Patent Application
20190217380
The present disclosure relates generally to manufacturing a vehicle frame, and more particularly to a multi-directional die casting machine for casting a unibody vehicle frame and associated methods thereof.
Conventional die casting, also known as high-pressure die casting (HPDC), is a metal casting process that has been in use for over a hundred years. Die casting typically includes forcing or injecting molten metal under high pressure into a mold cavity. The mold cavity is formed using two die portions which have been machined into a shape of the desired casting. Depending on metal material type being used, a hot or cold chamber die casting machine may be used, as well as squeeze casting methods, in addition to over-molding, where alloy is casted over/around existing substrates in order to achieve higher structural properties of an end product. One die portion is called a “cover die portion” and the other die portion an “ejector die portion”, and where they meet “the parting line” Conventionally, the cover die portion includes a sprue or shot hole configured to allow molten metal to flow into the dies from an injector fluidly coupled to the sprue or shot hole, and is attached to a stationary platen of a casting machine. The ejector die portion typically includes ejector pins and/or a plate to push the casting out of the ejector die portion (e.g., after solidification and the dies open), and is attached to a movable platen of the casting machine.
Typically, in the context of vehicle frame manufacturing and the die casting process, multiple die casting machines are each used to cast different components of a vehicle frame. For example, a single die casting machine cell in a factory may be dedicated to casting a single frame component. These components from each casting machine are then assembled or secured together (e.g., via welding) by factory workers or robotic systems to form a vehicle frame (e.g., a unibody vehicle frame). Because die casting generally involves higher capital costs relative to other casting and manufacturing processes including assembly of many individual components (e.g., due to high costs of casting equipment and metal dies), there remains a need for an improved die casting machine and associated methods thereof, particularly as related to casting a vehicle frame to reduce work required to achieve a final assembled product. The present disclosure describes embodiments of die casting machines and methods thereof that may reduce build time, operation costs, costs of manufacturing, factory footprint, factory operating costs, tooling costs, and/or quantity of equipment. Such casting machines may reduce a number of casting machines or actual castings required to cast a complete or substantially complete vehicle frame (e.g., to less than six, less than five, less than four, less than three, less than two, or one casting machine(s)).
The present disclosure relates generally to manufacturing and assembling a vehicle frame, and more particularly to a multi-directional die casting machine for casting a vehicle frame and associated methods thereof such multi-directional casting machines may be suitable for casting a unibody vehicle frame, and more specifically for an electrical vehicle unibody frame. In some embodiments, multiple portions of the vehicle frame may be integrally formed or casted without the need for further assembly and attachment (e.g., welding, rivets, etc.). This may reduce a number of castings and/or steps for manufacturing or casting a substantially complete vehicle frame. For example, the die casting machine as described herein may reduce a number of casting machines or actual castings required to cast a complete or substantially complete vehicle frame (e.g., to less than six, less than five, less than four, less than three, less than two, or to one casting(s) or casting machine(s)). Accordingly, this may reduce costs associated with manufacturing including, but not limited to, factory operating costs, tooling costs, time, and other equipment and labor costs.
In one aspect, a multi-directional casting machine for a vehicle frame configured in accordance with embodiments of the present disclosure, includes: a central hub having a cover die portion and a plurality of ejector die portions translatable relative to the cover die portion. The plurality of ejector die portions are configured to meet at the central hub. The plurality of ejector die portions includes a first ejector die portion configured to translate along a first axis between a closed position and an open position. The first ejector die portion is adjacent a first side of the cover die portion in the closed position and spaced apart from the cover die portion in the open position. A second ejector die portion is configured to translate along the first axis between a closed position and an open position. The second ejector die portion is adjacent a second side of the cover die portion opposite the first side in the closed position and spaced apart from the cover die portion in the open position. A third ejector die portion is configured to translate along a second axis extending substantially perpendicular to the first axis between a closed position and an open position. The third ejector die portion is adjacent a third side of the cover die portion in the closed position and spaced apart from the cover die portion in the open position. The plurality of ejector die portions form a mold cavity corresponding to at least a portion of a vehicle frame.
In another aspect, a multi-directional casting machine for a vehicle frame includes a central hub configured to receive a plurality of translatable ejector die portions. The plurality of ejector die portions are configured to form a mold cavity when received by the central hub. The mold cavity corresponds to at least a portion of a vehicle frame. The machine including an ejection system operably coupled to the central hub and configured to eject a casting of the vehicle frame in an upward direction along a substantially vertical axis relative to the central hub after the vehicle frame has been casted in the mold cavity.
An exemplary method of casting a frame of a vehicle according to embodiments of the present disclosure includes the steps of: translating a first ejector die portion towards a first side of a cover die portion along a first axis in a first direction and translating a second ejector die portion towards a second opposing side of the cover die portion along the first axis in a second direction opposite the first direction. The cover die portion is fixedly positioned on a central hub. The method further includes injecting molten metal into a mold cavity formed at least partially by mold cavity portions of the first and second ejector die portions to form a casting corresponding to at least a portion of a vehicle frame. The method includes ejecting the casting out of the first and second ejector die portions and translating the first and second ejector die portions away from the cover die portion in opposite directions along the first axis.
Certain details are set forth in the following description and in
Many of the details, dimensions, angles and other features shown in
The casting machine 100 configured in accordance with an embodiment of the present disclosure includes a central housing or hub 102. As illustrated in
In other embodiments, as illustrated in
The central hub 102 may be positioned at a center of an intersection (e.g., a four-way intersection) where rails or tracks 110a-110d meet. The rails or tracks 110a-110d provide a path or guide upon which corresponding ejector die portions 108a-108d may slide or otherwise translate along substantially horizontal axes (e.g., X- and Y-axes) toward or away from the central hub 102 (e.g., and corresponding cover die 106) during a casting process between open and closed positions. As illustrated, in some embodiments, a fifth ejector die portion 108e translates toward or away from the central hub 102 along a vertical axis (e.g., a Z-axis) extending substantially perpendicular to the horizontal axes, overhead or otherwise above the central hub 102. As illustrated, in some embodiments, ejector die portion 108e may translate along one or more support bars or poles 112a-112d that extend upward from the central hub 102 substantially parallel to the Z-axis. The poles 112 may be positioned at four respective corners of the central hub 102 (e.g., cover die portion 106).
Ejector die portions 108a-108e may thus form a mold cavity 114 with corresponding cover die portions 106a-106e for integrally casting (e.g., without having to further weld or otherwise couple separate portions of) a unibody vehicle frame 116. The mold cavity 114 may thus be formed by the multiple ejector die portions 108 in closed positions with respect to the multiple corresponding cover die portions 106. Ejector die portions 108 may include one or more cavity portions 109 configured or shaped to correspond to outer contours or shapes of respective sides and components of the vehicle frame 116. In some embodiments, the ejector die portions 108a-108e may include cavity portions corresponding to side portions (e.g., a left, a front, a right, a rear, and a roof, respectively) and/or portions thereof (e.g., pillars, panels, sills, rails, posts, tie bars, bumpers, reinforcements, wheel houses, and/or shock towers) of the unibody frame 116. For example, ejector die portion 108e may thus include cavity portions configured to correspond to a roof portion and/or other top-side portions thereof (e.g., roof panels, rails, trunk, hood) of the unibody frame 116. Thus, cavity portions 109 of the respective multiple die portions 108 combine to form the mold cavity 114 configured to form a casting of the unibody frame 116. The mold cavity 114 formed by the corresponding ejector and/or cover die portions may be a single cavity die, a multiple cavity die, a combination or family die, and/or a unit die. As described above, a casting formed by the mold cavity 114 may correspond to about or up to about 20%, 40%, 60%, 80%, 100%, or about any percentage therebetween of a complete unibody vehicle frame. The casted unibody vehicle frame 116 may rest or be positioned on a bottom side of cover die portion 106e.
As illustrated in
While the die casting machine 100 includes a cover die portion 106 with five sides and five corresponding ejector die portions 108, in other embodiments, die casting machine 100 may include more than or less than five corresponding cover and ejector die portions. As noted above, these die portions may correspond to five or more sides or side portions forming a mold cavity for a unibody vehicle frame. In certain embodiments, the die casting machine 100 does not include corresponding die portions on one or more sides of the central hub 102 (e.g., bottom, top, left, right, front, and/or rear sides). In the illustrated embodiment, the die casting machine 100 does not include corresponding die portions on an underside or bottom side of the central hub 102 opposite the top side. In such configurations, an underfloor or bottom side of a unibody vehicle frame is excluded from the mold cavity 114 as an underfloor may be provided by a battery housing or tray for electric vehicle. In other embodiments, the die casting machine 100 does not include corresponding die portions for casting a top, left, right, front, and/or rear side or portion of a unibody vehicle frame.
A die casting machine 100 with the central hub 102 and multiple die portions 106, 108 configured forming the mold cavity 114 in this manner provides a casting machine with multiple degrees of freedom or multi-directional casting for integrally casting the unibody frame 116. As described above, the multiple ejector die portions 108 may translate along their respective axes (e.g., X-, Y-, and Z-axes) towards and away from the central hub 102 during the casting process and use multiple sides of the central hub 102 as noted above to integrally cast multiple sides or portions of the unibody frame 116. In yet further embodiments, one or more of the ejector die portions 108 and/or platens may be configured to rotate about respective X-, Y-, or Z-axes (e.g., up to 90 degrees, up to 180 degrees) as well as translate to provide additional degrees of freedom for casting additional parts, sides, or portions of the vehicle frame 116, or to cast other vehicle frames different from vehicle frame 116. In some embodiments, the ejector die portions 108 are translated axially with electric propulsion. In such embodiments, tie rods or bars may not be included such that the ejector die portions 108 are rotatable as well as translatable axially.
For example, an ejector die portion 108 may form a first mold cavity portion with a corresponding cover die portion 106 in a first closed position (e.g., rotated 0 degrees about a respective axis) and may form a second mold cavity portion with the corresponding die portion 106 in a second closed position (e.g., rotated 90 degrees about the respective axis). The first and second mold cavities portions may form portions of first and second different mold cavities. The different mold cavities may correspond to castings of unibody frames of different vehicles (e.g., a first and a second vehicle). In some embodiments, the second mold cavity corresponds to a casting for a different portion or part of the same vehicle. In some embodiments, the ejector die portions 108 may be rotated between more than two positions (e.g., three, four, five, six) to provide the ability to form multiple different mold cavities with corresponding cover die portions 106 corresponding to multiple vehicle unibody frames, portions, or components thereof.
In yet other embodiments, in addition to or alternatively to translatable or rotatable ejector die portions configured to provide multiple casting directions and degrees of freedom, the die casting machine 100 may include one or more modular components configured to be replaceable (e.g., interchangeable, switchable, substitutable). For example, the central hub 102 with cover die portions 106 may be a modular component that may be replaced with another central hub having cover die portions corresponding to different vehicle frame portions or vehicle frames. In some embodiments, different die portions 106 may be provided with the same central hub 102. In yet other embodiments, the ejector die portions 108 may be modular and be replaced with different ejector die portions. Such modularity may provide improved servicing of the die casting machine 100 in addition to allowing the die casting machine 100 to cast different vehicle frames and/or frame portions by switching hubs, ejector die portions, or cover die portions.
With reference to
As further illustrated in
As further illustrated in
The die casting machine 100 further includes an ejection system 130 configured to eject a solid or otherwise finished casting of frame 116 out of the mold cavity 114. For example, each of the ejector die portions 108 may include typical or conventional ejection components for ejecting a die out of and away from (e.g., towards the central hub 102 along a substantially horizontal axis) each corresponding ejector die portion 108. For example, the ejection components may include conventional ejector plates, pins, actuators, or other suitable ejection features.
With reference to
In the description above, various embodiments of the present invention are described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art that the present invention may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described. The subject matter of the present invention is described here with specificity, but the claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies.
This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.
Other variations are within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
