Casting Study: Busbar for electric fan

As an individual part, the award-winning casting is a very filigree, long and sensitive component. Four individual and very thin conductor strands with dimensions in the millimeter range have to be produced by casting with a cross-section of perhaps just one cm². The production of the long flow paths in the casting tool for this busbar with connector area and the associated conception of the work paths in the casting tool could only be implemented with a mold filling simulation. This simulation was used to determine the optimal sprue geometry, which achieves the high casting quality. Since it is not possible to deburr the component by trimming due to the filigree overall geometry, this work step is carried out using a special tool as well as plastic granulate blasting. The workpiece, which is tinsel-free as a result, is insulated for use as a current-carrying connection by overmoulding with plastic. The plastic also gives the component the required stability and shields any moisture. These properties represent an improvement over the conventionally used cabling. The casting is used as a connection component in a fan.

The jury honored the zinc die-cast component with the winner in the electrical engineering category. The precision and the filigree of the component with the associated design of the casting mold and the further coating by plastic injection molding are particularly emphasized.