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Loctite Adhesives Design Guide for Electric Motors and Generators

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Loctite Adhesives Design Guide for Electric Motors and Generators DESIGN GUIDE FOR ELECTRIC MOTORS AND GENERATORS TABLE OF CONTENTS APPLICATION TABLE OF CONTENTS INTRODUCTION ROTOR MOTOR CUTAWAYS Armature, retain to shaft 14 Bearings, retain to shaft 14 DC Motor 2 Commutator, retain to shaft 14 AC Motor 4 Fan, bond to armature 6 APPLICATIONS Fan, bond to shaft 6 Insulation, bond to rotor ends Bonding, General 6 16 Insulation, bond to rotor slots 16 Bonding, Magnets 8 Key, retain to slot in shaft 14 Gasketing 10 Magnet segments, bond to rotor 8 Potting 12 Ring magnets, bond to rotor 8 Retaining 14 Rotor, retain to shaft 14 Speed control, retain to shaft 14 Tacking 16 Wires, reinforce at 22 Threadlocking 18 commutator tang STATOR Thread Sealing 20 Insulation, bond to stator 16 Wire Reinforcement 22 Insulation, bond to wires 16 CHEMISTRIES Lead wires, bond or reinforce 16, 22 Overview 24 Stator, bond and unitize laminates 6, 14 Applications Summary 25 Stator, bond to housing 6 HOUSING General Adhesive Comparison 26 Bearing, retain to housing 14 Acrylics, Two-Step 28 Bolts, prevent from loosening 18 Acrylics, Two-Part 29 Brackets, bond to housing 6 Anaerobics 30 Controller boards, pot 12 Cyanoacrylates 32 End plate, retain into housing 14 End plate, seal to housing 10 Epoxies 33 Fittings, seal threads 20 Hot Melts 35 Flanges, seal to gearboxes 10 Light Cure 36 Frame, bond supports 6 Polyurethanes 37 Magnet segments, bond to rotor 8 Plugs, seal threads 20 Silicones 39 Screws, prevent from loosening 18 PRODUCT SELECTOR 42 Wire connectors, seal 12 INTRODUCTION To accomplish this, the following key areas are reviewed in this design guide: Electric motor and generator manufacturers have used Loctite® brand products to improve performance, Typical Applications A detailed review of the to facilitate manufacturing processes and to reduce common applications of adhesives and sealants on costs for more than 40 years. While almost all motors and generators. This includes illustrations, manufacturers use adhesives and sealants in some an overview, a comparison of the adhesive assembly operations, very few manufacturers have technologies suitable for that application, developed the experience to fully take advantage of and a product selector chart. the benefits that adhesives and sealants can offer. Adhesive Chemistries There are The objective of this design guide is to educate detailed descriptions of each chemistry. design, manufacturing and quality engineers on This includes a general description, typical where and why adhesives and sealants are applications, advantages, disadvantages, commonly used on motors and generators and manufacturing process considerations. to help them recognize their full potential. Product Selector One table that summarizes all the adhesives and sealants that are most commonly used on electric motors. 1 CONDUIT OR JUNCTION BOX WIRE CONNECTOR END PLATE COMMUTATOR BEARING BRUSH BRUSH HOLDER THROUGH BOLT 2 HOUSING OR CAN END PLATE KEY SHAFT BEARING ROTOR INSULATION MAGNET ROTOR WIRES 3 STATOR WINDING STATOR WIRE INSULATION THROUGH BOLT END PLATE KEY SHAFT BEARING 4 END PLATE FAN BEARING ROTOR STATOR SLOT INSULATION STATOR HOUSING 5 TYPICAL APPLICATIONS STATOR TO HOUSING BRACKET BOND TO HOUSING SUPPORT FRAME OVERVIEW General bonding applications are usually characterized by the use of an adhesive as the ADHESIVE TYPE sole means of structurally joining two parts that COMPARISON have a relatively small gap between them, typically There are a wide variety of adhesives that can be 0.002" to 0.10". Adhesives are widely used used for general bonding applications. The key for bonding applications instead of welding, selection criteria involves, but is not limited to, the soldering, ultrasonic welding, riveting, following adhesive properties: mechanical fasteners, and tapes. • Cure speed The key benefits of adhesives over • Temperature/environmental resistance these alternative methods are: • Cost • Lower cost • Adhesion to substrates • Easily automated • Processing requirements (dispensing and curing) • Distribute stresses evenly Table 1 compares and contrasts the five most commonly used types of adhesives for bonding. • Better cosmetic appearance Table 11 on page 26 gives a more • Bond dissimilar substrates complete comparison of all ten adhesive types. 6 GENERAL BONDING TABLE 1. COMPARISON OF ADHESIVE TYPES FOR GENERAL BONDING ACRYLIC, ACRYLIC, EPOXY, ATTRIBUTE TWO-STEP TWO-PART CYANOACRYLATE TWO-PART HOT MELT OVERVIEW • Room • Fast fixture speed • High gap fill temperature cure • Fast fixture speed • No mixing • Fast fixture speed • Structural strengths • High gap fill • Low volumetric cost • Good adhesion to • High adhesion Key Benefits • High impact strength • Excellent temperature • Many types of hot metals and ceramics to most materials • Able to cut through resistance melts offer a wide • Excellent toughness • Light cure available surface contaminants • Wide variety range of performance • Light cure available of formulations • Long cure times • Long cure time • Limited gap fill • Adhesive cures • May have poor • Limited gap fill • Will cure in mix tip • Low temperature in mix tip adhesion to metals • Exposed adhesive during idle times resistance • Limited adhesion • Dispensing Key Limitations may remain tacky • May have strong odor • Durability may to plastics and equipment required • Separate dispensing • May have be affected by elastomers • Hot dispense point can of activator flammable vapors substrate corrosion • Equipment needed be a safety concern for bulk dispensing PERFORMANCE Metals Excellent Excellent Very Good Excellent Good Adhesive to Plastics Fair Very Good Excellent Fair Very Good Substrates Paper Excellent Excellent Excellent Excellent Excellent Ideal 0.002 - 0.004" 0.004 - 0.006" 0.001 - 0.003" 0.004 - 0.006" 0.002 - 0.005" Gap Fill Maximum 0.040" >0.50" 0.010" >0.50" 0.25" Temp. Typical Range -65 to 300°F -65 to 300°F -65 to 180°F -65 to 300°F -65 to 250°F Resistance Maximum 400°F 400°F 250°F 400°F 330°F PROCESSING Average 1 - 2 min 15 - 30 min 20 - 30 sec 20 - 30 min 30 sec Fixture Time Fastest 15 - 30 sec 3 -5 min 5 - 10 sec 3 - 5 min 5 - 10 sec Full Cure 24 hours 24 hours 24 hours 24 hours 24 hours Equipment Required No Two-Part Dispensing No Two-Part Dispensing Hot Melt Dispenser LOCTITE® BRAND PRODUCTS • 392TM – Gen. purpose • H3000TM – Gen. purpose • 380TM – Gen. purpose • E-20NSTM – Gen. purpose • 7804FRM-HVTM – • 326TM – Fast fixture • H4500TM – Metal bonding • 4500TM – Fast cure • E-40FLTM – Flexible Gen. purpose • 334TM – High temp. • H8000TM – High impact • 4205TM – High temp. • E-20HPTM – High impact • 3631TM – High & impact • H8500TM – Ultra high • 4307TM – Light cure adh. to metals • 332TM – Severe impact • 0450TM – Long open time environment • H8600TM - Severe Env. • 7901TM – High temp. • 3920TM – Light cure For additional information on the Loctite® products listed, please refer to the product selector in the back of this guide or visit www.loctite.com/datasheets. 7 TYPICAL APPLICATIONS MAGNET SEGMENTS RING MAGNETS MAGNET SEGMENTS TO HOUSING TO ROTOR TO ROTOR OVERVIEW ADHESIVE TYPE Magnets in electric motors are almost exclusively COMPARISON assembled today using adhesives. While a handful In general, any of these adhesives can of different adhesive technologies are employed achieve bond strengths that exceed the tensile to meet the unique challenges of each specific or compressive strength of the magnet. As motor’s performance and processing requirements, a result, the key performance attributes that it is widely accepted that adhesives create a higher typically differentiate these adhesive types are: quality joint at a lower cost than mechanical • Cure speed fasteners such as clips and bolts. • Gap fill The key benefits of adhesives • Temperature resistance over clips and bolts are: • Impact strength • Lower cost components Table 2 compares and contrasts the four most commonly used types of • Decreased inventory cost adhesives for magnet bonding. • Easier to automate • Will not chip magnets • Prevent vibrational noise • Prevent corrosion 8 MAGNET BONDING TABLE 2. COMPARISON OF ADHESIVE TYPES FOR BONDING MAGNETS EPOXY, ACRYLIC, EPOXY, ATTRIBUTE CYANOACRYLATE ONE-PART TWO-STEP TWO-PART HEAT CURE OVERVIEW • Room temperature cure • Fast fixture speed • Fast fixture speed • High gap fill • High gap fill • No mixing • High adhesion to • Excellent temperature Key Benefits • Excellent temperature • High impact strength plastics and elastomers resistance resistance • Light cure available • Light cure available • Fully cured in one hour • Wide variety of formulations • Long cure times • Limited gap fill • Limited gap fill • Curing equipment • Adhesive cures in mix tip • Must control activator • Low temperature required • Limited adhesion to Key Limitations amount precisely resistance • Long cure times plastics and elastomers • Activator may • Durability may be affected • Must allow parts to cool • Equipment needed contain solvents by substrate corrosion for bulk dispensing PERFORMANCE Ideal 0.002 - 0.004" 0.001 - 0.003" 0.004 - 0.006" 0.004 - 0.006" Gap Fill Maximum 0.040" 0.010" >0.50" >0.50" Typical Range -65 to 300°F -65 to 180°F -65 to 350°F -65 to 300°F Temp. Resistance Maximum 400°F 250°F 400°F 400°F Impact Strength (steel) Excellent Fair Good Good PROCESSING Average 1 - 2 min 20 - 30 sec 30 - 45 min 20 - 30 min Fixture Time Fastest 15 - 30 sec 5 - 10 sec 15 - 30 min 3 - 5 min Full Cure 24 hours 24 hours 1 hour 24 hours LOCTITE® BRAND PRODUCTS • 392TM – Gen. purpose • 380TM – Gen. purpose • 9423NATM – Gen. purpose • E-20NSTM – Gen. purpose • 326TM – Fast cure • 4500TM – Fast cure • 3984TM – Fast cure • E-40FLTM – Flexible • 334TM – High temp. & impact • 4205TM – High temp. • 3985TM – High viscosity • E-20HPTM – High impact • 332TM – Severe environment • 4307TM – Light cure • 3920TM – Light cure For additional information on the Loctite® products listed, please refer to the product selector in the back of this guide or visit www.loctite.com/datasheets. 9 TYPICAL APPLICATIONS HOUSING TO JUNCTION BOX COVER TO JUNCTION BOX END PLATE OVERVIEW TO HOUSING Henkel has been replacing or augmenting cut gaskets for decades. Formed-in-place gaskets are the most commonly used “liquid gaskets”.
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