DC gear motors are a customized combination of DC motors and gearboxes. In the market for micro DC gear motors, there are mainly three types: planetary gear motors, worm gear motors, and spur gear motors. Since DC motors can be equipped with all these gearboxes, I will introduce DC motors and gearboxes separately so that you can understand their pros and cons, which could help you choose the right gear motor.
DC Motors
A DC motor is any of a class of rotary electrical motors that converts direct current (DC) electrical energy into mechanical energy. The most common types rely on the forces produced by induced magnetic fields due to flowing current in the coil. Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current in part of the motor.
DC motors were the first form of motors widely used, as 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 windings.
Worm gear motor
Worm gear system, characterized by their distinctive worm screw and worm wheel configuration, offer a range of benefits and considerations in various applications. In this article, we will delve into the features of worm gear motors, including their compact design, high-speed reduction capabilities, low noise operation, and self-locking properties. We will also explore the efficiency, durability, and other factors that make them a suitable choice for specific applications.
Compact Design and high torque low rpm:
One of the key advantages of worm gearboxes is their compact design compared to traditional spur gears. By using a one-spiral worm, the gear ratio achieved per revolution of the worm is significantly higher than that of spur gears. For instance, a 20-tooth worm wheel can achieve a 20:1 reduction ratio with just one complete turn of the worm, whereas spur gears would require a 240-tooth gear to achieve the same ratio. This compactness makes worm gearboxes an ideal choice when space is limited and high torque and low rpm is desired.
Efficiency and Heat Dissipation:
While worm gear systems offer notable advantages, they also have some considerations. Due to the sliding contact between the worm and worm wheel, power transmission efficiency is lower compared to other gear types. The efficiency can vary between 30% to 60% depending on factors such as the load and gear design. It’s important to note that cylindrical worm gears tend to have lower efficiency compared to other forms. Additionally, the sliding contact can result in heat retention, which should be carefully managed to prevent overheating.
Durability and Wear Resistance:
Worm and worm wheel(usually it’s a helical gear) are prone to wear out mostly. To reduce wear, worms are typically made from harder materials than the worm wheels. Even though, they are less durable compared to other gear types such as spur gears or planetary gears, especially when heavy load or in vibration environment.
Direction of Transmission and Self-Locking Properties:
A unique characteristic of worm gear systems is the direction of transmission. Unlike ordinary gear trains, the direction of transmission between the input and output shafts is not reversible when large reduction ratios are used. This is due to the increased friction between the worm and worm wheel. This property can be advantageous when the goal is to prevent the output from driving the input. Additionally, worm drives can be self-locking, meaning the wheel cannot drive the worm. The self-locking capability is mainly up to spiral No. of the worm. Usually high gear ratio means one-spiral worm and complete self-lock. 2-spiral or 4 spiral worm would weanken the self-lock capability. Please refer to the picture.
Planetary Gear Motor
Planetary gears,consist of a central sun gear, planet gears or pinions, and an outer ring gear. The sun gear remains fixed while the planet gears revolve around it. These gears are typically mounted on a movable carrier, which can rotate relative to the sun gear. In some configurations, the planet gears roll on the inside of a fixed ring gear. This combination of gears forms a planetary gear train, with the ring gear usually being stationary and the sun gear being driven.
In a planetary gear system, the planet gears revolve about the sun gear, tracing an epicycloid curve on their pitch circles. The interaction between the planet gears and the outer ring gear, forms the basis of power transmission. The planet gears mesh with both the sun gear and the ring gear, allowing for efficient torque transfer. This arrangement provides a compact and versatile solution for gear reduction and speed control in various applications.
Planetary gears find wide applications in industries such as automotive, aerospace, robotics, and machinery, where compactness, high torque capacity, and efficiency are essential. Their versatility and ability to handle higher loads make them a preferred choice for demanding applications. By utilizing different combinations of gears and adjusting the number of teeth, engineers can customize the gear ratios and achieve precise speed control or torque multiplication based on specific requirements.
Overall, planetary gears offer significant advantages in terms of their reduction capabilities, torque output, and flexibility in design. By selecting the appropriate configuration, engineers can optimize gear systems for efficient power transmission and meet the requirements of various industries.
Spur Gear Motor
Spur gearboxes are widely recognized as the simplest and most cost-effective gear reduction systems available. They are commonly used in various applications that require speed reduction and torque increase. However, one notable drawback of spur gearboxes is their tendency to generate significant noise when operated at high speeds.
The construction of a spur gear head involves larger gears meshing with smaller gears. These gears are mounted on parallel shafts but offset from one another. As the smaller gears engage with the larger gears, the rotational speed is reduced, resulting in an increase in torque. The tooth pitch of the gears plays a critical role in determining the final output speed and torque of the gear motor. By incorporating multiple gear stages within the gear head, a spur gearbox can achieve even greater reduction in output speed and higher output torque.
It’s important to note that spur gearheads operate with a single contact point between the gears at any given time. This means that the entire load is supported by a single point of contact between two gears. While this design simplicity offers advantages in terms of cost and mechanical efficiency, it also limits the load-bearing capacity and introduces the potential for increased wear and stress on the gear teeth.
Despite the noise and limitations associated with spur gearboxes, they remain popular in applications where their simplicity, cost-effectiveness, and moderate torque requirements outweigh the need for ultra-smooth operation or extremely high gear ratios. Their straightforward design and wide availability make them a practical choice for many industrial and mechanical applications.
| Planetary Gear Motor Vs. Spur Gear Motor Vs. Worm Gear Motor | |||||
|---|---|---|---|---|---|
| Feature | Rank | ||||
| High Efficiency | Planetary Gear Motor > Spur Gear Motor > Worm gear motor | ||||
| Durablity | Planetary Gear Motor > Spur gear motor > Worm gear motor | ||||
| Low noise | Worm gear motor > Planetary gear motor > Spur Gear Motor | ||||
| Low cost | Spur gear motor> worm gear motor > planetary gear motor | ||||
| Holding Torque(Self-lock) | Womr gear motor > Planetary Gear Motor > Spur Gear Motor | ||||
