How to Bond Motors & Electronic Speed Controllers

Billions of electric motors are manufactured worldwide every year. Without proper bonding and assembly, they quickly become ineffective. That is why, in this article, we are exploring how to bond motors and electronic speed controllers.

Table of Contents

electric motor

Types of Motors

Brushless Motor Controllers

Brushless motor controllers are used in many industrial applications, ranging from linear motors, robot actuators, servomotors and drive motors for CNC machines. In general, brushless motor controllers are used for motion control and positioning systems.

The advantages of brushless motors include their high power-to-weight ratio, high speed and low maintenance.

Electronic Speed Controllers

Electronic speed controllers (ESC) are electronic circuits that control the speed of an electric motor. ESCs have applications in cars, helicopters, aeroplanes and boats. ESCs go hand-in-hand with motors, and therefore bonding them is an essential part of the manufacturing process of an electronic device.

Outrunners

An outrunner is a brushless electric motor that is used in an electrical unmanned aerial vehicle (UAV). Outrunners have many poles, making them spin slow while producing a high torque. This makes them ideal for use in small aerospace applications as they are lightweight, powerful, efficient and not as noisy as a gearbox.

To learn more about UAVs, their advantages and disadvantages, and how to bond their panels, read our article “Versatile Adhesives to Bond UAVs, Drones, Robots“.

How to Bond Motors

When it comes to electronic equipment, bonding with adhesives is preferred over traditional methods such as soldering, welding and fasteners. The reasons for this include improved aesthetics, motor life and process speed, as well as reduced corrosion, vibration and hazard potential. To learn more about the advantages of adhesives over traditional fastening methods, read our article “What Are Structural Adhesives?“.

Typically, motor bonding applications include:

  • Magnet Bonding
  • Mounting Brackets
  • Bonding Brush Holder to Bracket
  • Bonding Bracket to Housing

Types of Adhesives to Bond Motors

Cyanoacrylates

Cyanoacrylates provide a fast cure and good shear strength on many materials. These include wicking grades ideal for post-assembly applications. High-temperature resistant grades are also available with cyanoacrylates. However, they provide limited impact strength and resistance to polar solvents.

Permabond 910 is a cyanoacrylate adhesive which will cure to a fixture strength in 10 seconds on most surfaces. It is ideal for the bonding of metal surfaces and provides excellent bond strength to steel and aluminium.

Permabond 2011 is a cyanoacrylate adhesive ideal for use on vertical and porous substrates. It is surface insensitive and has the maximum gap-filling capability.

UV / Anaerobic Cures

UV curing adhesives provide fast, room-temperature curing, as well as wicking grades ideal for post-assembly applications. However, they require a UV lamp in order to cure.

Permabond HM165 is an anaerobic retaining compound that can be used to structurally bond cylindrical parts. It is ideal for use in electric motor retaining applications.

Permabond UV630 is a UV curing adhesive designed for bonding plastics such as polycarbonate.  It is ideal in applications involving substrates with different coefficients of thermal expansion.

Surface Activated Acrylics

Surface activated acrylics provide room-temperature curing, high strength, and a long open time. Additionally, they are capable of withstanding machining, grinding, and other finish processes. They are ideal in electric motor magnet bonding applications.

Permabond TA437 is a structural adhesive designed for bonding metals. It can be used without the initiator, provided at least one surface is metal.

Permabond TA439 is a two-part structural adhesive similar to TA437; however, it has better chemical resistance and a non-corrosive formulation.

Epoxy Adhesives

Epoxies provide excellent thermal conductivity, strength and environmental resistance. Additionally, they are capable of withstanding machining, grinding, and other finish processes. However, they require a curing oven to fully set.

Araldite 2014-2 is a two-component epoxy that has high-temperature resistance and good adhesion to various substrates. The superior gap-filling capabilities allow 2014-2 to reliably bond motor casing.

Araldite 2033 has UL94 approval and can be used in applications which require a high-temperature resistance and self-extinguishing properties. With a medium open time and high strength when cured; 2033 provides a premium long term bond for motors.

Araldite AW4859 is a two-component heat-resistant epoxy that is ideal for bonding metals, composites and thermoplastics. The heat resistance and versatility of the bondable substrates make it a reliable option for bonding motors and speed controllers that endure high temperatures.

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