When searching for the best electric motor or gear motor for your application, speed, torque, power and voltage aren’t the only factors to consider. Selecting the right motor requires a detailed understanding of your application’s requirements to ensure efficiency, performance, and longevity. In this guide, we’ll break down 20 essential factors to help you choose the right fractional horsepower motor for your needs.

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1. Voltage:  Will your motor be powered by a wall outlet or batteries? If using an outlet, is it a standard 115V supply or an industrial 230V+ system?
   
2. Frequency:  Motors in the United States typically run at 60Hz, while international applications may require a 50Hz or dual-frequency (50-60Hz) options.
   
3. Speed Requirements:  Does your application need a fixed speed or an adjustable range? If precision control is needed, a motor controller may be required.
   
4. Torque Demands: Starting torque — Does your motor need extra force at startup? Gravity impact — Will it lift or move heavy loads? Variable torque — Does the torque requirement fluctuates throughout operation? Worst-case scenario — What is the max torque needed?
   
5. Power Consumption:  Is the amount of power you think your application needs equal to the power it is actually using? When providing specifications, know if you are using running power or maximum power.
   
6. Duty cycle (Continuous vs. Intermittent Use):  Will your motor run continuously or in short bursts? Intermittent-duty motors generate less heat, allowing for smaller and more cost-effective solutions. Watch our video for more about the importance of duty cycles when selecting a motor.
   
7. Motor Life Expectancy:  Applications running intermittently may get by with DC or Universal motors, while long-running applications that need to operate thousands of hours without maintenance often require AC or Brushless DC motors for longevity and minimal maintenance.
   
8. Enclosure Rating & Environmental Conditions:  Will the motor be exposed to water, dust, or extreme conditions? Does it require stainless steel or food-grade applications? Need corrosion protection? Check out the full IP ratings chart.
   
9. Frame Size & Configuration:  Is space limited in your application? Do you need an inline gearbox or a right-angle configuration for the output shaft position to work with the product’s design? Groschopp offers 5 different gearbox styles to fit your needs.
   
10. Ambient Temperature Considerations:  Extreme heat or cold impacts motor materials and lubrication choices. Selecting oil or grease-lubricated motors depends on operating conditions.
    
11. Altitude: Operating above 5,000 feet? Thinner air affects cooling and motor performance. High-altitude motors may require special adjustments.
    
12. Noise Levels: For hospitals, offices, or public spaces, consider low-noise motors. Gear reconfiguration and material changes can further reduce noise.
    
13. Ventilation & Cooling Systems:  Fan-cooled motors dissipate heat faster but offer less protection against the elements. Non-vented motors provide better ingress protection but take longer to cool down after operation.
    
14. Feedback Device:  Do you need to understand how your motor is operating? Encoders and hall effect sensors collect data from the motor and can be combined with a control to allow motor speed and direction to be regulated.
    
15. Motor Control & Adjustability:   Soft start/stop for handling fragile items? Motor speed and direction changes? Multi-voltage compatibility? Motor controllers enhance efficiency while providing overload protection. Explore Groschopp’s AC and BLDC controls.
    
16. Operating Costs & Energy Efficiency:  Before investing, compare: motor efficiency, maintenance needs, initial vs. long-term costs. Download our free speed torque power and efficiency calculator to help determine motor operating costs.
    
17. Motor Efficiency: Efficiency matters most for motors over 1 HP. Fractional Horsepower motors are often more efficient due to design optimizations.
    
18. Maintenance Requirements:  DC Motors require brush replacements – Can they be accessed easily? Maintenance-free options like Brushless DC motors may be better for long-term reliability.
    
19. Load Variations:  Does your application deal with a range of loads or is the load consistent? Will the changes in load be gradual or sudden? If you are dealing with a range of loads, be sure to provide multiple load points when determining motor specifications.
    
20. Back-drive & Holding Power:   Is it essential for the motor in your application to remain in a locked position if power is cut? Do you need to be able to easily drive a motor without the use of power? For high-mass loads, back-drivability can be beneficial as it allows the load to coast to a stop and protects the gearbox if power is lost. Depending on the application, it might be necessary to add a brake to the motor unit. For more about back-drive, check out our video.

Get Expert Help Choosing the Right Motor

Choosing the right electric motor or gear motor for your application requires careful consideration. If you are unsure which specifications apply to your project, our experts are here to help!

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Factors to Consider When Choosing an Electric Motor for Your Facility

Maintaining industrial and commercial machinery requires many tasks. One of the most significant responsibilities is inspecting, maintaining and repairing electrical motors. You need to ensure facility tools meet safety standards and efficiency requirements, and choosing a suitable electric motor is a key part of that job.

How to Choose an Electric Motor

Electric motors power numerous industrial and commercial applications and support many functions, like powering machine compressors, pumps and tools. 

However, not all electric motors are equal, and some suit specific applications better than others. Considering factors like speed, torque, duty cycle, load compatibility and maintenance requirements can help you select a compatible electric motor for your industrial facility.

Torque

Suitable torque is necessary for driving electric motor startup and acceleration speeds. Applications require varying amounts of force to start up and accelerate load to a specific rate in a set time. You’ll need to consider a piece of equipment’s torque requirements when choosing an electric motor to ensure it can operate without excessive strain.

Speed 

Your electric motor’s output speed must be compatible with your needs. Some electric motors suit high-speed applications, while others are better for moderate- to low-speed processes. Your application might also require adjustable controls that accommodate specific increments. Understanding different motor designs and output capabilities is vital for selecting a suitable range for your applications:

• Industrial AC horizontal electric motors: Horizontal AC motors are widely used in applications such as pumps, compressors, fans, conveyors and other machines that require continuous and reliable mechanical power. These motors offer high efficiency, durability and the ability to operate under demanding conditions. 
• Industrial DC electric motors: DC electric motors are commonly used in applications that require precise control of speed and torque, such as robotics, CNC machines and conveyor systems. Advantages of these motors include ample starting torque, adjustable speed and relatively simple control mechanisms. 
• Industrial AC vertical electric motors: AC vertical electric motors are designed to handle the challenges of vertical applications, such as the weight of the rotating parts and the thrust load from the pump or compressor. They are built with robust construction and specialized features to ensure reliable and efficient operation in these demanding environments. 

Power Source

Do you need an AC or DC motor? Selecting a suitable power source is vital for running your equipment effectively. DC motors allow for fine speed control since their rpm output is directly affected by the amount of voltage supplied. AC motors require a variable frequency drive for speed variation but offer greater efficiency. An AC motor tends to excel in low- to medium-speed operations, while DC performs better when higher speeds are needed.

Speed Settings

Does the motor offer different speed ranges and control settings? Some applications require a definite operating speed, while others need adjustable rates. You can add a controller or drive to your DC or AC electric motor to manage torque and rotation. A controller can also regulate different application speeds, weights and loads. 

Operating Lifetime 

The motor’s operating lifetime determines the life span of a product or tool. Consider how long you’ll need the motor to last and how much time and money you plan to put into maintaining it. Brushless DC and stepper motors have fewer wear components and tend to last longer, while brushed DC motors deteriorate more quickly. 

Duty Cycle

The duty cycle determines how long the motor can run over production cycles. You might run applications continuously or over short periods. A longer run time will require a motor with a higher duty cycle to ensure you don’t lose power. You can use a smaller motor if you only need it intermittently and it will have enough rest time to return to ambient temperature. 

The environmental temperature will affect a motor’s duty cycle, as the objective behind limiting run time is preventing overheating and any resulting damage. 

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Enclosure Ranking

The enclosure ranking depends on the conditions a motor must operate under. Consider the environment surrounding the installation — will the motor be exposed to moisture, dirt, debris or extreme heat? Neglecting to provide proper protection during installation is one of the most common causes of motor failure. 

You’ll need suitable protection for your motor depending on your working conditions. For example, food and beverage industries might need stainless steel castings to protect machinery motors from spills, corrosion and wear. 

Voltage

Some electric motors can run on batteries or a power outlet. Depending on the facility, you’ll need to decide if you’ll connect a motor to the power grid, inverter or batteries. The voltage must be compatible with your motor if you use a wall socket or outlet. Smaller tools and lower power applications can use standard voltage, but you will likely need to draw more power for industrial motors. 

Performance Temperatures

Depending on your working conditions, a motor can require climate protection. Consider the temperature of the facility. Is it a hot or cold environment? Understanding the climate will help you select a motor with suitable materials or coverings. 

Control

Some applications require both backward and forward rotation. Some motors do not have multiple reverse or rotation capabilities, so be sure to choose a motor that can do everything your tasks require. 

Capacity and Size

Electric motor capacity and size will impact operational efficiency. An electric motor must offer sufficient torque for your application’s load without generating more heat than the insulation present can handle.

A key factor in selecting motor size is whether you will be installing it permanently or in a system you plan to move often. You can get a bigger motor for equipment that will remain in one place, like a large lathe in an industrial building. Anything you need to transport often will call for careful consideration. 

Noise levels

Whether noise is a concern will depend on where you’re using the motor. You might select a model geared for noise reduction if the installation will be in a public area like a hospital. 

Maintenance

Motors have different maintenance requirements. Consider the motor type and if you can maintain and repair it yourself or need professional services. DC motors tend to be more challenging to maintain and require expert knowledge. 

Feedback Components

Having a way to collect data on motor performance can enhance your applications. With encoders or sensors, you can get feedback on how well the motor works and adjust speed and other settings for better performance. Data components offer diagnostic capabilities to indicate wear or damage so you can schedule maintenance, preventing breakdowns and downtime. 

Operating Costs

A motor’s operating costs depend on its life span, maintenance requirements and initial price. You’ll need to decide which model will offer the best value for your money or return on investment. Weighing potential costs is necessary before selecting an electric motor for your commercial facility.

Rely on Industrial Electrical Company for Comprehensive Electric Motor Services

Deciding on an electric motor for your industrial or commercial facility requires you to look at many complex factors. If you want to ensure you select the best model based on your unique circumstances, it’s best to consult a professional. Industrial Electrical Company specializes in various electric motor services, including installations, preventive maintenance and repairs. 

Our certified technicians are experts in their craft. We’re also committed to delivering exceptional customer service, and we’ll answer your calls 24 hours a day. Whether you want us to evaluate trouble signs with an existing motor or assess your requirements and help you choose a new model, our team will make sure you have everything you need.

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