Design of battery pack mounting bracket as part of prototype battery-driven electric train development

Abstract

Tema ovog završnog rada je konstruiranje i simuliranje nosača krovnih baterija vlaka putem programskog paketa CATIA na način da zadovolje normu HRN EN 12633. Nosače je potrebno izraditi iz legure AlZn10Si8Mg postupkom gravitacijskog lijevanja u pješčani kalup. Prije konstruiranja objašnjena je navedena norma, postupak lijevanja i razlog korištenja navojnih umetaka za vijčane spojeve. Zatim rad prikazuje iterativni postupak dolaska do konačnog proizvoda simuliranjem inačica nosača jednu za drugom unaprjeđujući ih sve do zadnje. Nakon dobivenog oblika konačnog nosača proizveden je 3D printani model koji služi za proizvodnju pješčanih kalupa. Korištenjem programskog paketa Altair Inspire Cast simulirano je lijevanje aluminijske legure u kalup i naznačeni potencijalni problemi prilikom lijevanja te je prikazan postupak lijevanja uživo. Na kraju rada nalaze se rezultati ispitivanja provedenih tokom proizvodnje nosača kako bi se usporedio nosač dobiven u programskom paketu sa stvarnim rezultatima ispitivanja.The subject of this final paper is the construction and simulation of train roof battery supports using the CATIA software package in such a way that the HRN 12633 standard is met. The supports must be made from the AlZn10SiMg alloy using gravity die casting into a sand mold. Before constructing, the stated norm, casting process and the reason for using threaded inserts for screw connections were explained. Then the paper shows the iterative process of working towards the final product by simulating the mounting bracket versions one after the other and improving them until the last one. After obtaining the shape of the final mounting bracket, a 3D printed model was produced, which is used for the production of sand molds. Using the software package Altair Inspire Cast, the casting of the Aluminium alloy into a mold was simulated and potential problems during the casting were indicated after which a live casting process was shown. At the end of the paper, the results of tests carried out during the production of the mounting brackets are shown so that real results could be compared to the ones obtained in the software packages