Electrical Connections

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

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

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.

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.

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.

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.

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

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.

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.

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

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.

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.