Gear motors are electric motors paired with a gear reducer that allows you to multiply the output shaft torque and/or speed. The trade off is that the motor draws more power.
For example, a 12V motor paired with a 24V gear motor will draw twice as much current from its power supply to produce the same mechanical load power. This is called efficiency.
Power
A DC gear motor is a combination of a DC motor and a gearbox that operates on direct current to limit speed and enhance torque. Choosing the right one for your application requires careful consideration of power requirements, efficiency, noise level and availability.
Electric motors convert electrical energy into mechanical energy through the use of magnets to create a magnetic field. This field interacts with the permanent magnets inside the motor to produce a rotating force, or torque. The amount of torque produced by the motor depends on the number and type of permanent magnets, the number of coils in the motor and the size of the motor.
The rated voltage of the motor is the amount of power (in watts) that it is designed to deliver at full load for continuous operation. The rated speed is the maximum number of revolutions per minute that the motor can achieve while delivering its rated power.
The motor’s power efficiency is defined by the ratio of its mechanical power (in lb-in) to its electrical power (in watts). To maximize the performance of your gear motor, you should operate it close to its rated speed and torque.
Efficiency
24V DC gear motors are capable of a wide range of speeds and torques. To ensure your application gets the most out of this versatile component, look for a model 24V DC gear motor that has a high efficiency rating. Motors with a higher efficiency rating operate more efficiently and require less current to perform tasks.
Motors are rated on an efficiency scale that typically looks like a standard parabolic curve. This curve represents the relationship between speed and torque. Essentially, the curve shows how much power is being produced by the motor at different points in its operating range. Power generally peaks early in the torque range, then decreases as you approach the maximum stall torque.
To determine the most efficient 24V DC gear motor for your application, compare its performance curve to your project’s specifications. If the motor is being used continuously, it’s important to evaluate its peak efficiency point to understand how much current it will draw over long periods of time. Ideally, your motor should operate close to its peak efficiency point, as this will give you the most balanced and consistent performance.
Stall Torque
A 24V DC gear motor can produce a lot of torque, enough to handle most mechanical loads. This is because the motor comes with a gear reducer which multiplies the available power from the motor by reducing the shaft speed. However, the resulting increase in mechanical load speed is usually only about 10%.
To increase or decrease the rated output torque, simply swap the polarity of the power supply wires connected to the motor (connect blue to black for brake, disconnect to unbrake). This is important because it can affect the torque delivered by the motor depending on how much voltage is supplied.
For this reason, many users opt for a DC gear motor that is optimized for use with a 24-volt setup, as opposed to 12 volts. This does not mean that it cannot be used 24V DC gear motor manufacturer at other voltages, but if the motor is operated above its optimum voltage, it will experience decreased performance. In some cases, operating the motor above its rated voltage can even shorten its lifespan. So make sure that the voltage is correct before you connect your motor.
Size and Weight
DC gear motors are relatively small and light for their power output. This makes them an ideal choice for use in applications where space is limited. They can also be easily mounted in a variety of different ways.
The DC gear motor’s shaft is usually threaded so that it can be attached to a sprocket of the same size. The sprocket can then be used to transmit the motor’s torque to a load. The speed of the motor can then be reduced by using a gearbox that reduces the input speed to match the output shaft speed.
Traditional BLDC motors often have high peak performance at very high RPMs. This can result in an inefficient system when paired with a standard gearbox. To solve this issue, Buhler has created a series of planetary and spur gear motors that can be combined with a wide range of sprockets to provide the desired output speed and torque.
Availability
A 24V DC gear motor is a great option for projects that require a lot of power but do not need high speed. It is typically used in appliances such as compressors, pumps and electrically-driven doors. It is also commonly used in robotic applications as it provides a lot of torque while maintaining relatively low speed.
Generally, it is recommended to use a power supply with the same voltage as the DC gear motor’s rated voltage for optimal performance and longevity. Providing a higher voltage to the DC motor may cause it to operate above its rated speed which can increase heat generation and lead to premature failure.
ATO offers a wide selection of brush-commutated DC gear motors including spur, planetary and worm gears. We have several options in both small and large sizes for a variety of applications. All of our gear motors can be customized per customer’s request. This includes shaft dimensions, mounting holes and cabling connections. Contact us for more information about our customization services.