ASLONG JGB37-520GB DC Gear Motor: Problem and Solution Case Study

I. Problem Identification

The ASLONG JGB37-520GB DC gear motor is widely used in smart self - balancing scooters, smart home devices, and small - scale industrial automation equipment thanks to its high torque, low speed, and compact size. However, users have reported the following issues:

1. Motor Overheating: Some users have experienced motor overheating during high - load operation, especially after prolonged use, leading to performance decline.

2. Insufficient Speed Control Precision: While the motor's speed control meets basic requirements, it lacks the precision needed for high - accuracy applications, with significant speed fluctuations.

3. Vibration Issues: Obvious vibrations occur under certain loads, particularly on uneven roads or during high - load operation, affecting device performance and lifespan, and worsening user experience.

These common issues require technical improvements to enhance motor performance and reliability.

II. Problem Analysis and Solutions

1. Motor Overheating

Problem Analysis: High - load operation increases current, causing heating. Inadequate heat dissipation traps heat, raising the motor surface temperature and risking insulation material aging and performance degradation.

Solutions:

• Improved Heat Dissipation: Redesign the motor's cooling structure with larger heat sinks or efficient materials like aluminum, and add a micro - fan for forced air - cooling to lower temperature.

• Temperature Monitoring and Protection: Embed a temperature sensor to monitor in - real - time. If the temperature exceeds the safe limit, automatically activate the fan. Restrict power output or shut down temporarily if overheating persists.

2. Insufficient Speed Control Precision

Problem Analysis: The motor's speed control precision is affected by the control algorithm and electronic component accuracy. Advanced algorithms are needed for high - accuracy applications like smart self - balancing scooters, which require real - time speed adjustments based on road conditions and user input.

Solutions:

• Upgraded Speed Control Algorithm: Use advanced algorithms like vector or direct torque control for dynamic adjustments based on real - time operation, enhancing precision. Improve the motor drive board's control accuracy.

• Feedback Control System: Install an encoder on the motor shaft for speed monitoring. Compare the feedback with the set value to automatically adjust power output, ensuring stable speed.

3. Vibration Issues

Problem Analysis: Vibration may stem from mechanical imbalance within the motor or uneven external loads. It intensifies under high loads or on uneven roads, impacting device performance and lifespan.

Solutions:

• Balancing Optimization: Perform precise dynamic balancing of the rotor to reduce imbalance forces during high - speed rotation. Check assembly accuracy to minimize vibration from installation errors.

• Anti - vibration Measures: Install vibration - damping pads or use flexible couplings between the motor and load to absorb and disperse vibration energy. Fit vibration - damping brackets on the motor housing to further reduce impact.

III. Implementation Results and Verification

These improvements have significantly elevated the ASLONG JGB37-520GB DC gear motor's performance:

1. Overheating: The optimized cooling and temperature monitoring have effectively lowered motor temperature during high - load operation, ensuring it remains within the safety threshold and enhancing performance and lifespan.

2. Speed Control Precision: The new algorithm and feedback mechanism have improved speed control precision, reducing speed fluctuations by about 50% for better application accuracy.

3. Vibration: Rotor balancing and anti - vibration measures have markedly decreased vibration amplitude under various loads, ensuring smoother device operation and a better user experience.

IV. Conclusion and Future Outlook

By deeply analyzing and improving the ASLONG JGB37-520GB DC gear motor's overheating, speed control, and vibration issues, we've enhanced its performance, reliability, and user experience. Moving forward, ASLONG will keep innovating and optimizing products. We'll also strengthen user communication to address their concerns promptly, delivering higher - quality products and services.