MAGNESIUM – OVER 0.5 LBS
PSW Group, Ningbo Sinyuan ZM Technology Co., Shanghai Jiao Tong University, Shanxi Regal Material Co & XIAOMI AUTO TECHNOLOGY CO LTD
PART: Integrated E-Drive Housing AssemblyMATERIAL: XMM1 (Mg-RE-Al alloy)WEIGHT: 22 lb (10 kg)END MARKET: Automotive Caster Award Nominee: Tao Wang, Zhuoxiong Qiu, Liming Peng, Pengyu Wang, Maogu Lin, Xin LiuCustomer: Xiaomi Automotive
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FUNCTION OF PART
Integrated E-Drive Housing Assembly serves several essential functions: meet the installation and fixing requirements of four major drive modules, including the motor, gearbox, oil cooling system and mount system. It can resist vibration, shock load, extreme temperature and sealing pressure under various operating conditions and service environments.
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PREVIOUS PROCESS TO PRODUCE PART
Die cast with AZ91D as separate structures, including motor housings, gearbox housings, mounting brackets and the like. Material properties restricted the design, requiring more reinforcement.
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ADVANTAGES GAINED
The use of XMM1 alloy allows for integrated housing design that combines the motor housing, gearbox housing, oil cooling system, and mounting system into a monolithic unit, while increasing the creep resistance, corrosion resistance, and high-temperature strength of the component.
Weight reduction – 25%
Enhanced E-Driver Systems reliability due to improved creep resistance, corrosion resistance, and high temperature strength
Application range can cover E-Drive systems over 450W and high-temperature resistant components for engines.