6 Common Gearmotor Selection Mistakes to Avoid

Selecting the wrong gearmotor can seriously affect your application, from premature failure to decreased efficiency and increased operating costs. Unfortunately, several common mistakes can occur when selecting a gearmotor. In this blog, we will explore some of the most common mistakes to avoid, including overlooking environmental factors, ignoring duty cycle, oversizing the gearmotor, and not considering motor overload capacity. By understanding these mistakes, you can make informed decisions when selecting a gearmotor and ensure optimal performance and reliability.

Overlooking environmental factors when selecting a gearmotor can have significant consequences on the gearmotor's performance and lifespan. Environmental factors such as temperature, humidity, and exposure to dust and debris can affect the gearmotor's internal components, including bearings and seals, leading to premature wear and tear.

For instance, if the gearmotor operates in a highly humid or corrosive environment, the gearmotor's internal components may corrode, leading to reduced efficiency and a shorter lifespan. Similarly, if the gearmotor is exposed to dust and debris, it can result in increased friction and wear, leading to premature gear failure.

Choosing a gearmotor with appropriate environmental protection can increase the gearmotor's lifespan and reduce maintenance requirements. Therefore, it's essential to consider the operating environment when selecting a gearmotor and choose one with suitable protection ratings. For instance, if the gearmotor operates in a highly humid environment, choosing a gearmotor with a higher ingress protection (IP), rating can ensure that moisture does not penetrate the motor's internal components.

What are Ingress Protection (IP) ratings?

Ingress Protection (IP) ratings are a standard way of measuring an enclosure's protection against intrusion by solid objects and liquids, such as dust, water, and other environmental factors. The IP rating consists of two digits signifying the enclosure's protection level against solids and liquids. The first digit refers to the level of protection against solid objects, such as dust and debris, while the second digit refers to the level of protection against liquids, such as water and other fluids.

The first digit ranges from 0 to 6 and indicates the level of protection against solid objects, with 0 indicating no protection and 6 indicating complete protection against dust and other solid particles.

The second digit ranges from 0 to 9. It indicates the level of protection against liquids, with 0 indicating no protection and 9 indicating complete protection against high-pressure water jets and immersion in water.

The most common IP ratings are IP65 and IP66, which offer protection against dust and low-pressure water jets. These ratings are often used in outdoor applications where the gearmotor is exposed to environmental factors such as rain, snow, and dust.

IP67 and IP68 are also popular ratings, especially in applications where the gearmotor is frequently exposed to water, such as marine or underwater applications. IP67 offers protection against water immersion up to a depth of 1 meter for up to 30 minutes, while IP68 provides complete protection against long-term water immersion.

IP69 is another rating that is gaining popularity in the food and beverage industry, where high-pressure water jets are frequently used for cleaning. This rating offers complete protection against high-pressure water jets and is often required in applications where frequent cleaning is necessary.

It's also crucial to ensure that the gearmotor is appropriately maintained based on the operating environment. Regular maintenance, such as cleaning the gearmotor and replacing lubricants and seals, can help extend the gearmotor's lifespan and improve its performance.

Overlooking environmental factors when selecting a gearmotor can lead to premature gear failure, reduced efficiency, and increased maintenance requirements. Therefore, it's crucial to consider the operating environment and choose a gearmotor with suitable protection ratings. 

Not considering the motor overload capacity is a common mistake when selecting a gearmotor. The motor overload capacity is the maximum amount of torque the gearmotor can produce for a brief period. Overloading the motor beyond its overload capacity can cause it to overheat, leading to premature failure, increased maintenance requirements, and decreased efficiency. 

Calculating the motor overload capacity based on the load requirements and the duty cycle is essential, as choosing a gearmotor that meets or exceeds the requirements. Overloading the motor can lead to higher energy consumption, reduced efficiency, overheating, and increased operating costs. Additionally, overheating can cause damage to other internal components, resulting in more extensive repairs or replacement. 

To ensure the gearmotor operates efficiently and has a longer lifespan, it's crucial to consider the motor overload capacity and choose a gearmotor that meets the load requirements and duty cycle. Choosing a gearmotor with an adequate motor overload capacity can provide the necessary protection to ensure optimal performance and reliability.

The duty cycle refers to the ratio of the gearmotor's operating time to the total time of the application cycle. It's essential to consider the duty cycle when selecting a gearmotor as it affects the gearmotor's thermal performance. Choosing a gearmotor with an inadequate duty cycle rating can result in overheating and increased stress on the gearmotor's components, leading to premature gear failure. A gearmotor with a high duty cycle rating is designed to operate for more extended periods without overheating and can provide better thermal performance and reliability.

To calculate the duty cycle, the total time of the application cycle must be determined, along with the time the gearmotor will operate. For instance, if the gearmotor will run for 10 seconds out of a 60-second cycle, the duty cycle would be 10/60 or 0.17. Choosing a gearmotor with a duty cycle rating that meets or exceeds the calculated duty cycle is crucial to ensure optimal performance and reliability.

Choosing an oversized gearmotor can result in unnecessary costs, energy waste, and reduced efficiency. Oversizing occurs when the gearmotor's torque and speed requirements exceed the load requirements, resulting in an overpowered gearmotor. 

Also, choosing an oversized gearmotor can increase maintenance requirements and a shorter lifespan. Oversized gearmotors can lead to overheating and increased stress on the gearmotor's components, resulting in premature gear failure.

To avoid oversizing the gearmotor, it's essential to calculate the required torque and speed based on the load requirements and choose a gearmotor that matches the requirements. It's also necessary to consider the gear ratio and ensure that it's appropriate for the load requirements. 

Choosing a gearmotor with a safety factor of 1.2 to 1.5 can provide adequate protection without oversizing. The safety factor provides additional torque and speed capacity to handle unexpected or occasional peak loads. However, exceeding the recommended safety factor can lead to unnecessary costs and decreased efficiency.

Choosing a gearmotor with suitable lubrication and cooling systems is essential, ensuring they are correctly maintained. Proper lubrication and cooling are crucial to ensure the gearmotor operates within its temperature limits and achieves optimal performance and lifespan. Neglecting appropriate gearmotor lubrication and cooling can result in premature gear failure and increased maintenance requirements.

For instance, using the wrong type of lubricant or neglecting to change the lubricant regularly can result in increased friction and wear, leading to premature gear failure. Similarly, using inadequate cooling systems can result in overheating and reduced efficiency.

Select Sumitomo gearmotors include maintenance-free options, where they are grease-packed for the life of the unit. We also offer Hi-Shock, a unique synthetic lubricant that provides superior protection against shock loads and extreme temperatures. Hi-Shock can extend the gearmotor's lifespan and reduce maintenance requirements, making it an ideal choice for harsh operating environments. Wondering if Hi-Shock is a fit for you? Read this Whitepaper.

Failing to consider the motor overload capacity is another common mistake when selecting a gearmotor. The motor overload capacity refers to the maximum amount of torque the gearmotor can produce for a brief period without overheating or damaging the motor.

Choosing a gearmotor with inadequate motor overload capacity can lead to many operational issues. Overloading the motor beyond its capacity can cause the motor to overheat, leading to premature failure and increased maintenance requirements. Additionally, overheating can cause damage to other internal components, resulting in more extensive repairs or replacement.

To ensure optimal performance and reliability, it's crucial to calculate the motor overload capacity based on the load requirements and duty cycle and choose a gearmotor that meets or exceeds the requirements. 

It's also important to note that the gear ratio can affect the motor overload capacity. Choosing the correct gear ratio can improve the gearmotor's efficiency and thermal performance, reducing the risk of motor overload.
 

Selecting the right gearmotor is critical for ensuring optimal performance and reliability in your application. However, there are several common mistakes to avoid when selecting a gearmotor. Overlooking environmental factors, ignoring duty cycle, oversizing the gearmotor, and not considering motor overload capacity can lead to premature failure, increased maintenance requirements, and reduced efficiency.

By understanding these common mistakes and taking steps to avoid them, such as calculating motor overload capacity, selecting the correct gear ratio, and considering environmental factors, you can select the right gearmotor for your application and ensure optimal performance and reliability.

Seeking expert advice from a gearmotor manufacturer or distributor, such as Sumitomo Drive Technologies, can also help ensure that the right gearmotor is chosen for your specific needs. Avoiding these common mistakes and choosing the right gearmotor can save time, money, and resources in the long run, and help your application run smoothly and efficiently.