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11 comments
Active Contributor

Join Date: Oct 2008
Location: Nebraska
Posts: 12

Electrical Connections

08/03/2012 12:09 PM

In our manufacturing process we connect our PCBA motor leads to a gear motor using a quick disconnect type fitting on the blades of the motor. We have had some field returns where the motor leads have become disconnected. What we found was that in the original design of our gear motor we did not spec out the correct terminals on our gear motor to be used with a quick disconnect so we get no locking action from the quick disconnect which leads to the motor leads becoming disconnected due to field conditions.

The original intent of our design was to use a quick disconnect design to facilitate online rework in the case of PCBA or motor failure during the assembly process. Of course designing rework of failure into the product is folly.
We solder the other end of the motor leads to the PCBA and do not wish to rediesign the PCBA to change as this would create a rather large project in recertification of our PCBA. This is also the case in a redesign of the terminals on the gear motor.

What I am asking is for better Ideas for this connection, we are considering many options, personally I lean towards a solder connection but need ideas as to equipment available to quickly solder this connection without the possibilty of cross contamination created by solder splatter, flux contamination on the sealing areas of our product (one of our claims to fame is that we are water resistant and protect against ignition sources in an explosive environment).

Do any of you have a quick clean solder solution or perhaps a solder free solution (some type of conductive adhesive perhaps?)

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Guru

Join Date: Mar 2007
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#1

Re: Electrical connections

08/03/2012 12:45 PM

You might check with manufacturers for best price/solution....here's one...

http://www.masterbond.com/properties/electrically-conductive-adhesive-systems

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#2

Re: Electrical connections

08/03/2012 12:53 PM

From your picture there appears to be a hole in the quick connect terminal of the motor. Which is the retainer. I do notice also that the terminal end on the wire looks it's too big for it. Are they matched in size? If not that is a problem and you will have align issues with the lock.

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Active Contributor

Join Date: Oct 2008
Location: Nebraska
Posts: 12
#3
In reply to #2

Re: Electrical connections

08/03/2012 1:28 PM

Very observant ozzb, in fact they are not matched in size. In fact we have a different gear motor that has different sized blades. This was a design oversight when this series was introduced.

One issue that has presented is that our motor vendor has informed us these motor blades and the internal structure of same was not designed or intended to be subjected to the external forces that would be required for a quick disconnect type connector. Their assumption was that we would be using a solder connection for the leads.

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#8
In reply to #3

Re: Electrical connections

08/04/2012 8:42 AM

Well the wire looks long enough, replace the terminal to the right size. Or after cutting it off solder it in place. Another option would be to order the motor with wire leads. Have screw terminals solder on the board.

As far as the comments from the motor vendor he just covering his butt. Have seen it done both ways. The wire soldered when the device subjected to vibration that may cause many types of termination to come loose.

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#4

Re: Electrical connections

08/03/2012 8:04 PM

Why not solder a wire of the correct size to the solder terminal on the motor, leave enough length of wire to grasp with thumb/finger and solder the correct spade lug to the other end. I'd say an inch or two would do it.

That takes the stress off the motor terminal.

BTW, this is a prime source for sparks. I'd back off on my claims to, "protect against ignition sources in an explosive environment" for now, if I were you.

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Guru

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#5
In reply to #4

Re: Electrical connections

08/03/2012 11:01 PM

....then there's the sparks from the brushes.

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#11
In reply to #5

Re: Electrical connections

08/05/2012 7:43 PM

Lyn & Wal - That's just what I saw - an unsealed brushed motor in explosive environments: NO WAY!

To bgot: If you want your system to work in an explosive environment, you don't just need to change the connections, you need a totally different motor or gearmotor. An appropriate one is going to cost significantly more than the current one, but that will be a whole lot cheaper than just one lawsuit from a company whose building blew up due to a spark from one of your units, even if no one is injured or killed in the process.

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Power-User

Join Date: Jun 2011
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#6

Re: Electrical connections

08/04/2012 3:08 AM

The very first thing that comes to mind is to drill a hole through the connector and put an appropriate sized cotter-pin in the hole to stabilize the connection. Simple, cheap low tech, and easily reversible.

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#7

Re: Electrical connections

08/04/2012 8:14 AM

http://www.semicro.org/conductiveproducts.aspx

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#9

Re: Electrical Connections

08/04/2012 10:31 AM

They look like standard blade connectors. You can buy latching versions of the female connector, these have a tab that has to be pressed to remove the connector, might be more secure.

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Commentator

Join Date: Mar 2007
Posts: 55
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#10

Re: Electrical Connections

08/04/2012 2:57 PM

Perhaps attaching the wires to the motor with a spot weld or ultrasonic weld would work. You may want to use insulating sleeving on the connections. I have seen this type of thing done on thermal controls but have never worked with these methods.

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Users who posted comments:

bgot (1); dkwarner (1); Doug (1); lyn (1); Nigh (1); ozzb (2); SolarEagle (1); SWB123 (1); Tom_Consulting (1); Wal (1)

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