How to design the Die Casting Control Box Housing of new energy electric vehicles to meet the needs of efficient heat dissipation?

Aluminum alloy is often selected as the material for Die Casting Control Box Housings due to its good thermal conductivity, low density, high strength and corrosion resistance. It can not only conduct heat effectively, but also reduce the overall weight, thereby improving the energy efficiency of the vehicle.
Designing heat dissipation fins on the Die Casting Control Box Housing can increase the heat dissipation area and improve the heat dissipation efficiency. The shape, size and layout of the fins should be optimized according to the heat load and heat dissipation requirements. Designing a heat dissipation channel inside the Die Casting Control Box Housing can guide the flow of air or coolant to take away the heat. This design needs to ensure the smoothness and sealing of the channel to prevent coolant leakage or air short circuit. For controllers with high power density, water cooling can be used for heat dissipation. By designing cooling water channels inside the Die Casting Control Box Housing, the coolant circulation is used to take away the heat. This method has higher heat dissipation efficiency, but requires additional cooling systems and sealing measures.
Applying thermal conductive silicone grease or fitting thermal conductive insulation sheets between the controller and the Die Casting Control Box Housing can reduce the thermal resistance between the heat source and the heat dissipation device and improve the heat transfer efficiency. Thermal grease has the characteristics of low thermal resistance and good thermal conductivity, while thermal insulation sheets can provide additional insulation protection.
The high-pressure casting process used in the product can reduce the wall thickness of the product while maintaining structural strength, which is conducive to heat conduction. In addition, high-pressure casting can also improve production efficiency and reduce costs. Reasonable pouring system design can ensure that the aluminum liquid can smoothly discharge gas during the filling process, reduce defects such as pores and oxide inclusions, and thus improve the heat dissipation performance of the die-casting.
The design of the die-casting control box housing also needs to consider electromagnetic compatibility to prevent the electromagnetic radiation generated inside from interfering with other electronic equipment. The housing should have sufficient protection level to prevent dust, moisture and other contaminants from entering the interior to ensure the long-term and stable operation of the electric drive system.