Can 45MM Tubular Motors Lift 100kg Loads Without Gear Damage?

A 45mm tubular motor typically generates torque through a combination of an electric motor and a planetary gear system. The gearbox is designed to amplify the motor’s output while maintaining durability. Key factors influencing load capacity include:
Gear Material: High-quality motors use hardened steel or reinforced polymer gears for wear resistance.
Torque Output: Rated torque (measured in Newton-meters, N·m) determines how much rotational force the motor can generate.
Duty Cycle: Continuous vs. intermittent operation impacts heat dissipation and gear stress.
For a 45mm motor, standard load ratings often range between 40kg and 60kg, depending on the manufacturer. However, exceeding this threshold—such as lifting 100kg—raises concerns about gear integrity.
Can 100kg Loads Be Safely Lifted?
The short answer is yes, but with critical caveats:
Dynamic vs. Static Loads:
A motor’s dynamic load (weight during movement) requires more torque than a static load. Lifting 100kg dynamically may push the motor beyond its rated torque, increasing gear wear.
Some motors are rated for higher static loads (stationary holding capacity), but prolonged use at this level risks overheating.
Gearbox Reinforcement:
Motors engineered for heavy-duty applications often feature multi-stage planetary gears or helical gears, which distribute stress more evenly. If the 45mm motor includes such a design, it may tolerate occasional 100kg lifts.
Safety Margins and Testing:
Reputable manufacturers test motors beyond their nominal ratings. For example, a motor rated for 60kg might withstand 100kg in short bursts—provided it includes overload protection (e.g., thermal cutoffs) to prevent gear damage.
Risks of Overloading
Pushing a 45mm motor beyond its specifications invites three primary risks:
Gear Tooth Shearing: Excessive force can fracture gear teeth, especially in low-quality gearboxes.
Bearing Wear: High loads accelerate wear on support bearings, leading to misalignment and motor failure.
Motor Overheating: Continuous overloading reduces efficiency, increasing heat buildup that degrades lubricants and plastic components.
Best Practices for Safe Operation
To maximize longevity when lifting heavy loads:
Select a Motor with a Safety Factor: Choose a model rated for at least 20–30% above your maximum expected load.
Optimize Installation: Ensure the load is balanced, and use pulleys or counterweights to reduce strain.
Monitor Usage: Avoid frequent cycling at peak loads and install temperature sensors for early fault detection.