Here are questions we might ask to help you identify the electric motor you’re looking for.

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Shopping for electric motors can be tricky. There are just too many details and specifications which you must be certain of when looking for one. 

Of course, the easiest scenario is that you have the motor you want to replace, and you just provide the vendor with the motor’s identification plate which is usually affixed to the side. 

Shown is the ID plate for a TechTop TA2B0223TAI aluminium motor 

Most motors have such a plate that has important specifications, including: 

• Power/current requirement (AC or DC) 
• Power type (single phase or three phase) 
• Material (cast iron vs cast aluminium) 
• Speed rating 
• Power rating 

Some information, such as mounting options (foot vs flange, or both), are typically added post-manufacturing, as they could vary depending on the customer order. Therefore, you can’t rely on the identification plate for that information. 

This article walks you through the questions to point you in the right direction when choosing an electric motor, when you should consider:

 

Average lifespan of an electric motor

Studies generally indicate an average lifespan of over 12 years for some motor types under normal operating conditions. Nevertheless, it depends heavily on several factors, such as:

• Type of motor
• Kilowatt / Horsepower rating relative to load
• Usage
• Operation conditions
• Maintenance
• Voltage imbalances and fluctuations

Read more about them in detail in these supplementary articles about:

 

Is it an AC or DC motor?

The most apparent difference, as the names suggest, is the type of current that powers the motor. 

Alternating current (AC) motors: 

• Are known for their high efficiency 
• Are quieter and more flexible 
• Are available in single-phase and three-phase configurations 
• Convert energy from magnetic fields (from the coils) 

In comparison, direct current (DC) motors: 

• Are known for their output range 
• Are capable of running at variable speeds 
• Are available only in single-phase configuration 
• Convert energy from external power sources with constant voltage, such as batteries 

We sell a wide range of AC induction motors from TechTop Australia. Here’s their latest catalogue.

 

Is it a single-phase or three-phase AC motor?

Generally, single-phase motors:  

• Run on a single-phase power source 
• Are simpler and easier to build and maintain 
• Are commonly used in light household and consumer and industrial applications with lower power requirements (eg. conveyors, fan pumps, fans, washing machines, pumps) 

In comparison, three-phase motors: 

• Run on a three-phase power source 
• Are more complicated and harder to build and maintain 
• Are commonly used in heavy duty commercial and industrial applications with higher power requirements (eg. driving lathes, cranes, agitators, crushers)

In addition, there are dual voltage motors that: 

• Are designed to use either of two stated voltages (usually 240 V and 480 V) but are wired differently to maintain the motor output

• Are commonly used in country areas where 240V is not available, so they have the option to take one of the three phases from the mains supply and run with a neutral to get 480V 

 

Do you prefer cast aluminium or cast iron?

Cast aluminium electric motors: 

• Are aesthetically more pleasing 
• Have better heat dissipation 
• Corrode less easily 
• Are lighter and easier to install 

In comparison, cast iron electric motors: 

• Are made of more robust casing/shell, thereby able to take much more of a “beating” 
• Have higher mechanical strength 
• Known to last much longer 
• Are heavier and harder to install

Consider these two remarkably similar motors in terms of specifications, and how one (the cast aluminum motor) is significantly lighter than the other (the cast iron motor).

 

What’s the speed rating?

The speed of a motor is derived from its frequency rating and the number of poles it has. This is rated by the number of revolutions per minute (RPM).

Generally, the more poles (or pole pairs), the slower the speed of the motor, but the greater its torque.  

For example, a 2-pole motor will be twice as fast as a 4-pole one, which will be twice as fast as an 8-pole one, and so on. 

 

To calculate rated RPM: 

[120 x Frequency] ➗ # of poles  

 

So, using the Australian standard of 50 Hz, the speed of a 2-pole motor is: 

[120 x 50 Hz] ➗ 2 = 3,000 RPM 

That of a 4-pole motor: 

[120 x 50 Hz] ➗ 4 = 1,500 RPM 

That of an 8-pole motor: 

[120 x 50 Hz] ➗ 8 = 750 RPM 

Also, it’s important to note the difference between synchronous and operating speeds: 

• Synchronous speed: The speed of the motor as it is, with no load. (This is the one we calculated above, using the AU standard frequency of 50 Hz.) 
• Operating speed: The speed of the motor under load. 

*Using an automotive analogy, synchronous speed is like brake horsepower (engine power measured at the flywheel), while operating speed is like wheel horsepower (engine power measured at the wheels, factoring in inertia, power transmission inefficiencies and vehicle weight). 

Important: If you have a three-phase motor and you want to operate the machine at different speeds, you’ll need a variable frequency drive (sometimes called a variable speed drive). As suggested by the name, it controls the frequency of the electricity powering the motor, which, together with the number of poles, dictates the speed of the motor. 

Otherwise, you will have to use a gearbox to alter the speed. 

The rule of thumb is that you should go no more than +/- 20% of the rated speed. So, for instance, you should not run a motor rated at 3,000 rpm any faster than approximately 3,600 rpm or any slower than approximately 2,400 rpm, or you’ll damage it.

Speed rating is a critical factor when choosing a motor, as is the power rating.

 

What’s the power rating?

This number tells you the output capacity of the motor, or the amount of work that can be completed in each amount of time. In terms of small electric motors, this is (often) rated in kilowatts and horsepower.

*Here’s a kilowatt-horsepower calculator for your convenience. 

Of course, this is not to be confused with torque, which is the actual rotary force produced by the motor – the one that turns the shaft. Torque is quantified in Newton metres (Nm). 

To emphasise, aside from speed rating, power rating is the other critical factor when deciding which electric motor to choose.

 

What is the shaft diameter and length?

In terms of compatibility, proper fitting and alignment of the shaft with the component to be moved (eg. fan, pulley, etc) is critical to the function, safe operation and life span of the electric motor.

In general: 

• Short length but large diameter shafts can spin more torque but rotate slower (less speed) 
• Long length but short diameter shafts can spin less torque but rotate faster (more speed)

 

What’s the mounting position?

This tells you how the electric motor can be installed.

Here are the most common examples: 

• Foot mount 
• Flange mount (sometimes called a face mount) 
• Multi-mount (foot and flange mounts) 

On the TechTop motors we sell, the foot mount can be repositioned to the side of the motor, so it is installed with the terminal box on the side instead of the top, as shown in the image.

According to the TechTop Installation and Maintenance Manual, the motors should ideally be mounted to a rigid base to prevent excessive vibration. Shims may be used if the foundation is uneven and should be placed next to and between the motor mounting bolts.

*Mounts and size chart (page 28 of the TechTop catalogue) 

Important: Installation must only be done by qualified personnel. When improperly installed or used, rotating equipment can cause serious or fatal injury. As always, please refer to the installation manual.

 

Mind the manufacturer nomenclature

Keep in mind that different manufacturers may use different nomenclature when labeling their motors.  

Below is an example from TechTop motors: 

For more information, please visit drone with carrying capacity.

*Shown is the part number logic for the TechTop TM Series of aluminium single-phase motors 

Specific considerations when buying TechTop motors: 

• Capacitor Start (CS) / Capacitor Run (CR): Without getting too technical, that essentially tells you that the motor uses two parallel-connected capacitors, each rated according to how they control torque values upon starting and while the motor is running. These motors are sometimes called two-value capacitor motors for the reasons just mentioned.  Colloquially, they are often simply referred to as Cap Start/Cap Run. Cap Start/Cap Run motors are typically used where the motor is expected to be turned on and off regularly (eg. a lathe).
• Permanent Split Capacitor (PSC): This has only one capacitor used in the operation of the motor, and it is connected in the circuit “both at the starting and running conditions”. These motors are typically used where the motor will be turned on and then run for extended periods. For example, where a fan is turned on at the beginning of a shift and then only turned off 8 hours later. These are often used in fan and pump applications.

Important: Choose the correct option for your application as motors used in the wrong application will fail quickly.

 

Other important considerations

• Most motors are designed to be unidirectional, meaning they can rotate only in one direction: either clockwise (CW) or counterclockwise (CCW), depending on how it’s wired up. 
• Some motors are designed to be bi-directional (can rotate both clockwise and counterclockwise), and even self-reversing.
• Some motors are specially designed to be used in hazardous areas where there are increased risks of explosion occurring. One such example is TechTop’s TCD YBX3 series of flameproof motors “Ex d”, which is certified for use in Zone 1 hazardous areas and conforms to IEC60034 and IEC60072 standards. Other popular designs include non-sparking motors (Ex nA) and dust ignition protected motors (Ex tD).
• Some motors have brakes designed to hold the load in case the shaft stops turning.

More reminders 

Make sure: 

• The motor is protected against (ingress of) dust particles and liquids upon installation and during operation 

This refers to the ingress protection (IP) ratings of the motor, which is particularly important in some use cases, such as in marine and mining applications. It is possible to have the motor upgraded to higher IP ratings as needed. The TechTop motors we sell are mostly IP55: protection against dust limited ingress (no harmful deposit) and low-pressure jets of water from all directions. 
Read more about electric motor IP ratings.

• Electric connections are solid and continuous, and circuit breakers, fuses and protective devices are compatible and rated accordingly to work with the motor -- especially during starting operations and under full motor load 
• Starter and overloads are set with correct trip and load ratings 
• There are no loose objects on the motor or within the fan/pulley cow 

Do not: 

• Obstruct the cooling system or air meant to keep the motor running at safe operating temperatures. 
• Mate the motor with an inappropriate pulley, fan and/or gearbox.

Refer to our motor selection guide for more details.

 

The Ultimate Guide to Choosing the Perfect 12V DC Gear Motor for Your Next Project

Jiaming Cai

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8 min read

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Aug 3, 2024

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Are you working on a project that requires a 12V DC gear motor but feeling overwhelmed with the numerous options available in the market? Look no further! In this comprehensive guide, we will walk you through everything you need to know to choose the perfect 12V DC gear motor for your next project. Whether you are an experienced engineer or a hobbyist, selecting the right gear motor is crucial for the success of your project. From understanding the basics of gear motors and their applications to evaluating important factors such as torque, speed, and efficiency, we have got you covered. We will also delve into the different types of gear motors available, including spur, planetary, and worm gear motors, and help you determine which one suits your specific requirements. With our expert advice and practical tips, you can confidently make an informed decision and find the ideal 12V DC gear motor that meets all your project needs. So, let’s dive in and embark on this exciting journey of gear motor selection!

Understanding the basics of gear motors

Gear motors play a crucial role in various applications, from robotics and automation to automotive and industrial machinery. Before delving into the details of choosing a 12V DC gear motor, it’s essential to understand the basics of how gear motors work.

A gear motor consists of two main components: the motor and the gears. The motor provides the power, while the gears help in transmitting and adjusting the speed and torque output. Gear motors are known for their efficiency and ability to provide high torque output, making them ideal for applications that require precise control and high power.

When selecting a gear motor, it’s important to consider factors such as power requirements, torque specifications, speed, efficiency, size, weight, noise levels, mounting options, and compatibility. Let’s explore each of these factors in more detail to help you make an informed decision.

Factors to consider when choosing a 12V DC gear motor

1. Power requirements and torque specifications

One of the first things to consider when choosing a 12V DC gear motor is the power requirements of your project. Determine the power source available and ensure that the motor you choose can operate within the specified voltage range. Additionally, consider the torque requirements of your application. Torque is the rotational force produced by the motor and is crucial for applications that require lifting, pushing, or rotating objects.

2. Speed and RPM considerations

The speed of a gear motor is measured in revolutions per minute (RPM). It determines how fast the output shaft of the motor rotates. Consider the desired speed for your application and choose a gear motor that can meet those requirements. Keep in mind that gear motors can provide different speeds depending on the gear ratio used.

3. Size and weight limitations

The size and weight of the gear motor are important considerations, especially if you have limited space or weight restrictions in your project. Measure the available space and ensure that the gear motor will fit without causing any interference. Additionally, consider the weight of the motor, as it can affect the overall weight and balance of your project.

4. Gear ratio and efficiency

The gear ratio determines how the motor’s speed and torque output are adjusted. A higher gear ratio provides higher torque output but lower speed, while a lower gear ratio provides higher speed but lower torque. Consider the specific requirements of your project and choose a gear motor with the appropriate gear ratio to achieve the desired performance. Additionally, consider the efficiency of the gear motor, as a higher efficiency motor can help reduce power consumption and improve overall performance.

5. Noise and vibration levels

Noise and vibration can be a concern, especially in applications that require quiet operation or where excessive vibration can affect the performance or longevity of the system. Look for gear motors that are designed to minimize noise and vibration levels, especially if your project requires precise control or operates in a noise-sensitive environment.

6. Mounting options and compatibility

Consider the mounting options available for the gear motor and ensure that it is compatible with your project. Some gear motors come with specific mounting brackets or attachment points, while others may require additional customization. Choose a gear motor that can be easily integrated into your project without any major modifications or compatibility issues.

Choosing the right type of gear motor for your project

Now that you have a good understanding of the factors to consider when choosing a 12V DC gear motor, let’s explore the different types of gear motors available in the market. The most common types of gear motors include spur, planetary, and worm gear motors. Each type has its own unique characteristics and is suited for different applications.

1. Spur gear motors: Spur gear motors are the simplest and most common type of gear motors. They consist of two meshing gears with straight teeth. Spur gear motors are known for their high efficiency and low cost. They provide high torque output but may not be suitable for applications that require high precision or low noise operation.

2. Planetary gear motors: Planetary gear motors are known for their compact size and high torque output. They consist of a central gear called the sun gear, surrounded by multiple smaller gears called planet gears. Planetary gear motors offer high precision, low backlash, and are suitable for applications that require high torque and accurate positioning.

3. Worm gear motors: Worm gear motors are designed for applications that require high gear reduction ratios and self-locking capabilities. They consist of a worm gear and a worm wheel. Worm gear motors are known for their high torque output, low noise operation, and ability to prevent backdriving. They are commonly used in applications such as conveyor systems, winches, and lifts.

Consider the specific requirements of your project and choose the type of gear motor that best suits your needs. You can also consult with experts or refer to manufacturer guidelines to ensure that you make the right choice.

Top brands and manufacturers of 12V DC gear motors

When it comes to choosing a 12V DC gear motor, it’s important to consider the reputation and quality of the brand or manufacturer. Here are some top brands and manufacturers known for their high-quality gear motors:

1. Maxon Motor: Maxon Motor is a leading manufacturer of precision gear motors. They offer a wide range of gear motors suitable for various applications, including robotics, medical devices, and industrial automation.

2. Faulhaber: Faulhaber is known for its high-performance miniature gear motors. They offer compact and efficient gear motors that are widely used in applications such as aerospace, robotics, and medical devices.

3. Anaheim Automation: Anaheim Automation is a trusted brand that offers a wide range of gear motors for different industries and applications. They provide customizable solutions and have a reputation for delivering high-quality products.

4. Oriental Motor: Oriental Motor is a global manufacturer of gear motors and motion control systems. They offer a diverse range of gear motors suitable for applications such as packaging, printing, and robotics.

Research the different brands and manufacturers available in the market, read customer reviews, and consider their track record to ensure that you choose a reliable and reputable supplier for your gear motor needs.

Where to buy 12V DC gear motors

Now that you have a better understanding of the factors to consider and the top brands available, let’s explore the different avenues where you can purchase 12V DC gear motors.

1. Online marketplaces: Online marketplaces such as Amazon, eBay, and Alibaba offer a wide range of gear motors from various sellers and manufacturers. You can compare prices, read customer reviews, and choose the gear motor that best fits your requirements.

2. Manufacturer websites: Visit the websites of the gear motor manufacturers mentioned earlier to explore their product offerings and make a direct purchase. Manufacturer websites often provide detailed product information, specifications, and technical support.

3. Local distributors: Check with local distributors or suppliers specializing in electrical components or industrial automation. They may carry a selection of gear motors and can provide valuable guidance and support in choosing the right one for your project.

4. Specialty stores: Some specialty stores or hobby shops may also carry gear motors suitable for smaller-scale projects or hobbyist applications. Visit these stores to explore their product offerings and seek advice from knowledgeable staff.

Consider your preferences, budget, and convenience when deciding where to purchase your gear motor. It’s also a good idea to compare prices, warranty terms, and customer support offered by different sellers or suppliers.

Maintenance and troubleshooting tips for 12V DC gear motors

Once you have chosen and installed your 12V DC gear motor, it’s important to properly maintain and troubleshoot any issues that may arise. Here are some tips to ensure the longevity and smooth operation of your gear motor:

1. Regular cleaning: Keep the gear motor clean and free from dust, debris, or any contaminants that may affect its performance. Use a soft brush or cloth to remove any buildup and ensure that the motor’s cooling vents are not blocked.

2. Lubrication: Some gear motors may require periodic lubrication to reduce friction and ensure smooth operation. Refer to the manufacturer’s guidelines for the recommended lubrication intervals and use the appropriate lubricant.

3. Check for loose connections: Periodically inspect the wiring and connections of the gear motor to ensure that they are secure. Loose connections can lead to poor performance or even damage to the motor.

4. Monitor temperature: Keep an eye on the temperature of the gear motor during operation. Excessive heat can indicate a problem and may require further investigation or adjustments.

5. Troubleshooting: If you encounter any issues with your gear motor, refer to the manufacturer’s troubleshooting guide or seek assistance from their technical support team. They can provide guidance on identifying and resolving common problems.

By following these maintenance tips and promptly addressing any issues, you can ensure the optimal performance and longevity of your 12V DC gear motor.

Conclusion

Choosing the perfect 12V DC gear motor for your project doesn’t have to be a daunting task. By understanding the basics of gear motors, evaluating important factors such as power requirements, torque specifications, speed, efficiency, size, weight, noise levels, and compatibility, you can make an informed decision. Consider the different types of gear motors available, such as spur, planetary, and worm gear motors, and choose the one that best suits your specific requirements. Explore reputable brands and manufacturers, and consider purchasing from trusted sources. With proper maintenance and troubleshooting, your 12V DC gear motor will provide reliable performance and contribute to the success of your project. Happy gear motor selection and project building!

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