Dimension (L x W x H): 1.258 mm x 1.152 mm x 165 mm

Weight: 30.067 gram

Alloy: Al Si 10 Mn Mg

Description:
As the central components of a high-voltage storage system, the lower housing parts (UT) must meet various high functional requirements over their entire service life.

Design, casting and molding requirements:
DG housings for high-voltage storage units of this dimension are usually two-piece.
In order to exploit cost potentials, this SP52 high-voltage storage unit was designed in one piece for the first time.
On the mold side, a 2-plate concept prevailed because it offered advantages in terms of circuit material, optical casting run, mold weight and design of the die casting machine.
The design of the die took particular account of:

• minimum quantity application of release agent
• the long flow paths in the mold,
• the heat treatment of the DG components
• the weldability of the DG components
• the crashworthiness of the DG components
• Dimensional requirements of the DG components

In addition, the tightness (absence of pores in the machined housing flanges) of the assembled HVS plays a major role.

Reasons for manufacturing in die casting:
Advantages with die-cast hybrid housing compared to conventional sheet metal construction:

• reduction of 16 individual parts
• reduction of seal weld length by more than 50%
• 6 kg weight reduction
• significant savings in manufacturing costs