Gearmotor Basics

By John Mazurkiewicz
Baldor Electric
Gears have existed before the invention of rotating machinery. Early gears were made from wood with
cylindrical pegs for cogs and were often lubricated with animal fat grease. Because of their force
multiplying properties, gears were used for hoisting heavy loads, such as ship anchor hoist, catapult
pretensioning, wind and water wheel machinery.
The industrial revolution in Britain in the eighteenth century saw an explosion in the use of metal gearing. A
science of gear design and manufacturing rapidly developed through the nineteenth century.
Today, modern metallurgy has added signification developments to gearing used in machines.

Gear types
There are several gear types, each with their respective advantages and limitations. Amongst the list are
worm, spur and helical gears.
Worm gears (Figure 1) are relatively inexpensive and are available in high ratios in single gear set up to
100:1, also available in right angle configurations. They will tolerate high shock loads, and are quiet.
However they are less efficient than other forms of gearing.
Spur gears (Figure 2) are produced by many manufactures and therefore are easy to locate. They are
compact, efficient, and are available in a parallel shaft arrangement. They are available in 10:1 ratio per
gear stage. The limitations are that spur gears are slightly more expensive, are more likely to produce
noise and have less shock capability (compared to worm gears).

Figure 1 Worm gears

Figure 2 Spur gears

Helical gears (Figure 3) can be used on nonparallel and even perpendicular shafts, and can carry heavier
loads than spur gears. They are compact, efficient, and are available in 5:1 ratio per gear stage. Limitations
of helical gears are that they are slightly less efficient than a spur gear of the same size, are more
expensive, and produce thrust loading on the bearings.

Figure 3 Helical gears

Determining ratio
In designing a machine, the gear ratio selected depends upon the machines desired RPM and the RPM
of motor selected.
The motor selected depends upon the power source available, and other various benefits, such as speed
range, frequent starts, reversibility, starting torque, variable or fix speed requirements. An attachment (at
the end of this document) summarizes benefits of commonly used motors.
For a fixed speed application, an AC induction motor may be selected. These provide base output speeds
of 3450 RPM, 1750 RPM, 1150 RPM, or 850 RPM. Thus, if the machines desired RPM is 58 RPM, and
the motor which is available operates at 1750 RPM, gearing will be used to reduce the speed. The ratio is
determined from:
(1) Gear Ratio +

Input RPM
+ 1750 + 30.2 (30:1)
58
Desired Output RPM

Determining torque
For load transmission applications, an easy way to determine the required torque, is to attach a pulley to
the shaft of the machine. Wrap a cord around the pulley, and fasten a spring scale to the other end of the
cord. By pulling, and reading the scale, the amount of force is determined. Do this several times and
average the readings.
Since torque is the product of force and distance from the centerline of the shaft, you can determine torque
simply by multiplying the force by the radius of the pulley.
As an example, as shown in Figure 4 if a gearmotor is driving a 2 ft. drum which is lifting a cable with a 90
pound load, the required torque is:

Figure 4 Torque is the product of force and distance from the shaft centerline
1 ft
Diameter

Torque + Force x Radius + 90 lbft

This is also:
Torque + 90 lb x 12 in + 1080 lbin

90 lbs

(2) Torque transmitted + Force x Radius + 90 lb x 1 ft + 90 lb x 12 in + 1080 lbin

To determine the rate of transmitting torque, or the horsepower to move the bucket, assuming the drum is
turning at 58 RPM, use the formula:
(3) Horsepower +

Torque transmitted (lbft) x RPM

+ 90 x 58 + 1 hp
5250
5250

Torque & rotating masses

For applications that include heavy rotating masses, additional torque is required to bring the machine up
to speed. This would include applications involving flywheels, large conveyor rolls, rotating tables, and
rotating drums.
For applications like these, the load inertia (referred to as WK2) must also be considered. These inertia
loads invariably use more power to start and accelerate to running speed, than they do to keep running at
full speed.
The torque to accelerate load inertia (WK2) may be calculated from:
2
(4) Torque inertia + WK x RPM
308 x time

where:
Torqueinertia is in poundfeet (lbft);
WK2 is in lbft2 ;
308 is a conversion factor;
time is in seconds.

The torque required to accelerate the load from standstill to running speed varies inversely with the time
allocated for acceleration.
As an example, if the application has a WK2 of 480 lbft2, and an acceleration time of 0.5 second to 58
RPM, then:
2
(5) Torque inertia + 480 lbft x 58 RPM + 181 lbft
308 x 0.5

Note that actual torque to accelerate the entire machine would also include the transmitted torque. So we
have:
(6) Torque actual + Torque transmitted ) Torque inertia + 90 lbft ) 181 lbft + 271 lbft

This machine would require a starting horsepower (to get the load moving) equal to:
(7) Horsepower actual + 271 x 58 + 3 hp
5250

Service factor
Once the actual horsepower/torque has been defined for the application, this should be multiplied by a
service factor. This provides a redefined or design horsepower/torque which should be used in the
selection process.
Table 1 presents service factors for various machine load classifications and duration of service. As an
example, if an application has uniform shock loading and will be used ten hours, then the service factor
multiplier to use is 1.00. With the application torque of 271 lbft torque, then:
(8) Torque design + Torque actual x ServiceFactor + 271 x 1.00 + 271 lbft

Table 1 Service factors for applications with frequent starts and stops (more than
10 starts/hour)
Prime Mover

Duration of Service

Electric Motor

Occasional (0.5 Hr)

Intermittent (2 Hr)
10 Hr
24 Hr

Driven Machine Load Classifications

Uniform
Moderate Shock
0.8
0.9
0.9
1.00
1.00
1.25
1.25
1.50

Heavy Shock
1.00
1.25
1.50
1.75

Overhung load
An overhung load is a force applied at right angles to a reducer shaft. This results in a bending force in the
shaft that must be resisted by both the reducer shaft and the bearings.
This bending force is produced whenever a pulley, sprocket, gear or cable assembly is directly mounted
onto the reducer shaft. To minimize the effects of overhung load on the bearings and shaft, the drive
component should be mounted as close to the reducer as possible. When directly connecting to a load,
flexible couplings must be used to avoid overhung load due to shaft misalignment.
As an example, if a gear belt drive application is transmitting 271 lbft of torque through a
10 inch diameter sprocket, the overhung load (OHL) is calculated from:
(9) Overhung load +

Torque
x Factor + 271 lbft x 1.25 + 814 lb
Radius
0.416 ft

Where factor depends upon the coupling mechanism, refer to Figure 5 to determine value to insert in the
equation.

Figure 5 Overhung load calculation

Radius
Diameter

Overhung load +

Torque
x Factor
Radius

Coupling Mechanism

Factor

Chain & Sprocket

Gear Belt
VBelt
Flat Belt

1.0
1.25
1.5
2.5

Overhung Load

Table 2 Universal series single reduction ratio & capacity selection table

Refer to typical manufacturers published data as shown in Table 2. The application is
using a 30:1 ratio
using, with  a 1750 RPM motor, and  the output torque required is 271 lbft (3252 lbin). The smallest
unit capable of meeting these requirements is the size 400FC. The overhung load capacity of this gear is
 1950 lbs, well within the application requirement.
A manufacturers specs and ratings are based upon testing. And your application may differ radically.
Therefore after calculation, it is important to test a sample under actual operating conditions.

Gearmotor terminology
Axial Movement Endwise movement of the input or output shafts, sometimes called
endplay, is usually expressed in thousands of an inch.

Backlash Rotational movement of the output shaft, when holding the input shaft stationary
and rotating the output shaft alternately clockwise and counterclockwise. Backlash may be
expressed in thousands of an inch measured at a specific radius at the output shaft.

Center Distance On a single reduction reducer, this is the distance between the
centerlines of the input and output shafts. Shaft centerlines may be parallel or at right
angles to one another. The center distance of multiple stage reducers usually refers to the
slowest speed stage (last reduction).
Input Horsepower The amount of power applied to the input shaft of a reducer by the
prime mover is its input horsepower. Input horsepower ratings represent the maximum
amount of power that the reducer can safely handle.

Output Horsepower The amount of power available at the output shaft of a reducer is its
output horsepower. Due to losses caused by inefficiency, output horsepower is always less
than input horsepower.

Mechanical Rating The maximum power or torque that a speed reducer can transmit,
based on the strength and durability of its components. The reducer may be rated no
higher than the strength or durability of it weakest component. Reducers typically have a
safety margin of two to three on their mechanical ratings. Thus, a reducer can withstand
momentary overloads of 200300% of its mechanical rating during a startup or other brief
overload situation. Note that thermal limitations or duty cycle must be considered in the final
analysis.
Mounting Position The relationship of the input and output shafts relative to the floor line.

Gearmotor terminology Continued

Prime Mover The machine that provides power to a reducer. The most frequently
encountered prime movers include electric motors, internal combustion engines, hydraulic
motors and air motors.

Ratio The ratio of a reducer is based on the relationship of its input shaft speed to its
output shaft speed. It is commonly expressed as a proportion.
V1
V1:V2
Service Factors The service factor is a multiplier, which is applied to the known load,
which redefines the reducer ratings in accordance with the drive conditions at which the
reducer will be used. The service factor varies with the type of application in which the
reducer is to be used, the kind of prime mover involved and duty cycle. The factors are
used with gears only, and should not be applied to the selection of the motor.
Thermal Rating The maximum power or torque that a speed reducer can transmit
continuously, based on its ability to dissipate heat generated by friction.

Thrust Load Forces imposed on a shaft parallel to the shaft axis. It is often encountered
on shafts driving mixers, fans, blowers and similar machines. When a thrust load acts on a
speed reducer, you must be certain that the thrust load rating of the reducer is high enough
so its shafts and bearing can absorb the load.

Torque A twisting effort exerted around as axis. It is the product of a force and its distance
from the axis around which the force acts.

V2

Attachment:

Benefits of various gearmotors

Permanent magnet DC


Smaller overall size

Higher efficiency than wound field

Wide voltage operating range (12230)

Typical 20:1 constant torque speed range

Provide high starting torques

Linear speed regulation

Instant reversing capability

Locked rotor torque 7 to 10 times full load torque

Speed adjustable via potentiometer, full wave rectifiers, electronic controls

Low voltage applications may require current limiting

Low temperature may demagnetize magnets

High altitude operation may reduce brush life

Series wound AC/DC brushtype

Also known as universal motor


Field winding connected in series with armature (small changes in motor load results in larger
changes in speed)

Operation at high speeds (above 3600 RPM)

Higher horsepower output compared to single phase AC motor

3lead & 4lead reversing capability

Speed adjustable via rheostat, auto transformer, electronic controls

Poor speed regulation

Brushes should be fully seated for best operating performance

High speed operation may reduce brush life

Permanent split capacitor

Motors start winding remains energized


Less current draw at startup compared to split phase motors

3lead reversing capability

Frequent starting capability

Instant reversing capability

Smooth operation throughout speed range

Available with dual voltages

Will overheat at light loads

Must be operated at rated temperatures otherwise premature capacitor failure

Split phase motor (nonsynchronous)

Motor design to operate without capacitor


Higher starting torques compared to split capacitor

Reversible from stop condition

Lower slip in speed compared to split capacitor

Relatively constant speed (noload through rated)

Available in single voltage only

Less efficient compared to permanent split capacitor

Start winding designed for very short duty, may burn out if subjected to frequent starts

Capacitor start motor (induction run)

Capacitor in series with start winding


Higher starting torque compared to split phase motor

Lower inrush current compared to split phase motor

Reversible from stop condition

Relatively constant speed (noload through rated)

Start winding designed for very short duty, may burn out if subjected to frequent starts

May not start properly if subjected to low terminal voltage