists will find the best conditions
to advance further developments in
foundry technology: On October 11,
2019, the foundation stone for a
modern center for foundry technology
was laid. „With the new building here
in Garching, we are already expanding
existing strategic and synergy effects
with the neighboring Chair for Forming
Technology and Foundry
Engineering and other engineering
faculties of the Technical University of
Munich – thus strengthening our core
competencies,“ says Institute Director
Prof. Dr.-Ing. Wolfram Volk, „With this
combination and in such a location, we
are in an excellent position for interdisciplinary
research.“
The focus is on the areas of molding
materials, sand and mold casting processes
and simulation. In the field of
Laying of the foundation
stone of the
new center for
foundry technology.
On the right: Prof.
Dr.-Ing. Wolfram
Volk.
molding materials, especially inorganic
binders and novel combinations of
molding base materials are of interest.
In the field of sand and gravity mold
casting innovative approaches to the
integration of quality assurance measures
as well as the embedding of casting
systems in complete control solutions
(Industry 4.0) are investigated.
The Department of Simulation sets itself
the task of closing existing gaps in
the prediction of casting processes. In
addition, exciting solutions for a
long-distance cooperation are explored.
These can be virtual production
environments, but also augmented
reality visualizations.
In the future, various functional
areas will be accommodated on the
1,500 m² main floor space. The centerpiece
is the foundry hall, which is supplemented
by workshops, laboratory
areas, meeting and seminar rooms,
office areas for scientists, administration
as well as communal and communication
zones. The completion is
planned for 2021, a total of 20 jobs
will be created in the new technical
center.
www.igcv.fraunhofer.de/en.html
CASTING PLANT & TECHNOLOGY 4/2019 55