Gear Motor

Duowei Electric: Your Leading Gear Motor Supplier

Why Choose Us?

Wide Range of Applications

Our products can be used in various industries including automotive, industrial automation, robotics, household equipment, medical equipment, HVAC systems, office equipment, defense and aerospace, electrical equipment, and power tools.

Professional Services

We can provide customers with "customized services" to meet their long-term needs through tailor-made products. At the same time, we have more than 20 years of production experience and can provide large-scale electric motor production services.

Quality Assurance

ZWS series brushless DC motors, HC series motors, and YY series induction motors have passed UL certification. HC series motors, YY series induction motors, and YDK series air-conditioning motors have passed 3C certification and obtained "Export Product Quality License"

Mass Production of Various Motors

We have realized mass production of 57ZWS, 83ZWS, 120ZWS brushless DC motors. Besides, the linear motor was also successfully developed and put into mass production.

Definition of Gear Motor

A gear motor is a mechanical system consisting of an electric motor and a gearbox containing a series of gears. The function of the gearbox coupled to the motor is to reduce its speed and increase its torque to do a given job at a given speed. The addition of the gearbox on the motor and the extremely simple design that can be easily adapted to the customer’s needs, increases the usability of gear motors and makes them highly versatile in any field of mechanical automation (industrial and home automation, printers, vending machines, just to name a few applications). The motor can be with brushes, brushless, or stepper.

Working Principle of Gear Motor

An important part of the gear motor is the gearbox and its gear pairs or stages. The gears transmit the force of the motor from the input to the output shaft. The gear box therefore functions as a converter of torque and speed. In general, the gear unit slows down the rotational speed of the motor while simultaneously transmitting significantly higher torques than the electric motor alone could provide. Based on this principle, the design of the gear unit determines whether a gear motor is suitable for light, medium, or heavy loads and for short or long operating times.
A gear ratio or reduction ratio steps down the incoming speed from the motor (input speed). The speed ratio ‘I’ between the gear unit's input speed and output speed serves as a measure of this. Another important gear motor variable is the output side's maximum torque. This torque is specified in Newton meters (Nm) and is the measurement of the force of the gear motor and the load that it can move with that force. At the same incoming speed this results in a low torque at low ratio and a high torque at a high gearbox ratio.

Performance Specifications of Gear Motor

Gear Ratio
Gear ratio, gearbox ratio, or reduction ratio is the ratio of the velocity of the input gear to the velocity of the output gear in a gearbox. A ratio greater than one indicates speed reduction, while a ratio less than one indicates speed increase. This ratio is directly proportional to the correlation between the numbers of teeth of different gears in the system. If an output (driven) gear has 20 teeth and an input (drive) gear has 10 teeth, the gear ratio would be 2:1. In compound gearing configurations, the overall ratio is the product of the ratios of each connection.

Torque
Torque is the angular force generated by the motor to handle a required load, expressed in force distance units such as foot-pounds (ft-lb) or newton meters (N-m). Starting torque defines the torque the motor produces at startup. Continuous torque defines the torque the motor produces at constant running conditions. Output torque in a gearmotor is largely dependent on the gear ratio used. Larger torque can be achieved using a higher gear ratio, which also reduces shaft speed.

RPM
Speed (RPM) is the rotational speed of the shaft generated by the motor, expressed in rpm (rotations per minute). The shaft speed in a gearmotor is proportional to the gear ratio. The output speed can be found by dividing the input speed by the gear ratio. Gear ratios above one will reduce speed, while those below one will increase speed.

Gearbox Efficiency
Gearbox efficiency is the percentage of power or torque that is transferred through a gearbox. Manufacturers typically specify the gearbox efficiency as part of the gearmotor specifications list to indicate overall gearbox performance. This efficiency factor takes into account losses that occur due to friction and slippage inside the gearbox.

Backlash
Backlash is the angle that the output shaft of a gearbox can rotate without the input shaft moving, or the gap between the teeth of two adjacent gears. For applications without load reversals or reverse-operation, this factor is insignificant. However, in precision applications where load reversals occur (such as robotics, automation, CNC machines, etc.), backlash is crucial to consider for accuracy and positioning.

Benefits of Gear Motor

Cost Savings

Using a gear motor to multiply torque, and reduce speed helps to decrease the overall cost of operating the system. The efficiency and reliability of the gear motors offers benefits to an application immediately. Many gear motors are inexpensive to install and require little maintenance, meaning there will be less unscheduled downtime to repair the gears.

Environmental Benefit

Efficient speed reducers can achieve significant savings, both in energy and drive component costs. In addition, gear motors also assists the environment and the workers operating them. Industrial electric motor systems are responsible for approximately 1/12 of all greenhouse gas emissions from fossil fuel power plants. By reducing motor power consumption with efficient speed reducers, like gear motors, the production of greenhouse gases can be significantly reduced.

Torque

Gear motors provide an advantage when directly coupled to the motor output shaft. This creates a mechanical advantage based on a ratio between the number of gears and the number of teeth on each gear. For example, if a motor generates 100 lb-in. of torque, attaching a 5:1 gearhead generates an output torque of 500 lb-in.

Speed Reduction

Gear motors are also known as gear reducers because as they increase output torque they decrease output speed. A motor running at 1,000 rpm fitted with a 5:1 ratio gearhead outputs 200 rpm. This speed reduction improves system performance because many motors do not operate efficiently at low rpm.

Types of Gear Motor

Spur Gears

Spur gears are the simplest type of gear, with straight teeth mounted on a parallel shaft. Spur gearboxes include one or more sets of pinion-gears, in which one pinion drives one gear. These sets can be stacked or cascaded to achieve higher reduction ratios. Spur gear systems are versatile, and can come in a range of sizes and gear ratios to meet specific torque and speed requirements.

Planetary Gears

Planetary gear heads involve several gears per stage rather than one pinion-gear set. A "sun gear" drives multiple planet or satellite gears, which then mesh on the inside of an internal (annular) gear to provide relatively high torque and power transmission ratings.

Worm Gears

Worm gearing uses right-angled drives in which a worm drives a wheel coupled to the output shaft or shafts. This arrangement is used for high reduction and compact right-angle power transmission. Because the wheel cannot turn the worm it can be used as a braking system for the gearbox. The gears are designed to handle high shock loads.

Bevel Gears

Bevel gear sets have intersecting axes that are commonly, but not always, perpendicular. They mate via teeth on angled edges. The teeth can either be straight or spiral. Straight bevel gear teeth are used for slow speed applications, while spiral teeth are used for higher speed and performance requirements.

Applications of Gear Motor

Transport and Logistics Systems

Gear motors are essential in transport and logistics, driving conveyor belts, sorting systems, and other machinery that requires precise control of speed and torque.

Automotive Industry

In the automotive sector, gear motors are used throughout the production process, from assembly lines to quality control systems, ensuring efficiency and precision.

Food & Beverage Sector

The food and beverage industry relies on gear motors for various applications, from packaging to filling. Their ability to provide controlled speed and torque makes them ideal for handling delicate products.

Robotics and Handling Machines

Gear motors are at the heart of modern robotics and handling machines. They provide the necessary torque and control for precise movements, enabling complex tasks to be performed with accuracy.

Medical Equipment and More

From hospital beds to medical laboratory equipment, gear motors are used in various medical applications, offering reliability and precision where it matters most.

Components of Gear Motor

1. Casing

The casing is very important in gear motors as it houses all the other components. The casing must be strong enough to contain the mechanical stress of the gears while also protecting the gears from outside forces. A casing is usually made from high-strength materials such as steel or aluminum.

2. Gear Trains

Gear trains play an important role in gear motors. They transfer the power from the input shaft to the output shaft. Gear trains are made up of a series of gears that mesh together. When one gear turns, it forces the adjacent gear to turn as well, allowing the gear motor to function.

3. Input & Output Shafts

The input shaft is responsible for transferring power from the power source (usually an electric motor) to the gear train. On the other hand, an output shaft is responsible for powering the load. They are critical components of gear motors and must be able to withstand the high levels of stress placed on them.

4. Bearings

Bearings support and reduce friction in the gear train. Without bearings, the gear train would grind against the housing, causing excessive wear and tear on the gears. Bearings also help to reduce friction, which makes the gear motor run more smoothly.

5. Sealants

Gear motors often have sealants to keep contaminants from entering the gear train and causing damage. Contaminants can include dirt, dust, water, or other particles that can cause excessive wear and tear on the gears.

Difference Between DC Gear Motors and Stepper Gear Motors

Since there are so many types of gear motors, it is important to comprehend the differences. When it comes to small geared motors, there are some basics that we need to know in order to distinguish them and select the right one. The micro gear motor is a combination of a micro reducer and an electric motor. With this gearbox system, the gear motor can be employed for low-speed and high-torque applications. According to the motor used, you can choose between DC gear motors and stepper gear motors. Here are the main differences.
Speed range: Stepper motors reach a maximum of 2000 RPM, while DC motors have a higher speed range
Brushes: Stepper motors don't have brushes, while DC motors do
Control: Stepper gear motors need a driver, for this reason, Micro Motors has designed a dedicated control board for its range of products. DC gear motors do not require external control to operate
Motion: Stepper gear motors have an incremental movement, while the DC geared motors are continuous
Efficiency: Stepper gear motors have a very high current consumption at maximum load when the stator poles are excited, which reduces energy efficiency and increases heat losses. The maximum efficiency of the DC gear motor is reached at around 85%
Durability: Stepper gear motors have a longer lifetime than DC gear motors because they do not have brushes, which are normally subject to wear and tear

Applications of DC Gear Motors vs Stepper Gear Motors
You can choose between a DC gear motor or a stepper gear motor also depending on the application area.
DC Gear Motors: are mainly used in vending, industrial automation, and for other applications including printers and electrical suspensions adjustment.
Stepper Gear Motors: are mainly used in applications requiring accurate positioning control, such as in robotics, home automation, telecommunication antennas, surveillance cameras, valves, airflow controllers, and projectors.

Maintenance Tips for Gear Motor

1. Maintain Good Housekeeping

Although it may appear simple, gearboxes frequently operate in a dirty and dusty environment. While to some extent this is unavoidable, it is critical to minimise the consequences of the employment environment. Such a dirty and rusty environment could raise the gearbox’s working temperature or perhaps cause it to become contaminated. As a result, industrial gearboxes should be dusted and brushed clean on a regular basis.

2. Conduct Regular Inspections

While a full inspection may appear to be too difficult, a simple visual inspection of gear contact patterns through an inspection port can help prevent catastrophic failures in the future. If there isn’t any in-house inspection experience, an expert might be recruited to execute the examination and train people. By overcoming problems for conducting an inspection, you can help to extend the life of your gearbox and avoid catastrophic failure. This could save time, money, worker harm, and damage to nearby equipment.
Before opening the gearbox inspection port, you should conduct a comprehensive external inspection. Use an inspection form to keep track of critical information that would otherwise be lost once the cleaning is done. Examine the exterior of the gear housing for symptoms of overheating, corrosion, contamination, oil leaks, and damage before cleaning it. Tightening torque of structural fasteners carrying large stresses, such as torque arm bolts is to be measured and corrected Look for signs of movement at structural interfaces, such as cracked paint or fretting corrosion. Note the condition of the fasteners and look for fretting corrosion or other signs of movement on load-bearing surfaces of components, for taking corrective action.

3. Keep an Eye out for Overheating

Overheating can be detected by discoloured or burned external paint, as well as dark oil in the sight glass. Using an infrared temperature gun, monitor the gearbox temperature on a regular basis and look for any rapid variations in temperature. Overheating can be detected by the following symptoms:
● Shafts, seals, and breathers all emit smoke.
● Housings with discoloured or burned paint
● Water placed on the housing or shafts immediately evaporates, boiling or crackling.
● Colors should be tempered on unpainted surfaces.
● Components made of melted plastic, such as shipping plugs
● Low levels of oil in the sight glass or on the dipstick
● In a sight glass or on a dipstick, there is a dark oil.
● Foam in the sight glass
● Sludge on the filter element or water in the sight glass (may indicate oil cooler failure)
● Chip detectors, filters, or metal chips on magnetic plugs (may denote gear or bearing failure caused by overheating)

4. Look for Wear & Tear Signs

Internal gears can be inspected by removing inspection covers or using an endoscope. Look for pitting and spalling as evidence of wear (material from the surface of gear tooth flanks being removed). Using ‘engineers blue,’ check the contact patterns between gear teeth for misalignment, since this could indicate bearing or bearing housing wear.

5. Conduct Vibration Analysis

Since many gearboxes work in a noisy environment, not all changes in gearbox noise can be captured. Vibration study of the internal bearings and gears on a regular basis will identify any substantial changes in the gearbox’s internal condition and help prevent any unanticipated production loss.

5. Check the Condition of Your Shaft

Check for any increase in backlash between the gears’ mesh, as well as any increase in end play or lift at the input and output shafts, with a dial indicator. Backlash increases could be a sign of gear tooth wear, which isn’t usually evident to the human eye. Increased shaft end play or lift indicates wear in the bearings’ rolling elements, as well as wear in the bearing housings.

Factors to Consider When Selecting Gear Motor

Gear Ratio

Gear ratio, gearbox ratio, or reduction ratio is the ratio of the velocity of the input gear to the velocity of the output gear in a gearbox. A ratio greater than one indicates speed reduction, while a ratio less than one indicates speed increase. This ratio is directly proportional to the correlation between the numbers of teeth of different gears in the system. If an output (driven) gear has 20 teeth and an input (drive) gear has 10 teeth, the gear ratio would be 2:1. In compound gearing configurations, the overall ratio is the product of the ratios of each connection.

Torque

Torque is the angular force generated by the motor to handle a required load, expressed in force distance units such as foot-pounds (ft-lb) or newton meters (N-m). Starting torque defines the torque the motor produces at startup. Continuous torque defines the torque the motor produces at constant running conditions. Output torque in a gearmotor is largely dependent on the gear ratio used. Larger torque can be achieved using a higher gear ratio, which also reduces shaft speed.

Speed (Rpm)

Speed (RPM) is the rotational speed of the shaft generated by the motor, expressed in rpm (rotations per minute). The shaft speed in a gearmotor is proportional to the gear ratio. The output speed can be found by dividing the input speed by the gear ratio. Gear ratios above one will reduce speed, while those below one will increase speed.

Gearbox Efficiency

Gearbox efficiency is the percentage of power or torque that is transferred through a gearbox. Manufacturers typically specify the gearbox efficiency as part of the gearmotor specifications list to indicate overall gearbox performance. This efficiency factor takes into account losses that occur due to friction and slippage inside the gearbox.

Backlash

Backlash is the angle that the output shaft of a gearbox can rotate without the input shaft moving, or the gap between the teeth of two adjacent gears. For applications without load reversals or reverse-operation, this factor is insignificant. However, in precision applications where load reversals occur (such as robotics, automation, CNC machines, etc.), backlash is crucial to consider for accuracy and positioning.

Certifications

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Our Factory

Changzhou Duowei Electric Co.,Ltd. was founded in 1997 and has more than 200 employees. It has developed hundreds of different product applications and established extensive strategic partnerships around the world with these products. Duowei Electric, the manufacturer of Wit Motors, our company does not use "conflict minerals", and the broad service industries include: automotive, industrial automation, robotics, household equipment, medical equipment, HVAC systems, office equipment, defense and aerospace, Electrical equipment and power tools.

Ultimate FAQ Guide to Gear Motor

Q: Do Brush Motors Have More Torque?

A: Brush motors can perform well when providing an initial torque, but they usually fall short when great torque is required, because their commutation system is so simple. Hence, brush friction increases as speed increases and viable torque decreases. In this case, they are less efficient in comparison with brushless DC motors.

Q: How to Make A Brushed Motor Faster?

A: By adjusting the operating voltage or the intensity of the magnetic field in the Brushed DC Electric Motor, using brushed motor driver, the speed and torque may be adjusted to give a constant speed or a speed that is inversely proportional to the mechanical load. (The controller sends current pulses to the motor windings, which govern the motor’s speed and torque.)

Q: Where do brush dc motors are used?

A: Brush dc motors, on the other hand, provide high peak torques and may be driven by simple speed controllers to move a wide range of applications. They are frequently less expensive than alternative options, especially in big quantities. They can also have a linear torque-speed connection, which simplifies control.

Q: When to use a brushed motor?

A: Brushed motors do not need additional electronics to run. Hence, they offer a plug-and-play option. The lack of electronics saves considerable costs. Brushed motors can work with gearheads, and their lifespan is not affected by the same. Both the motor and the gearhead are mechanical components that witness a high degree of wear and tear. They offer high starting torque.

Q: What is the use of brush in DC motor?

A: A carbon brush is a critical part of a dc motor, which relies on the brush for the transmission of electrical current coming from the machine's rotating part. The brush is also responsible for changing the course of current in the conductors during the rotation process.

Q: How do I know if my DC motor is brushed?

A: If there's two heavy wires, with or without light ones, it's a brushed DC motor. If there's light wires, too, then chances are the motor has some feedback built in; either a tacho-generator (gives a voltage proportional to motor speed) or a shaft encoder of some sort.

Q: How long do brushed DC motors last?

A: Brushed motor life is limited by the brush type and can attain 1,000 to 3,000 hours on average, while brushless motors can attain tens of thousands of hours on average, as there are no brushes to wear.

Q: What happens when DC motor brushes wear out?

A: Once the carbon brushes are completely worn the motor will begin to underperform before failing – running a motor with worn carbon brushes can result in extensive damage to the motor.

Q: How long should motor brushes last?

A: Carbon brushes will on average last between 1 and 5 years in most power tools but this is all dependant on how much they are used in number of hours, the more daily use the power tool has the quicker it will wear over a certain period of time.

Q: How do you control a brushed DC motor?

A: Brushed motors generally operate at low speed and can be driven by a simple pulse width modulation (PWM) controller to vary the voltage supplied to the motor to control the speed in one direction and provide the torque for the motor drive.

Q: How can I make my brushed motor quieter?

A: Capacitors are usually the most effective way to suppress motor noise, and as such we recommend you always solder at least one capacitor across your motor terminals. Typically you will want to use anywhere from one to three 0.1 µF ceramic capacitors, soldered as close to the motor casing as possible.

Q: How can I slow down a DC motor?

A: If you want to go really slow, the resistor method will probably cause the motor to stall way before you reach your desired RPM. Using PWM ensures you get pulses of full torque, which allows you to drive the motor to really slow speeds. Yes, using resistors were the first method of controlling motor speed.

Q: What causes a DC motor to run too fast?

A: For a dc motor, speed is proportional to back emf / field flux. If you reduce the field-flux of an already running motor, its speed increases. If you reduce it to a very low value, the speed becomes dangerously high.

Q: Are brushed DC motors efficient?

A: Yes, although not as efficient as brushless motors. Brushless motors are typically 85-90% efficient whereas brushed DC motors are around 75-80% efficient.

Q: Do brushed DC motors require regular maintenance?

A: Yes, they require periodic maintenance due to brush wear, but maintenance is generally simpler compared to other motor types. Many brushed motors – especially large ones – have replaceable brushes, typically made of carbon, which are designed to maintain good contact as the wear. These motors require periodic maintenance. Even with replaceable brushes, eventually the commutator also wears to the point that the motor must be replaced.

Q: Do brushed DC motors generate heat?

A: In a DC motor with a mechanical commutator and brushes, the copper windings are wound in slots around the “rotating” part of the motor (called the armature). The heat generated by the copper windings on the armature will conduct through the armature laminations and to the motor shaft and bearing system.

Q: Can brushed DC motors be used with variable power sources like batteries?

A: Yes, they are compatible with variable power sources, making them suitable for battery-operated devices. In case of brushed DC motor, however, operation directly from a voltage source or battery is possible too. If the voltage is adjustable, the speed can also be varied.

Q: How does the efficiency of brushed DC motors change with load?

A: Trivially, at zero load, the efficiency is zero. At very high load, we also know that the losses increase as current squared, while the torque varies as the current, and as the speed drops at high loads, the power output increases less than linearly with current, so the efficiency also drops.

Q: How to drive brushed DC motors?

A: To drive a brushed motor, DC voltage is applied across the brushes, which passes current through the rotor windings to make the motor spin. In cases where rotation is only needed in one direction, and speed or torque doesn't need to be controlled, no drive electronics at all are required for a brushed motor.

Q: When should I replace my DC motor brushes?

A: Generally, if the brush is worn down to 1/4th of its original length, it is time for replacement. If you need to replace your brushes make sure that the brush is the correct dimensions, type and grade for the motor. Typically you can find this information in your motor's manual.

Q: What are the main advantages of using a gear motor?

A: Multiplies the torque of the motor. This feature is very important because it allows high torque even in a small space.

It reduces the speed of the input motor. Gear motors have a variety of reduction ratios to select the appropriate speed for your application.

Availability of multiple combinations of both gearbox and motor at different voltages.

Having an integrated motor + gearbox solution makes it easier for the end user to develop the machinery and allows him to be able to apply it within his project without wasting time searching for individual parts.

It is a ready-to-use all-in-one solution that requires no alignment work by the end user.

Q: What are the differences between DC motors and geared motors?

A: DC MOTORS

A DC motor is any of a class of electrical machines that converts direct current electrical power into mechanical power. The most common types rely on the forces produced by magnetic fields. Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current flow in part of the motor. Most types produce rotary motion; a linear motor directly produces force and motion in a straight line.

DC motors were the first type widely used, since they could be powered from existing direct-current lighting power distribution systems. A DC motor's speed can be controlled over a wide range, using either a variable supply voltage or by changing the strength of current in its field winding. Small DC motors are used in tools, toys, and appliances. The universal motor can operate on direct current but is a lightweight motor used for portable power tools and appliances. Larger DC motors are used in propulsion of electric vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of power electronics has made replacement of DC motors with AC motors possible in many applications.

GEARED DC MOTORS

Geared DC motors can be defined as an extension of DC motor which already had its insight details demystified here. A geared DC Motor has a gear assembly attached to the motor. The speed of motor is counted in terms of rotations of the shaft per minute and is termed as RPM .The gear assembly helps in increasing the torque and reducing the speed. Using the correct combination of gears in a gear motor, its speed can be reduced to any desirable figure. This concept where gears reduce the speed of the vehicle but increase its torque is known as gear reduction.

Q: What are the applications of gear motors?

A: The possible applications of gear motors are many. Here is a short list of possible applications.

In the automation industry gear motors are used in the entire production process, assisting in the movement of components for the manufacturing of the final product. For example, in the food & beverage industry, they handle bottles, packaging and boxes and are used to fill containers or select empty packages. The same kind of application can be found in other sectors such as medical, pharmaceutical, cosmetics.

Heat recovery and ventilation: flow regulation

Telecommunication: adjustment of antennas

Security: locking, safety and deterrence systems

Horeca: Vending machines, food & beverage dispensers, coffee machines

Plotters and Printers: Mechanical and colors settings

Robotics: Robots, robotic cleaners, lawnmowers, rovers

Home automation and fitness

Automotive industry: Special applications (shock absorber and sunroof adjustments)

Q: What are the types of gear motors?

A: The first step in selecting a gearmotor is determining the type of motor. A gear motor can be classified in a number of different ways, but the primary distinction is whether it is an AC motor or DC motor. This designation defines the power source requirements of the motor (AC or DC) and can affect a number of other performance factors such as cost, reliability, and speed control complexity. Some other specific types of motors to consider are DC servomotors and stepper motors.

DC servomotors have an output shaft that can be positioned by sending a coded signal to the motor. As the input to the motor changes, the angular position of the output shaft changes as well. Servomotors are generally small and powerful for their size and are easy to control. Visit the DC Servomotors Selection Guide for more information.

Stepper motors provide incremental motion, or steps, in response to pulses of current that alternately change the polarity of the stator poles. Step motors do not require feedback and are sometimes used in "Open Loop," or no-feedback applications. Visit the Stepper Motors Selection Guide for more information.

As one of the leading gear motor manufacturers and suppliers in China, we warmly welcome you to wholesale high-grade gear motor for sale here from our factory. All custom products made in China are with high quality and competitive price. Contact us for OEM service.

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