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DESIGN GUIDE FOR ELECTRIC MOTORS AND …

DESIGN GUIDE FORELECTRIC MOTORS AND GENERATORSTABLE OF CONTENTSINTRODUCTIONMOTOR CUTAWAYSDC motor 2AC motor 4 APPLICATIONSB onding, General6 Bonding, Magnets8 Gasketing10 Potting12 Retaining14 Tacking16 Threadlocking18 Thread Sealing20 Wire Reinforcement22 CHEMISTRIESO verview24 Applications Summary 25 General Adhesive Comparison26 Acrylics, Two-Step28 Acrylics, Two-Part29 Anaerobics30 Cyanoacrylates32 Epoxies33 Hot Melts35 Light Cure36 Polyurethanes37 Silicones39 PRODUCT SELECTOR42 APPLICATION TABLE OF CONTENTSROTORA rmature, retain to shaft14 Bearings, retain to shaft14 Commutator, retain to shaft14 Fan, bond to armature6 Fan, bond to shaft6 Insulation, bond to rotor ends16 Insulation, bond to rotor slots16 Key, retain to slot in shaft14 Magnet segments, bond to rotor8 Ring magnets, bond to rotor8 Rotor, retain to shaft14 Speed control, retain to shaft14 Wires, reinforce at commutator tang22 STATORI nsulation, bond to stator16 Insulation, bond to wires16 Lead wires, bond or

ATTRIBUTE ACRYLIC, TWO-STEP ACRYLIC, TWO-PART CYANOACRYLATE EPOXY, TWO-PART HOT MELT Key Benefits • Fast fixture speed • No mixing

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Transcription of DESIGN GUIDE FOR ELECTRIC MOTORS AND …

1 DESIGN GUIDE FORELECTRIC MOTORS AND GENERATORSTABLE OF CONTENTSINTRODUCTIONMOTOR CUTAWAYSDC motor 2AC motor 4 APPLICATIONSB onding, General6 Bonding, Magnets8 Gasketing10 Potting12 Retaining14 Tacking16 Threadlocking18 Thread Sealing20 Wire Reinforcement22 CHEMISTRIESO verview24 Applications Summary 25 General Adhesive Comparison26 Acrylics, Two-Step28 Acrylics, Two-Part29 Anaerobics30 Cyanoacrylates32 Epoxies33 Hot Melts35 Light Cure36 Polyurethanes37 Silicones39 PRODUCT SELECTOR42 APPLICATION TABLE OF CONTENTSROTORA rmature, retain to shaft14 Bearings, retain to shaft14 Commutator, retain to shaft14 Fan, bond to armature6 Fan, bond to shaft6 Insulation, bond to rotor ends16 Insulation, bond to rotor slots16 Key, retain to slot in shaft14 Magnet segments, bond to rotor8 Ring magnets, bond to rotor8 Rotor, retain to shaft14 Speed control, retain to shaft14 Wires, reinforce at commutator tang22 STATORI nsulation, bond to stator16 Insulation, bond to wires16 Lead wires, bond or reinforce16, 22 Stator, bond and unitize laminates6, 14 Stator, bond to housing6 HOUSINGB earing, retain to housing14 Bolts, prevent from loosening18 Brackets, bond to housing6 Controller boards, pot12 End plate, retain into housing14 End plate, seal to housing10 Fittings, seal threads20 Flanges.

2 Seal to gearboxes10 Frame, bond supports6 Magnet segments, bond to rotor8 Plugs, seal threads20 Screws, prevent from loosening18 Wire connectors, seal12 INTRODUCTIONE lectric motor and generator manufacturers have used Loctite brand products to improve performance, to facilitate manufacturing processes and to reducecosts for more than 40 years. While almost allmanufacturers use adhesives and sealants in someassembly operations, very few manufacturers havedeveloped the experience to fully take advantage of the benefits that adhesives and sealants can offer. The objective of this DESIGN GUIDE is to educate DESIGN , manufacturing and quality engineers on where and why adhesives and sealants are commonly used on MOTORS and generators to help them recognize their full potential.

3 To accomplish this, the following key areas are reviewed in this DESIGN GUIDE :Typical ApplicationsA detailed review of thecommon applications of adhesives and sealants onmotors and generators. This includes illustrations,an overview, a comparison of the adhesivetechnologies suitable for that application, and a product selector ChemistriesThere are detailed descriptions of each chemistry. This includes a general description, typicalapplications, advantages, disadvantages, and manufacturing process considerations. Product SelectorOne table that summarizes allthe adhesives and sealants that are mostcommonly used on ELECTRIC ORJUNCTION BOXEND PLATETHROUGH BOLTCOMMUTATORBEARINGBRUSHBRUSH HOLDER2 HOUSING OR CANSHAFTKEYBEARINGMAGNETROTORINSULATIONR OTOR WIRESEND PLATE3 THROUGH BOLTSTATOR WINDINGSTATOR WIRE INSULATIONEND PLATEKEYSHAFTBEARING4 STATORHOUSINGROTORBEARINGFANEND PLATESTATOR SLOT INSULATION56 OVERVIEWG eneral bonding applications are usuallycharacterized by the use of an adhesive as the sole means of structurally joining two parts thathave a relatively small gap between them, " to ".

4 Adhesives are widely used for bonding applications instead of welding, soldering, ultrasonic welding, riveting, mechanical fasteners, and tapes. The key benefits of adhesives over these alternative methods are: Lower cost Easily automated Distribute stresses evenly Better cosmetic appearance Bond dissimilar substratesADHESIVE TYPE COMPARISONT here are a wide variety of adhesives that can beused for general bonding applications. The keyselection criteria involves, but is not limited to, the following adhesive properties: Cure speed Temperature/environmental resistance Cost Adhesion to substrates Processing requirements (dispensing and curing)

5 Table 1compares and contrasts the five mostcommonly used types of adhesives for 11on page 26 gives a more complete comparison of all ten adhesive APPLICATIONSSTATOR TO HOUSINGBRACKET TO HOUSINGBOND SUPPORT FRAMEATTRIBUTEACRYLIC, TWO-STEPACRYLIC,TWO-PARTCYANOACRYLATEEPO XY, TWO-PARTHOT MELTKey Benefits Fast fixture speed No mixing Good adhesion to metals and ceramics Excellent toughness Light cure available High gap fill Structural strengths High impact strength Able to cut through surface contaminants Fast fixture speed High adhesionto most materials Light cure available Room temperature cure High gap fill Excellent temperature resistance Wide variety of formulations Fast fixture speed Low volumetric cost Many types of hot melts offer a wide range of performanceKey Limitations Limited gap fill Exposed adhesive may remain tacky Separate dispensing of activator Long cure time Will cure in mix tip

6 During idle times May have strong odor May have flammable vapors Limited gap fill Low temperatureresistance Durability may be affected by substrate corrosion Long cure times Adhesive cures in mix tip Limited adhesion to plastics and elastomers Equipment needed for bulk dispensing May have poor adhesion to metals Dispensing equipment required Hot dispense point can be a safety concernAdhesive to SubstratesMetalsExcellentExcellentVery GoodExcellentGoodPlasticsFairVery GoodExcellentFairVery GoodPaperExcellentExcellentExcellentExce llentExcellentGap - " - " - " - " - " "> " "> " " Range-65 to 300 F-65 to 300 F-65 to 180 F-65 to 300 F-65 to 250 FMaximum400 F400 F250 F400 F330 FFixture TimeAverage1 - 2 min15 - 30 min20 - 30 sec20 - 30 min30 secFastest15 - 30 sec3 -5 min5 - 10 sec3 - 5 min5 - 10 secFull Cure24 hours24 hours24 hours24 hours24 hoursEquipment RequiredNoTwo-Part DispensingNoTwo-Part DispensingHot Melt Dispenser 392TM Gen.

7 Purpose 326TM Fast fixture 334TM High impact 332TM Severe environment 3920TM Light cure H3000TM Gen. purpose H4500TM Metal bonding H8000TM High impact H8500TM Ultra high impact H8600TM- Severe Env. 380TM Gen. purpose 4500TM Fast cure 4205TM High temp. 4307TM Light cure E-20 NSTM Gen. purpose E-40 FLTM Flexible E-20 HPTM High impact 7804 FRM-HVTM Gen. purpose 3631TM High adh. to metals 0450TM Long open time 7901TM High BRANDPRODUCTSTABLE 1. COMPARISON OF ADHESIVE TYPES FOR GENERAL BONDING7 For additional information on the Loctite products listed, please refer to the product selector in the back of this GUIDE or visit TYPE COMPARISONIn general, any of these adhesives can achieve bond strengths that exceed the tensile or compressive strength of the magnet.

8 As a result, the key performance attributes that typically differentiate these adhesive types are: Cure speed Gap fill Temperature resistance Impact strengthTable 2compares and contrasts the four most commonly used types of adhesives for magnet in ELECTRIC MOTORS are almost exclusivelyassembled today using adhesives. While a handfulof different adhesive technologies are employed to meet the unique challenges of each specificmotor s performance and processing requirements,it is widely accepted that adhesives create a higherquality joint at a lower cost than mechanical fasteners such as clips and key benefits of adhesives over clips and bolts are.

9 Lower cost components Decreased inventory cost Easier to automate Will not chip magnets Prevent vibrational noise Prevent corrosionTYPICAL APPLICATIONS8 MAGNET SEGMENTS TO ROTORRING MAGNETS TO ROTORMAGNET SEGMENTS TO HOUSINGATTRIBUTEACRYLIC, TWO-STEPCYANOACRYLATEEPOXY, ONE-PART HEAT CUREEPOXY,TWO-PARTKey Benefits Fast fixture speed No mixing High impact strength Light cure available Fast fixture speed High adhesion to plastics and elastomers Light cure available High gap fill Excellent temperature resistance Fully cured in one hour Room temperature cure High gap fill Excellent temperature resistance Wide variety of formulationsKey Limitations Limited gap fill Must control activator amount precisely Activator may contain solvents Limited gap fill Low temperature resistance Durability may be affected by substrate corrosion Curing equipment required Long cure times Must allow parts to cool Long cure times Adhesive

10 Cures in mix tip Limited adhesion to plastics and elastomers Equipment needed for bulk dispensingGap - " - " - " - " " "> "> " Range-65 to 300 F-65 to 180 F-65 to 350 F-65 to 300 FMaximum400 F250 F400 F400 FImpact Strength (steel)ExcellentFairGoodGoodFixture TimeAverage1 - 2 min20 - 30 sec30 - 45 min20 - 30 minFastest15 - 30 sec5 - 10 sec15 - 30 min3 - 5 minFull Cure24 hours24 hours1 hour24 hours 392TM Gen. purpose 326TM Fast cure 334TM High temp. & impact 332TM Severe environment 3920TM Light cure 380TM Gen. purpose 4500TM Fast cure 4205TM High temp. 4307TM Light cure 9423 NATM Gen. purpose 3984TM Fast cure 3985TM High viscosity E-20 NSTM Gen.


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