1. Kollmorgen Frameless Motor Mounting Practices Bonding with Structural Adhesives April 2012

2. Mounting Considerations …
Embedded Motion Technology Frameless Mounting Considerations
The benefits of Improved System Performance, Reduced Maintenance, Smaller Mechanical Footprint, Higher System Efficiency are understood
Customer still has a key question in mind …
I like the frameless design concept but how do I mount the motor components into my machine?

3. Mounting Considerations …
Mechanical Mounting Considerations
Customer’s own bearings
Customer’s shafting / drivetrain
Bearing precision and machining tolerances are dependent more on customer machine requirements than frameless motor mounting requirements
Run-out more dependent on customer requirements
Air gap of 0.015” – 0.075” (0.38 mm – 1.9 mm) each side of rotor needed for frameless motor
Mounting; Bonding, Clamping, and Shrink fit options discussed in some detail in the KBM Selection Guide

4. Radial Running Clearance – “AirGap”
Source: KBM Selection Guide p.75 – KM_SG_00073_RevB_EN
Source: KBM Selection Guide p.69 – KM_BR_00073_RevA_UK_KBM

5. KBM-43X03 Mounting Example Bonding
Customer Through-bore type Encoder
KBM-43X03 Stator
Customer Duplex Bearing
KBM-43X03 Rotor
Customer Machine Shaft
Customer Housing

6. KBM-43X03 Mounting Example Bonding
Customer Housing with Stator embedded
Customer Shaft with Rotor

7. KBM-43X03 Mounting Example Bonding
Customer Housing
KBM Stator
Customer Shaft
KBM Rotor

8. KBM-43X03 Mounting Example Bonding
Customer Housing
Housing / Stator Exploded View
KBM Stator

9. KBM-43X03 Mounting Example Bonding
Housing / Stator Assembly
See Detail A
3D to 2D

10. KBM-43X03 Mounting Example Bonding
Detail A – Stator / Housing
Depth stop shoulder feature
0.10/0.05 mm gap per side, “slip fit”
Insert Stator
0.26/0.13 mm additional adhesive groove, 50+% of surface
2 mm min. end turn to housing clearance
Recommended Structural Epoxy 3M Scotchweld Hysol EA934NA

11. KBM-43X03 Mounting Example Bonding
Recommended for KBM Frame size 118XX and smaller
Recommended Structural Epoxy:
3M Scotchweld 2214
Hysol EA934NA
Design Recommendations
Cylindrical cup shape customer housing
Locating shoulder for precise location
Lead in chamfer to aid in assembly operation
Maintain clearance over potted winding surfaces > 2 mm
Slip fit with housing of mm over stator OD max
Adhesive grooves with extra slip fit gap of mm
Parts will “self-center” during cure by orienting in vertical axis
Maximum Cure temperature of 155 C to prevent insulation damage
Please Note that:
Adhesive manufacture guidelines should be followed
Other adhesives can be used
Customer ultimately responsible for proper design of:
Housing dimensions accounting for thermal effects
Proper surface preparation and application of adhesive

12. KBM-43X03 Mounting Example Bonding
Customer Shaft
Rotor
Rotor / Shaft Exploded View

13. KBM-43X03 Mounting Example Bonding
Rotor / Shaft Assembly
3D to 2D
See detail B

14. KBM-43X03 Mounting Example Bonding
Recommended Retaining Compound: Loc-Tite 640
No adhesive grooves with Retainer Compound mounting configuration
Rotor
0.05/0.025 mm gap per side, “precise location slip fit”
Bolt-on Mounting also practical for removable rotor
Fit depth to shoulder
Shaft
Detail B – Rotor / Shaft Assembly

15. Mounting Considerations …
Bonding with Structural Adhesives
Bearing precision and machining tolerances are dependent more on customer machine requirements than frameless motor mounting requirements
Structural adhesives represent a cost-effective, industry proven, and mechanically sound approach to frameless motor mounting
Several mounting options; Bonding, Clamping, and Shrink fit options are discussed in some detail in the KBM Selection Guide