{"id":28951,"date":"2025-09-16T09:14:48","date_gmt":"2025-09-16T07:14:48","guid":{"rendered":"https:\/\/www.apexdyna.nl\/?p=28951"},"modified":"2025-09-16T10:26:49","modified_gmt":"2025-09-16T08:26:49","slug":"current-limitation-gearboxes","status":"publish","type":"post","link":"https:\/\/www.apexdyna.nl\/en\/news\/current-limitation-gearboxes","title":{"rendered":"Calculate current limitation for gearboxes"},"content":{"rendered":"<p><strong>Why does the Apex Dynamics Design Tool sometimes not show the desired gear ratio?<br \/>\nThis is usually due to excessive output torque in the selected combination. In this article, we explain how torque is calculated, the role of motor current limitation, and how you can still achieve a technically good solution without oversizing. <\/strong><\/p>\n<p>At Apex Dynamics, we regularly receive feedback that our <strong>Design Tool<\/strong> doesn&#8217;t display the desired gear ratio when selecting a gearbox in combination with a servomotor. While this may seem confusing at first, there&#8217;s almost always a technical explanation: the combination of motor and gear ratio generates an <strong>output torque<\/strong> that exceeds the gearbox&#8217;s allowable level.<\/p>\n<p style=\"text-align: center;\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-28760 size-full\" src=\"https:\/\/www.apexdyna.nl\/wp-content\/uploads\/2025\/07\/DesignTool_Overload.jpg\" alt=\"\" width=\"640\" height=\"335\" srcset=\"https:\/\/www.apexdyna.nl\/wp-content\/uploads\/2025\/07\/DesignTool_Overload.jpg 640w, https:\/\/www.apexdyna.nl\/wp-content\/uploads\/2025\/07\/DesignTool_Overload-300x157.jpg 300w, https:\/\/www.apexdyna.nl\/wp-content\/uploads\/2025\/07\/DesignTool_Overload-600x314.jpg 600w, https:\/\/www.apexdyna.nl\/wp-content\/uploads\/2025\/07\/DesignTool_Overload-150x79.jpg 150w\" sizes=\"auto, (max-width: 640px) 100vw, 640px\" \/><\/p>\n<p>This article explains step-by-step how torque is calculated, why the Design Tool excludes certain combinations, and how <strong>motor current limiting<\/strong> can be applied to arrive at a workable solution without having to immediately select a heavier \u2013 and often more expensive \u2013 gearbox.<\/p>\n<h3>Why doesn&#8217;t the Design Tool show the desired combination?<\/h3>\n<p>The Apex Dynamics Design Tool has been specifically developed to enable users to select the correct gearbox quickly and reliably.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignright size-full wp-image-28764\" src=\"https:\/\/www.apexdyna.nl\/wp-content\/uploads\/2025\/07\/Gearbox-Specification-1.jpg\" alt=\"\" width=\"300\" height=\"358\" \/>This involves strict checks to ensure that the selected combination meets <strong>all technical specifications<\/strong>. This check includes, among other things::<\/p>\n<ul>\n<li>Whether the <strong>output torque<\/strong> (nominal and peak) remains within the gearbox&#8217;s limits<\/li>\n<li>Whether the <strong>speeds<\/strong> are not too high<\/li>\n<li>Whether the gearbox&#8217;s <strong>no-load torque<\/strong> is not too high for the motor<\/li>\n<li>Whether the motor&#8217;s <strong>mechanical dimensions<\/strong> to the gearbox&#8217;s input side is compatible<\/li>\n<li>Whether the motor has sufficient <strong>inertia<\/strong> in relation to the gearbox (for stability and dynamics)<\/li>\n<\/ul>\n<p>In practice, however, the most common bottleneck is <strong>an output torque that is too high<\/strong>.<\/p>\n<h3>How is output torque calculated?<\/h3>\n<p>A gearbox multiplies the input motor torque by the <strong>gear ratio<\/strong>. This amplification is desirable to deliver more power to the output side, for example, when driving heavy loads. However, if this multiplied torque exceeds the gearbox&#8217;s capacity, it can lead to mechanical damage.<\/p>\n<p>Below a Current Limiting Calculator, enter the gear ratio, nominal and maximum torque of both the gearbox and the motor and you will see by how much you need to limit (if necessary):<\/p>\n        <div class=\"torque-calculator-container card card-body shadow-sm mb-4\">\n            <h5 class=\"card-title mb-3\">Current Limitation Calculator<\/h5>\n\n            <div class=\"row g-3\">\n                <div class=\"col-md-6\">\n                    <form id=\"torque-form\">\n                        <div class=\"form-floating mb-3\">\n                            <input type=\"number\" class=\"form-control\" id=\"motor-ratio\" placeholder=\"10\" value=\"10\" step=\"any\">\n                            <label for=\"motor-ratio\">Gearbox Ratio<\/label>\n                        <\/div>\n\n                        <div class=\"form-floating mb-3\">\n                            <input type=\"number\" class=\"form-control\" id=\"motor-torque-nominal\" placeholder=\"1\" value=\"1\" step=\"any\">\n                            <label for=\"motor-torque-nominal\">Motor Nominal torque<\/label>\n                        <\/div>\n\n                        <div class=\"form-floating mb-3\">\n                            <input type=\"number\" class=\"form-control\" id=\"gearbox-torque-nominal\" placeholder=\"10\" value=\"10\" step=\"any\">\n                            <label for=\"gearbox-torque-nominal\">Gearbox Nominal torque T2N (Nm)<\/label>\n                        <\/div>\n\n                        <div class=\"form-floating mb-3\">\n                            <input type=\"number\" class=\"form-control\" id=\"motor-torque-maximal\" placeholder=\"1\" value=\"1\" step=\"any\">\n                            <label for=\"motor-torque-maximal\">Motor Maximum torque T2B (Nm)<\/label>\n                        <\/div>\n\n                        <div class=\"form-floating mb-3\">\n                            <input type=\"number\" class=\"form-control\" id=\"gearbox-torque-maximal\" placeholder=\"10\" value=\"10\" step=\"any\">\n                            <label for=\"gearbox-torque-maximal\">Gearbox Maximum torque T2B (Nm)<\/label>\n                        <\/div>\n                    <\/form>\n                <\/div>\n\n                <div class=\"col-md-6\">\n                    <h5>Result<\/h5>\n\n                    <div class=\"card mb-3\">\n                        <div class=\"card-header bg-secondary text-white\">\n                            <h6 class=\"mb-0\">Nominal (T2N)<\/h6>\n                        <\/div>\n                        <div class=\"list-group list-group-flush\">\n                            <div class=\"list-group-item\">\n                                <div class=\"d-flex w-100 justify-content-between\">\n                                    <h6 class=\"mb-1\">Calculated Motor Torque<\/h6>\n                                    <span class=\"badge bg-secondary fs-6\" id=\"calculated-torque-nominal\">10 Nm<\/span>\n                                <\/div>\n                            <\/div>\n                            <div class=\"list-group-item\">\n                                <div class=\"d-flex w-100 justify-content-between\">\n                                    <h6 class=\"mb-1\">Current restriction<\/h6>\n                                    <span class=\"badge fs-6\" id=\"current-restriction-nominal\">0%<\/span>\n                                <\/div>\n                            <\/div>\n                        <\/div>\n                    <\/div>\n\n                    <div class=\"card\">\n                        <div class=\"card-header bg-secondary text-white\">\n                            <h6 class=\"mb-0\">Maximum (T2B)<\/h6>\n                        <\/div>\n                        <div class=\"list-group list-group-flush\">\n                            <div class=\"list-group-item\">\n                                <div class=\"d-flex w-100 justify-content-between\">\n                                    <h6 class=\"mb-1\">Calculated Motor Torque<\/h6>\n                                    <span class=\"badge bg-secondary fs-6\" id=\"calculated-torque-maximal\">10 Nm<\/span>\n                                <\/div>\n                            <\/div>\n                            <div class=\"list-group-item\">\n                                <div class=\"d-flex w-100 justify-content-between\">\n                                    <h6 class=\"mb-1\">Current restriction<\/h6>\n                                    <span class=\"badge fs-6\" id=\"current-restriction-maximal\">0%<\/span>\n                                <\/div>\n                            <\/div>\n                        <\/div>\n                    <\/div>\n                <\/div>\n            <\/div>\n        <\/div>\n        \n<p>The calculation is as follows:<\/p>\n<ul>\n<li><strong>T<span style=\"font-size: 8pt;\">2N<\/span> (nominal torque)<\/strong> = nominal motor torque \u00d7 gear ratio<\/li>\n<li><strong>T<span style=\"font-size: 8pt;\">2B<\/span> (maximum or peak torque) <\/strong>= peak motor torque \u00d7 gear ratio<\/li>\n<\/ul>\n<p>For example:<br \/>\nA servo motor with a nominal torque of 5 Nm and a peak torque of 15 Nm, combined with a gear ratio of 20:1, delivers:<\/p>\n<ul>\n<li>T<span style=\"font-size: 8pt;\">2N<\/span> = 5 \u00d7 20 = 100 Nm<\/li>\n<li>T<span style=\"font-size: 8pt;\">2B<\/span> = 15 \u00d7 20 = 300 Nm<\/li>\n<\/ul>\n<p>For example, if the selected gearbox can handle a T<span style=\"font-size: 8pt;\">2N<\/span> of 90 Nm and a T<span style=\"font-size: 8pt;\">2B<\/span> of 250 Nm, then the combination will exceed both limits \u2013 and will not be shown in the Design Tool.<\/p>\n<h3>What is current limiting and how does it help?<\/h3>\n<p>In many cases, the output torque is theoretically too high, but in practice, <strong>the application doesn&#8217;t require that much power<\/strong>. It&#8217;s a waste to select a larger (and more expensive) gearbox. The solution? <strong>Limit the current supply to the motor<\/strong>.<\/p>\n<p>The torque of an electric servomotor is directly dependent on the amount of current it receives. By limiting the current, the maximum torque the motor can develop\u2014and therefore also the output torque of the gearbox\u2014is limited.<\/p>\n<p>This can be done in two ways:<\/p>\n<ol>\n<li><strong>Limiting the nominal torque<\/strong><br \/>\nIn this case, the continuous current to the motor is adjusted so that the nominal output torque (T<span style=\"font-size: 8pt;\">2N<\/span>) is not exceeded.<\/li>\n<li><strong>Limiting the peak torque<\/strong><br \/>\nThe peak current \u2013 which is released during acceleration or sudden loads, for example \u2013 is also limited so that the output peak torque (T<span style=\"font-size: 8pt;\">2B<\/span>) remains within specification.<\/li>\n<\/ol>\n<p>The condition is of course that the actual torque required in the application remains <strong>below the limited level<\/strong>.<\/p>\n<h3>Why is current limiting often the ideal solution?<\/h3>\n<ul>\n<li><strong>Prevents oversizing<\/strong> of the gearbox<\/li>\n<li><strong>Cost savings<\/strong>: a smaller gearbox is more economical to purchase and install<\/li>\n<li><strong>Space savings<\/strong>: compact design in limited installation space<\/li>\n<li><strong>Better efficiency<\/strong>: smaller gearboxes often have a more favorable inertia<\/li>\n<\/ul>\n<p>Applying current limitation does require some coordination with the manufacturer of the servo motor or drive amplifier. Modern controllers usually offer standard settings for limiting the current (and therefore the torque) via software.<\/p>\n<h3>Practical example<\/h3>\n<p>A customer wants to combine a 40:1 gearbox with a servomotor rated at 6 Nm nominal and 18 Nm peak. The desired gearbox has a T<span style=\"font-size: 8pt;\">2N<\/span> of 200 Nm and a T<span style=\"font-size: 8pt;\">2B<\/span> of 400 Nm.<\/p>\n<ul>\n<li>T<span style=\"font-size: 8pt;\">2N<\/span> = 6 \u00d7 40 = 240 Nm \u2192 <strong>too high<\/strong><\/li>\n<li>T<span style=\"font-size: 8pt;\">2B<\/span> = 18 \u00d7 40 = 720 Nm \u2192 <strong>much too high<\/strong><\/li>\n<\/ul>\n<p>By limiting the motor current torque to 5 Nm nominal and 10 Nm peak, the output torques are as follows:<\/p>\n<ul>\n<li>T<span style=\"font-size: 8pt;\">2N<\/span> = 5 \u00d7 40 = 200 Nm<\/li>\n<li>T<span style=\"font-size: 8pt;\">2B<\/span> = 10 \u00d7 40 = 400 Nm<\/li>\n<\/ul>\n<p>These are <strong>exactly within the specifications<\/strong> of the gearbox \u2013 and the combination is therefore technically good, without any modifications to the mechanics.<\/p>\n<h3>What if te desired combination does not appear in the Design Tool?<\/h3>\n<p>If the Design Tool doesn&#8217;t show a result for a particular combination, this doesn&#8217;t mean it&#8217;s technically impossible. On the contrary: it means one or more values fall outside the standard limits, in which case current limitation could be a possible solution.<\/p>\n<p>In that case, you can simply contact Apex Dynamics. We&#8217;re happy to review the calculation, explain the bottleneck, and advise on the best solution. If desired, we can also send you the technical drawing of the gearbox so we can continue working on the application immediately.<\/p>\n<h3>Conclusion<\/h3>\n<p>Correctly calculating the output torque is essential when selecting a gearbox. When this torque exceeds the gearbox&#8217;s capacity, current limitation is often an efficient and safe solution. This prevents unnecessary oversizing and allows you to still use the desired gear ratio.<\/p>\n<p>Do you have questions about torque, gear ratios, or current limitation in combination with a servomotor? Feel free to contact Apex Dynamics \u2013 we&#8217;re happy to help!<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Why does the Apex Dynamics Design Tool sometimes not show the desired gear ratio? This is usually due to excessive output torque in the selected combination. In this article, we explain how torque is calculated, the role of motor current limitation, and how you can still achieve a technically good solution without oversizing. At Apex [&hellip;]<\/p>\n","protected":false},"author":5,"featured_media":28760,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[11,138],"tags":[],"class_list":["post-28951","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","category-gearboxes"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Calculate current limitation for gearboxes<\/title>\n<meta name=\"description\" content=\"Discover how motor current limiting helps with excessive torque in servo motor-gearbox combinations and why the Design Tool sometimes doesn&#039;t show the desired result.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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