What exactly is a worm gear motor. I am going to be building a power chair for my senior design class and was wondering what a worm gear motor was. It seems like these are the type of motors being used for high powered wheel chairs but what exactly are these motors and by having a large gear ratio wouldn’t that mean that the vehicle would go slower? Also what allows the vehicle to come to a stop, is it just killing the power to the motor or does there need to be some sort of mechanical braking system? Is the worm gear motor the best to use or is there something better. I need some serious help with motors…
Ok so i understand the use of worm gears in the sense it is a smaller version of a conventional gear assembly and that it helps to get more torque than speed which would be important. I guess maximum speed would probably be 6mph. But when it comes to braking isnt locking the motor a bad thing doesnt there need to be a slow down period. Does there need to be a electromechanical braking system in place or does this need to be done through a controller? or is there something that is better than both?
A worm gear is like a corkscrew. It is used with a large gear, like a sprocket from a bicycle. They are normally attached (pardon the crude drawing) like this:
/\/\/\—–[motor]
/***\
\__/
Most motors turn at a very high speed, much higher than you would want to drive wheel chair tires at. For example, DC motors in dremels and small vacuum cleaners can run between 10,000 and 30,000 rpm. If you had that outputted directly to the tires, and the tires were, say, 3 inch diameter tires, the wheelchair would move at 90 miles an hour.
So instead, the manufacturers slow that speed down, and they do it with a worm gear. If you used a conventional gear set to step down that output speed it would take up a lot of space, because you would need to step the speed down so many times.
The ratio between input and output speed is determined by the number of teeth on the input and output gears. So if you want to step a 10,000 rpm motor down to a 500 rpm output, you need a 20:1 gear ratio. So for every 1 tooth on the input gear there are 20 teeth on the output gear.
Since the gear on the shaft attached to the tires can’t be larger than the tires (else you’d be driving on gears and not tires), you need to use a worm gear and slow it down in one step, or you need to slow it down in multiple steps in a conventional gear setup.
More steps = more parts = more time = more money = more chances to fail. I made a crude drawing for you of the differences in how the gear train would be setup for with a worm gear and without.
http://imgurl.filetac.com/img/53225270.jpg
Also, the worm gear provides an advantage in that, when the motor stops turning, the gear train locks up. This causes the wheelchair to stop. It’s like an automatic brake system that locks the wheelchair whenever the motor is not in use.
Of all things, actually, LEGO kits have a FANTASTIC set of gears to play with. I would highly recommend getting a set of LEGO Techniq blocks and buildings a small prototype gear train before you try to find/build/buy a full size metal (or plastic bleh) gear set.
Hope this helps, and good luck with this project!