Kollmorgen Frameless Motor Mounting Practices Bonding with Structural Adhesives April 2012

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?

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

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

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

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

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

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

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

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 2214 Hysol EA934NA

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 0.1-0.2 mm over stator OD max Adhesive grooves with extra slip fit gap of 0.13-0.26 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

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

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

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

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