5 Reasons To Avoid Oversized Electric Gear Motors

The 5 big reasons to avoid oversizing electric gear motors include poor efficiency at partial loads, higher operating costs, increased maintenance complexity, starting current problems, and reduced equipment life. Bauer GMC, a major distributor of gear motors, gear reducers, and associated equipment in Mississauga, Ontario, explores these 5 reasons in detail in this blog.

What Are Some Issues With Oversized Electric Gear Motors?

Poor Efficiency At Partial Loads

To achieve maximum efficiency, gear motors must operate close to their rated capacity. However, when an oversized electric gear motor is considered, it is nowhere close to its rated capacity during operation. Therefore, the efficiency is not great, particularly at partial loads.

Higher Operating Costs

In terms of procurement, installation, and operation, oversized gear motors cost more than their regular counterparts. Even if the initial costs are adjusted, the motor will draw more current to operate due to its size, meaning that it will generate higher energy bills while delivering low efficiency.

Complex Maintenance

When removing the gear motor for repair or maintenance, the process requires more time and specialized equipment. Furthermore, technicians have to handle heavier and larger gear motor components, making scheduled maintenance more challenging. The same goes for instances of gear motor repair.

Starting Current Issues

Starting current is a factor that is directly impacted by motor size. The greater the size of the electric gear motor, the greater the starting current. This influx of current can cause voltage drops in other equipment in the facility, causing potential power quality issues. 

Reduced Equipment Life

Another major drawback of running an oversized motor below its rated capacity is a marked reduction in its lifespan. These motors require certain mechanical loads to ensure lubrication in the bearings. Premature bearing failures are common with oversized gear motors, which, in turn, increases other component wear and ultimately reduces the lifespan of the motor. 

Conclusion

To conclude, oversized gear motors are not ideal for industrial operations due to the drawbacks stated above.

Bauer GMC is a proud distributor of some of the best AC gear motors available in the market today. We also offer gear reducers and electric gear motors in our Mississauga facility. If you'd like to own brand new units or replace your existing ones, contact us today to learn more about our services.

FAQs:

Does oversizing gear motors increase energy consumption?

Yes, oversizing gear motors can lead to increased energy consumption and energy bills.

How to prevent sizing mistakes in gear motors?

To prevent sizing mistakes in gear motors, focus on load torque, speed, and duty cycles.