At HOTEC MOTOR, we pride ourselves on providing comprehensive solutions tailored to our customers’ needs. Recently, a valued client from the USA approached us with a pressing issue concerning their milkshake blending machines. Let’s delve into the details of how we tackled their challenges head-on and delivered effective solutions:
Understanding the Challenge
Our client had been utilizing a 12V electrical gear motor in their milkshake blending machines, but they encountered a recurring problem after approximately 30,000 to 50,000 duty cycles. Despite initially meeting performance expectations, the motors began to exhibit reduced power over time, sometimes even stalling out. Recognizing the importance of addressing this issue promptly, our client sought our expertise to find a resolution.
Customer’s Current Setup
The incumbent electric gear motor used by our client was equivalent to our HT-COG95A series, a flat gearbox motor. In their milkshake blending machines, these motors served the crucial function of lifting and lowering the cups via a timing belt, rather than directly participating in the blending process. During operation, the loaded torque varied continuously throughout each duty cycle, with speed and current controlled via firmware. Each duty cycle comprised a 70-second run time, with an extremely brief dwell time of less than 0.4 seconds before switching direction. The target lifetime for these motors was set at 70,000 duty cycles, equivalent to approximately 1,300 hours of operation.
Initial Assessment and Analysis
Due to the absence of physical samples for reference, our analysis relied solely on the information provided by the client, including descriptions and images. Upon examination, the gearbox components appeared to be intact, suggesting that the issue might lie elsewhere.
Possible Explanations
After careful consideration, we identified several potential causes for the torque-related issues:
- Motor Lifespan and Wear: Given the demanding duty cycles and prolonged usage, it was plausible that the motors had reached the end of their lifespan due to normal brush wear. In response, we recommended exploring the option of transitioning to 24V motors, which typically draw lower current and reduce brush sparking, greatly extending their operational lifespan.
- Quality Concerns: Another possibility was that the motors supplied by the current vendor might not meet the necessary quality standards. To address this, we suggested seeking alternative suppliers to ensure consistent performance and reliability.
- Machine Wear and Friction: Alternatively, the increased friction resulting from wear and tear on the machine’s moving parts might be placing additional strain on the motors, necessitating higher torque to compensate.
Proposed Solutions and Testing
To address these potential issues, we proposed a series of solutions and provided our client with samples of different motor options for testing. These options included both 12V and 24V variants, allowing our client to evaluate the performance and suitability of each option in their specific application context.
Final Resolution
Following extensive testing and evaluation, it was determined that the root cause of the power challenges lay primarily in the wear and tear of the machine’s moving parts, rather than the issues with the DC gear motors themselves. Armed with this knowledge, our client could now focus on implementing machine design improvements and maintenance protocols to mitigate friction-related issues and optimize the performance and longevity of their milkshake blending machines.
Continued Partnership
We take great pride in our ability to collaborate closely with our clients to identify and address their unique challenges effectively. By providing comprehensive solutions and unparalleled support, we aim to foster long-term partnerships built on trust, reliability, and mutual success.
At HOTEC MOTOR, we remain committed to delivering superior products and exceptional service to our valued clients. Contact us today to discover how our electric gear motors can elevate the performance and reliability of your machinery.
