Gearheads are essential components that help optimize motor performance. Each type of gear has its unique features and characteristics, and the gear ratio plays a significant role in adjusting the motor's output torque and speed. By carefully selecting the right gear type and ratio, engineers can fine-tune the motor's performance to precisely match the application's requirements.

A motor becomes a gear motor when a gearhead is attached to it. The gearhead case consists of a series of gears that multiply the motor's torque while reducing its speed by the same ratio. It also includes an output shaft where the load is connected.

Similar to a belt-and-pulley system, where one pulley rotates slower than the other due to differences in their diameters, the gearhead's output shaft rotates slower than the motor pinion shaft by the factor of its gear ratio. One advantage of gearheads is their rigidity and compact design compared to belt-and-pulley mechanisms.

In this article, I will discuss the types of gearheads available for brushless gear motors and how to choose the right one for your needs.

Topics covered:

  • About Brushless Motors
  • Gear Selection for Brushless Motors
  • Motor Sizing Example - Belt Conveyor
  • Summary
About Brushless Motors
 
First, let’s take a quick look at brushless motors. A brushless motor is a type of closed-loop DC motor that is continuously rated and commutates its windings using a dedicated driver. Due to their compact size, lightweight, speed regulation, and high efficiency, brushless motors are ideal for variable-speed material handling applications like conveyors or AGVs/AMRs. However, they lack holding torque, making them less suitable for positioning applications.
 

High Speed Stability

With closed-loop speed control via hall-effect sensors or encoders, the driver constantly monitors the motor's speed and adjusts the applied voltage to keep the actual speed close to the set point. Even with load fluctuations, the motor speed only varies by ±0.2% at most (±0.05% with encoder-equipped brushless motors). This makes them more reliable than open-loop VFD/inverter-controlled AC induction motors for applications such as pinch belt conveyors where synchronization is critical.
 
High speed stability from brushless motors
 

Space Saving

The compact yet powerful brushless DC motor uses permanent magnets in the rotor. Compared to an AC induction motor with a frame size of 3.54 inches (90 mm), a brushless DC motor of the same specifications is 62% shorter. With a much shorter length, it is also 62% lighter than an AC induction motor of the same frame size. This compact structure is beneficial when downsizing equipment or reducing the load on an AGV/AMR.

 
Compact size of brushless motors
 

Energy Saving

Brushless DC (BLDC) motors, which use permanent magnets in the rotor, generate little secondary loss. Compared to AC induction motors, brushless motors can have up to 66% less loss. For example, the BMU Series brushless DC motor consumes about 26% less power than a VFD/inverter-controlled AC motor at 1/6 HP (90 W). In the same frame size, a brushless motor can deliver 1.3 times more power than an AC induction motor.

Brushless motors are far more energy-efficient than AC induction motors thanks to their design.
 
Energy savings of brushless motors
 
Since brushless motors can run at 3,000 to 4,000 RPM, the gearheads paired with these motors must be quiet even at high speeds and must offer high permissible torque and long life to fully utilize the high-performance motor's capabilities. Our lineup of gearheads for brushless motors includes several parallel shaft gearheads (GFS, JV, JB), parallel shaft gearheads with centered output shaft (CS), hollow shaft right-angle gearheads (JH), and hollow shaft flat gearheads (FR).
 
By attaching a gearhead to a motor, you can:
  • Increase torque
  • Reduce speed
  • Reduce speed fluctuations
  • Reduce vibrations
  • Reduce overrun
  • Increase axial load
  • Increase radial load
 Relationship between gear ratio and torque

For other advantages of geared motors, please read this article.

 

FYI
When selecting gearheads, pay attention to the rotation direction of the gearhead shaft. Some gearheads reverse the shaft rotation with certain gear ratios.

 

II. Gear Selection
 
Here's the standard gearhead lineup for our brushless gear motors. We divide the lineup into two categories: long-life and high-torque.
 
Long-Life Gearheads
 
Long-life gearheads are designed for applications where reliability and durability are key. These gearheads are built to withstand continuous operation and provide consistent performance over time. They are ideal for applications that require extended service life without frequent maintenance.
 
High-Torque Gearheads
 
High-torque gearheads are engineered to handle heavy loads and provide maximum torque output. These are suitable for applications that require high force and strong mechanical support. They are often used in industrial settings where robustness is crucial.
 
When choosing between long-life and high-torque gearheads, consider the specific demands of your application. If you need a solution that lasts longer with minimal maintenance, go for the long-life option. If your application requires high torque and strength, then the high-torque gearhead would be the better choice.
 
III. Motor Sizing Example – Belt Conveyor
 
Let’s walk through a practical example of how to size a motor and gearhead for a belt conveyor application. This will give you a clear idea of how to apply the concepts discussed earlier in real-world scenarios.
 
Step 1: Determine Load Requirements
Calculate the required torque and speed based on the conveyor’s load, distance, and desired speed. Use the formula: Torque = Force × Radius.
 
Step 2: Select the Motor and Gearhead
Choose a motor and gearhead combination that can meet the calculated torque and speed requirements. Ensure the gearhead provides the necessary reduction ratio to achieve the desired output speed.
 
Step 3: Verify Performance
Check that the selected motor and gearhead can operate within their rated parameters under the expected load conditions. Make sure there is enough margin for unexpected variations in load or environment.
 
Step 4: Consider Mounting and Space Constraints
Ensure the chosen motor and gearhead fit within the available space and can be easily mounted and maintained.
 
By following these steps, you can ensure that your motor and gearhead selection is both efficient and effective for your specific application.
 
IV. Summary
 
Choosing the right gearhead for a brushless motor involves understanding the application requirements, considering the gearhead's type and ratio, and ensuring compatibility with the motor's performance characteristics. Whether you need a long-life or high-torque gearhead, the right selection can significantly improve the efficiency and reliability of your system.
 
Remember, proper gearhead selection is not just about matching the technical specs—it's about optimizing the entire system for peak performance and longevity.

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