Overview

A manufacturer needed a custom gearmotor solution for a bus transmission shifter application. The design required a built-in backup system in case the motor experienced a failure, helping prevent the bus from becoming stuck in one gear. Groschopp took on the unique challenge and engineered a custom gearmotor with a dual commutator design to meet the customer’s requirements.

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Challenges

• Backup system: The customer needed a design that could continue operating if the primary commutator or winding failed.
• Compact fit: The gearmotor needed to fit within the available space on the transmission assembly.
• Harsh environment: The application required protection from harsh road and weather conditions.
• Long service life: The gearmotor needed to deliver reliable performance over long-term operation.
• Mounting requirements: The motor housing needed to bolt directly onto the transmission.

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Groschopp’s Solution

Groschopp designed a PM6304 motor with a right angle reducer for the bus transmission shifter application. The gearmotor included a dual commutator design that allowed a backup system to operate if the primary commutator failed.

Key features included:

• Two sets of brushes to support the dual commutator design
• Non-conductive brush card mounted onto a custom housing
• Aluminum die-cast housing designed to bolt directly onto the transmission
• Right angle reducer to support the application’s space and mounting needs
• IP66 protection against road and weather exposure 
• Controls designed to support the dual commutator system
• 25,000 cycle performance testing to evaluate long-term operation

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Results

The final design gave the customer a custom right angle gearmotor solution for its bus transmission shifter application. With dual commutators, a built-in backup system, IP66 protection, and 25,000 cycle testing, the gearmotor was designed to provide reliable shifting performance in harsh road and weather conditions.