In July 2019, Tesla released a new patent, namely a multi-directional body integrated casting machine for automobile frames and related casting methods, proposing a frame integrated casting technology and related casting machine design.
The traditional manufacturing process of automobiles mainly includes stamping and welding, as well as painting and the four major process links.
The integrated die-casting technology is to use a super-large die-casting machine to die-cast hundreds of parts that need to be assembled, and the complete parts can be directly obtained, which is 79 fewer parts than before, and can reduce the manufacturing cost by 40.
More than 70 parts and welded parts that need to be stamped can be directly omitted, and the body can be directly die-cast through integrated die-casting technology.
The manufacturing time has been reduced from more than an hour to less than 3 minutes.
Originally 300 robots were needed in the manufacturing process, but now only one large die-casting machine is required.
The original 300 workers required in the welding workshop can be reduced to only about 30 maintenance personnel for the integrated die-casting machine.
The floor space of the welding workshop can be greatly reduced, saving about 30% of the floor space compared to the previous design.
In terms of the whole vehicle, the rear floor assembly adopts an integrated die-cast modei y that reduces the weight by about 30, thereby increasing the cruising range by 14 and saving electricity bills.
Compared with the original, the manufacturing cost has been saved by about 40%, which has greatly improved the Modii Y in terms of product power and cost performance.
1. In terms of materials, it mainly relies on aluminum alloy materials that are free of heat treatment.
2. In terms of equipment, there are higher requirements for the clamping force of the die-casting machine, and the die-casting machine has technical barriers for customized design and development, as well as relatively high capital expenditure.
3. In terms of molds, integrated die-casting parts, complex structure and high manufacturing costs, as well as long preparation cycle, which have higher requirements for the production of die-casting molds.
4. In terms of technology, because the current integrated die-casting technology is still in its infancy, it is necessary for die-casters to have rich experience and technical accumulation in the production process to ensure the yield rate of mass production.
Pay attention to the cooperative relationship between car companies and third-party die-casting companies, if the cooperation changes or is unstable, it will have a great impact.
Since the parts are die-cast into one piece, the repair cost will be high in the event of a collision.