Brushed DC Motor in Linear Actuators: Overview and Working

A brushed DC motor is a simple, small motor used in linear actuators. It utilizes mechanical brushes to commutate the motor, enabling rotational motion, which is then converted to linear motion by the actuator. A brushed DC motor comprises four key components – stator, rotor, commutator, and brushes.

Once DC voltage is applied across the brushes, current begins to flow through the rotor windings, creating a magnetic field around the rotor. The stator also has its magnetic field which interacts with that of the rotor, prompting it to spin. The commutator also rotates, changing the current flow direction. This process is called commutation, which ensures continuous changes in the magnetic field and maintains rotational motion by alternating the rotor and stator magnets. In a linear actuator, the motor’s rotational movement is then converted into linear motion via a lead screw or similar mechanism, driving the actuator’s mechanical parts to produce the desired movement.

Brushless DC Motor (BLDC) in Linear Actuators: Overview and Working

A brushless DC motor (BLDC) is an advanced motor used in linear actuators for precise, efficient motion. The motor consists of a rotor, stator, and electronic speed controller (ESC). In a linear actuator, the ESC sequentially energizes the stator windings, creating a rotating magnetic field. Its interaction with the rotor’s permanent magnets causes it to spin, converting rotational motion into linear movement via a lead screw or ball screw. The ESC ensures smooth, controlled operation, minimizing power loss and heat generation for efficient actuator performance.

Difference Between Brushed and Brushless Motors in Linear Actuators

Here are some key differences between brushed and brushless DC motors when used in linear actuators

• Working: While the basic principle of both motor types is the same, brushed motors use mechanical brushes for electrical contact, whereas brushless motors rely on electronic controllers for the same purpose. Brushless motors have a more advanced design, making them better suited for precision and efficiency in linear actuators.
• Efficiency: Efficiency of brushed motors may reduce over the time due to the friction between the brushes and the commutator. The brushes need to be replaced regularly to avoid such issues. In contrast, brushless motors are more efficient since they eliminate friction from brushes, resulting in lower wear and heat generation, and providing better overall performance. This makes them ideal for applications that require long-lasting performance in linear actuators.
• Noise: Brushless motors are much quieter than brushed motors, making them a better choice for applications with strict noise requirements, such as medical devices, robotics, or assistive technology that uses linear actuators.
• Complexity: Brushed motors are simple and easy to operate, which makes them ideal for cost-sensitive linear actuator applications. However, brushless motors require more complex control systems and algorithms to manage the electronic commutation, offering more precise and reliable performance in linear actuators that need fine control and smooth motion.
• Cost: While brushless motors are generally more expensive than brushed motors, their lower maintenance requirements, longer lifespan, and improved efficiency can make them more cost-effective in the long run, especially in linear actuators where continuous, high-performance operation is critical.

Learn more on this topic in our related blog: Understanding DC Gear Motors: Working Principles, Selection, and Applications

Are you looking for standard or custom DC motors for your linear actuators? If yes, ensure you partner with a reliable manufacturer that can meet your specific needs. The motor must align with the required speed, range, precision, and repeatability of your application, offering the right level of control. Many DC Motor manufacturers across the US offer custom options to cater to your exact requirements. Making the right motor choice is crucial, as it drives your actuator’s efficiency and enables smooth, precise movements, enhancing the overall performance and reliability of your system.

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What are DC Gear Motors?

A DC gear motor combines a direct current (DC) motor with a gearbox, which helps create smooth, precisely-controllable motion without consuming excessive power. The gearbox is attached to the motor’s output shaft, modifying the motor’s speed and torque to meet specific application requirements. Combining the remarkable power of DC motors with the mechanical advantage of gearboxes, they find immense applications in robotics, automotive systems, and industrial machinery, among others.

DC Gear Motor Working Principle

A DC gear motor works on the principle of electromagnetic induction. These units, by combining a DC motor with a gearbox, are known to offer high torque at low speeds. When direct current (DC) is applied to the motor – which is the primary workhorse – it forms a magnetic field that interacts with the armature, leading it to rotate. This rotational motion is then transferred to a series of gears within the gearbox – often referred to as a reduction gear. This process reduces the motor’s speed while increasing its torque. In other words, the function of gearbox here is to regulate the speed of the motor as per the needs of your applications. The gear reduction significantly enables the motor to offer force at controlled, lower speeds.

Benefits of DC Gear Motors

Extensively used in light, medium, and heavy-duty processes, DC gear motors are known for their following benefits.

• As gear reduction mechanisms increase torque output, DC gear motors are highly suitable for applications requiring substantial force at low rotational speeds.
• Owing to their adaptable design, these units find application across sectors including robotics, automotive systems, industrial automation, and medical devices.
• They are known for their high efficiency in converting electrical energy to mechanical power with minimal losses.
• DC gear motors are ideal for installations with limited space. Thanks to their compactness due to the integration of a gearbox with the motor.
• They allow for seamless integration with existing control systems and microcontrollers, due to their straightforward electrical control interfaces.
• Users can expect a fine-tuned motor performance out of these gear motors. Thanks to their speed regulation through voltage adjustment and pulse-width modulation (PWM).
• As these units are available in diverse gear ratios, they allow for tailored speed and torque configurations ideas for different application requirements.
• They incorporate features to minimize operational noise and vibration.
• They are designed with efficient heat dissipation, which enables easy handling of high-power loads without overheating.

Factors to Consider When Selecting DC Gear Motor

When selecting DC gear motors, some notable factors must be considered to ensure the motor meets the specific application requirements. A few of them include:

1. Torque/Speed: Analyze the necessary torque and speed requirements for your application. Consider both starting and running torque, and choose a model wisely.
2. Voltage and Current: Ensure that the motor’s voltage and current specifications properly match your power supply and control system.
3. Size: Check the motor’s physical dimensions and mounting configuration. Ensure that the model you have chosen fits well within the space constraints of your application.
4. Customization: Check whether the model allows for any customizations such as specific gear ratios, shaft configurations, or mounting options.
5. Noise/Vibration: Check the acceptable noise and vibration levels for your application and invest on a model accordingly. This is especially important in noise-sensitive environments.
6. Load: Understand the type of load the motor will drive. Check for any variations in load over time. Understanding these ensure a smooth performance.
7. Duty Cycle: Check how often and for how long the motor will be running. Continuous, intermittent, or variable duty cycles will affect motor selection. Also, it is important to choose an efficient motor to minimize energy consumption and heat generation.
8. Environmental Conditions: Assess the operating environment, including temperature, humidity, exposure to dust or chemicals, and the need for waterproof or dustproof designs.
9. Compliance and Standards: Choose a model that complies with relevant industry standards and certifications, such as CE, UL, or RoHS.

Application Areas

Applications of DC gear motors are endless. A few of their application examples include:

• Automotive: They find applications in seat adjustments, sunroof mechanisms, windshield wiper, and power windows.
• Industries: Conveyor belts, packaging machinery, and automated assembly lines are some of the areas where DC gear motors find their applications.
• Robotics: They guarantee the smooth and effortless functioning of robotic arms and grippers, drones and UAVs, servo mechanisms, among others.
• Consumer Electronics and Appliances: Electric toothbrushes, vacuum cleaners, electric shavers are some of the application examples of gear motors in the electronics sector.
• HVAC Systems: They are used to make actuators for damper control, variable air volume units, and motorized valves, among others.
• Medical: They play a critical role in the functioning of powered surgical tools, infusion pumps, prosthetic limbs, and so on.

Enjoyed this post? Read more in our related blog: Why DC Gear Motors are Ideal for Precision Motion Applications.

Overall, with an appropriate motor and gearbox combination, you can expect the speed and efficiency to virtually any precision motion requirement. Combining the robust power of DC motors with the mechanical advantage of gearboxes, DC gear motors from Venture Mfg. Co. contribute to providing an excellent range of power and speed required to power various devices and appliances. Get in touch with the team at sales@venturemfgco.com or call us at (937) 233-8792 and choose the right model that serves your purpose the most.

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Four Important Factors to Consider When Choosing the Power Supply for your 12V DC LinearActuator

12V DC linear actuators work at their best when they get a reliable power supply. Hence, it is very essential to choose an appropriate power supply that will suit your 12V DC linear actuator. Following are some tips that will help you in choosing the right power supply for your 12V DC linear actuator.

1. Voltage Input: There are different types of power supply inputs available for a 12V DC electric actuator. The most common of which are120V AC and 240V AC The choice of the right power supply will depend on your input voltage available and the actuator current requirements. To understand the current requirement, you need to address the maximum and minimum current drawn by the actuator in your particular application.
2. Voltage Output: Most 12V DC actuators will operate best between 11volts and 14 volts. The voltage output of the power supply for your 12V DC linear actuator must be chosen according to the type of application the linear actuator is used in. It is essential to match the right voltage output between the power supply and the actuator. If this is ignored then this will effect the performance of the actuator and may damage the application. If the application is of a more precise nature, you will probably want to choose a regulated power supply. These types of power supplies will maintain a constant 12 volt output regardless of amperage draw. With an unregulated power supply the voltage will drop as the current increases.
3. Current Rating: The power supply must be chosen with current rating higher than the maximum current requirement of the units connected to it. This will help avoid performance failures in the future. As most DC motors have a +/- 10% performance tolerance it is best to choose a power supply with a current rating at least 10% higher than the your actuators amperage rating.
4. IP Rating: IP ratings stands for ingress protection which is effectively used in blocking the foreign bodies like wind, water , dust and so on. If the application is installed in an area that is exposed to dust or other such elements then it is essential to select a sufficient IP rating.

Learn more on this topic in our related blog: 12 Volt Linear Actuators- What Makes Them So Popular?

If you are looking for a 12V actuator for your application, it is important to source them from a trusted source. Venture Manufacturing offers 12V DC actuators for use in different industrial applications. These actuators can be customized to meet your specific application requirements.

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Step-by-Step Procedure of DC Motor Replacement on Fifth Wheel Landing Gear

The landing gear repair or replacement is performed in two phases. The first step is preparatory and the second stage is where the DC motor is actually repaired. The stage-wise steps followed in landing gear repair are as follows.

• Preparatory Stage: The preparatory stage of the fifth wheel landing gear repair focuses on the diagnosis and parts collection. In the preparatory stage, following steps are performed.
  • Problem Diagnosis: There are two basic tests one should perform for problem diagnosis. At first, the driver must check if the leg is hitching and unhitching with the 5th gear. If not then it is a problem, which can be easily resolved by repairing the landing gear. If the vibration has increased and the car makes a choking noise while the DC motor assembly bounces, then it is a problem too. This problem needs DC motor assembly replacement. Sometimes, the failure may have been caused due to poor quality accessories.
  • Parts Collection: Before starting repair or replacement, the operator must have all required parts, accessories, and mounting tools. In the case of replacement, the operator may require a new DC motor assembly, mounting brackets, power kit, parts kit, crank handle assemblies, and so on.
• DC Motor Replacement Stage: Once the preparatory stage is done, the operator begins with the DC motor replacement. The steps followed to replace DC motor assembly are detailed below.
  • At first, the operator exposes the drive shaft that transmits power to the leg. This shaft is exposed by detaching the retaining bolts mounted on the sliding sheath. Once the bolts are off, the sheath can be slid back and forth. It exposes the drive shaft.
    
  • The motor assembly is secured by a plastic retainer. It is supported by a screw and by taking the screw off, the DC motor assembly can be taken off the leg.
    
  • The motor assembly is supposed to be slid off the drive shaft along with the gearbox.
    
  • Once the DC motor and gearboxes are off, the operator detaches the DC motor from the gearbox. The motor is bolted on the gearbox with the help of four bolts, in which only two are required to be removed by the operator and the motor comes off.
    
  • Once the motor is taken off, the operator replaces it with the new one that matches requirements.
  • However, re-attachment of the motor assembly is performed by moving opposite leg shaft aside. Then a manual attachment or override shaft is inserted into the housing. The operator aligns the center of assembly and the significant location on the drive shaft. Then the assembly is center nutted.
    
  • This completes the assembly process but then to finalize it, the component attachment is required to be done.
  • The operator activates the landing gear switch to ensure the position of the motor assembly. Once the position is assured, the operator re-attaches the plastic retainer.
    
  • The final step is to re-attach the opposite leg shaft and activating the landing gear switch by using a manual wrench. When this is done, the assembly is finalized with retainer bolts.

Learn more on this topic in our related blog – Which are the Types of DC Gear Motor Controls?

Although the above-discussed process of changing DC motor n 5th wheel landing gear is easy to follow, it is always recommended to get it done by professionals. Also, it is important that you use a branded or quality replacement parts. Venture Mfg. Co offers RV and 5th wheel landing gear and 12 VDC power kit.

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