Effect of Voltage on DC Gear Motor Performance

A. How voltage shapes the basic performance of motors
1. Balance between torque and speed
Torque output: When the voltage increases, the torque capacity of the motor output increases significantly. For example, the maximum torque of the same model motor at 24V voltage is usually more than twice that at 12V, but it should be noted that long-term overvoltage operation may cause magnetic circuit saturation, resulting in a slowdown in torque growth or even damage to the winding.
Speed ​​response: Voltage is positively correlated with speed. High voltage can drive the motor to a higher speed, but the gearbox reduction ratio needs to be adjusted to avoid excessive gear wear due to excessive speed.

2. Trade-off between efficiency and energy consumption
High efficiency range: Each motor has its "optimal voltage window", and the operating efficiency is highest within this range. After deviation, the efficiency will decrease due to abnormal increase in current or imbalance in magnetic field. For example, in order to maintain power at low voltage, the current increases significantly, resulting in coil heating and energy waste.
System energy consumption: High-voltage systems can reduce current intensity and power supply line losses under the same power demand, which is especially suitable for long-distance wiring or battery-powered scenarios, but require higher-specification insulation and protection designs.

3. Invisible connection between life and reliability
Temperature rise risk: Voltage overlimit will directly increase coil heating and accelerate the aging of insulation materials. For example, if a 24V motor is mistakenly connected to a 36V power supply, the temperature rise rate may double, resulting in a shortened life of less than 30% of the original design.
Material adaptation: High-voltage motors need to use reinforced components such as high-temperature resistant enameled wire and high-precision gears to cope with greater electromagnetic loads and mechanical stress.

B. Core design strategy at the production end
1. Refined matching of electromagnetic systems
Winding optimization: Customize the number of coil turns and wire diameter for the target voltage. High-voltage motors tend to have more turns and thinner wire diameters to balance resistance and inductance and avoid magnetic field distortion.
Magnetic circuit design: Use high-performance magnetic steel (such as neodymium iron boron) to ensure magnetic field stability under high voltage and prevent demagnetization risks.

2. Coordinated upgrade of gearboxes
Strength adaptation: High-voltage motors are often accompanied by greater torque output, and need to be matched with carburized and hardened steel gears or special engineering plastic gears to replace conventional nylon materials to avoid premature wear of the tooth surface.
Reduction ratio adjustment: By reducing the gearbox reduction ratio, the speed advantage brought by high voltage can be used to achieve higher output power.

3. Embedded integration of protection mechanism
Overvoltage protection: Built-in transient voltage suppression device to resist voltage spikes caused by power supply fluctuations or load mutations.
Intelligent shutdown: Configure voltage detection chip to automatically cut off the circuit when undervoltage or overvoltage occurs to prevent irreversible damage.

C. Selection suggestion: Decision logic based on scenario
1. Low voltage (6-12V) applicable scenario
Portable equipment: such as medical handheld tools and consumer electronics products, giving priority to lightweight and low heat generation characteristics.
Short-distance power supply: No complex cable modification is required, suitable for small automation equipment with limited space.

2. Medium and high voltage (24-48V) advantage areas
Industrial heavy load: such as robot arm joint drive and heavy conveyor belt, play the advantages of high torque and low current.
Long-distance power supply: Reduce wire diameter requirements and reduce line loss, commonly used in solar tracking systems and warehousing and logistics equipment.

3. Power adaptability considerations
Battery system: The voltage must match the nominal value of the battery pack (e.g., 24V motor with 7 strings of lithium batteries) to avoid performance fluctuations caused by insufficient voltage after power attenuation.
Wide voltage design: If the power supply environment fluctuates (e.g., vehicle-mounted system), select a motor model that supports wide voltage input (e.g., 9-36V) to enhance system robustness.

D. Practical points for maintenance and fault prevention
Voltage monitoring: Install a voltmeter or monitor in real time through the IoT module, and set abnormal threshold alarms.
Regular inspection: Use professional tools to check the insulation status of the winding to ensure that there is no risk of breakdown and leakage.
Heat dissipation enhancement: Sufficient heat dissipation space must be reserved for high-voltage motors, or a heat dissipation fan or metal heat-conducting casing must be added.

At ZD Motor, we have been deeply involved in the field of DC gear motors for 25 years. With precision manufacturing and innovative design as the core, we provide customers with highly adaptable, high-performance and highly reliable drive solutions.