ASLONG JGA20-180 DC Gear Motor: Problem - Solving Case Study
I. Problem Identification
The ASLONG JGA20-180 DC gear motor is popular for its excellent performance and wide - ranging applications in smart homes, smart transportation, medical equipment, and more. However, as application environments become more complex and user demands more diverse, some issues have arisen. These include:
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Current Surge at Startup: In applications with heavy loads, a significant current surge occurs when the motor starts. This can cause voltage fluctuations in the power supply and may even damage the power source or other electronic components.
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Jitter at Low Speeds: When operating at low speeds, the motor sometimes experiences jitter, especially in precision - demanding applications such as beauty devices or precision instruments. This affects the precision of device operation.
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Wear Issues After Prolonged Operation: In applications that require continuous long - term operation, components such as brushes and bearings in the motor can wear out. This leads to a decline in motor performance and potential malfunctions.
While these issues do not compromise the motor’s basic functionality, they do affect the overall performance of the equipment and the user experience. Therefore, it is necessary to conduct an in - depth analysis of these problems and devise effective solutions.
II. Problem Analysis and Solutions
A. Current Surge at Startup
Problem Analysis: When the motor starts, it needs to overcome significant static friction and load inertia, leading to a rapid surge in current. This can affect the stability of the power supply and may damage other electronic components.
Solutions:
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Soft - Start Technology: Gradually increase the voltage or current during startup to avoid instantaneous current surges. For example, using Pulse - Width Modulation (PWM) technology to control the startup process of the motor can achieve smooth startup.
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Startup Delay: Introduce a delay during motor startup to allow the motor to gradually accelerate. This can be achieved with a simple circuit design at a low cost.
B. Jitter at Low Speeds
Problem Analysis: At low speeds, control precision and mechanical vibrations can cause jitter in the motor. This is particularly evident in applications that require high - precision control.
Solutions:
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Optimized Motor Control Algorithm: Implement advanced vector control or direct torque control algorithms to enhance control precision and response speed at low speeds. These algorithms can precisely regulate the motor’s speed and torque based on real - time operating conditions.
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Mechanical Vibration Damping: Add vibration - damping pads or use flexible couplings at the motor mounting position to reduce the impact of mechanical vibrations. For example, rubber vibration - damping pads can effectively absorb vibrations during operation, improving low - speed stability.
C. Wear Issues After Prolonged Operation
Problem Analysis: Components such as brushes and bearings in the motor can wear out over long - term continuous operation. This leads to a decline in motor performance and potential malfunctions. It also increases the cost of equipment maintenance and can disrupt normal operation.
Solutions:
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Brushless Motor: Brushless motors do not require brushes or commutators, reducing the number of wearing parts and improving reliability and service life. Although brushless motors are relatively expensive, their advantages are significant in applications that require long - term stable operation.
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Regular Maintenance and Part Replacement: For brushed motors, regularly inspect the wear of brushes and bearings and replace worn parts in a timely manner. This can effectively extend the service life of the motor. Optimizing the motor’s heat - dissipation design to reduce heat accumulation during operation can also slow down the wear of components.
III. Implementation Results and Verification
The implementation of the above solutions has significantly improved the performance of the ASLONG JGA20-180 DC gear motor in practical applications:
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Current Surge at Startup: After adopting soft - start technology, the current surge during motor startup has been significantly reduced. This has minimized power - supply voltage fluctuations and ensured the safety of other electronic components.
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Jitter at Low Speeds: By optimizing the motor control algorithm and adding mechanical vibration damping, the jitter during low - speed operation has been effectively controlled. The precision of device operation has been notably improved.
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Wear Issues After Prolonged Operation: By using brushless motors or regularly maintaining brushed motors, the service life of the motor has been extended by 30 - 50%. This has reduced the cost of equipment maintenance and downtime due to malfunctions.
IV. Conclusion and Future Outlook
By conducting in - depth analyses of the issues that arose in the applications of the ASLONG JGA20-180 DC gear motor and implementing effective solutions, significant improvements have been made in the motor’s performance and reliability. Maintenance costs have been lowered and the user experience has been enhanced. Looking ahead, ASLONG will continue to invest in R&D to optimize motor design and improve adaptability and stability. ASLONG will also strengthen communication with customers to understand their needs in a timely manner and provide more personalized, high - quality products and services.