Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient upon the gearing for high efficiency.
Powered by long-long lasting worm gears.
Minimum speed fluctuation with low noise and low vibration.
Lightweight and compact relative to its high load capacity.
The structural strength of our cast iron, Heavy-duty Correct angle (HdR) series worm Gearbox Worm Drive gearbox is because of how we dual up the bearings on the input shaft. HdR series reducers are available in speed ratios ranging from 5:1 to 60:1 with imperial center distances which range from 1.33 to 3.25 inches. Also, our gearboxes are given a brass spring loaded breather plug and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have been the go-to answer for right-angle power transmission for generations. Touted for his or her low-cost and robust construction, worm reducers can be
found in almost every industrial environment requiring this type of transmission. Unfortunately, they are inefficient at slower speeds and higher reductions, produce a lot of warmth, take up a lot of space, and require regular maintenance.
Fortunately, there can be an alternative to worm gear pieces: the hypoid gear. Typically found in automotive applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that arise with worm reducers. Obtainable in smaller overall sizes and higher reduction potential, hypoid gearmotors have a broader range of feasible uses than their worm counterparts. This not merely allows heavier torque loads to become transferred at higher efficiencies, nonetheless it opens options for applications where space is a limiting factor. They can sometimes be costlier, however the cost savings in efficiency and maintenance are well worth it.
The following analysis is targeted towards engineers specifying worm gearmotors in the number of 1/50 to 3 horsepower, and in applications where speed and torque are controlled.
How do Worm Gears and Hypoid Gears Differ?
In a worm gear established there are two components: the input worm, and the output worm gear. The worm can be a screw-like equipment, that rotates perpendicular to its corresponding worm equipment (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will complete five revolutions while the output worm gear is only going to complete one. With an increased ratio, for instance 60:1, the worm will full 60 revolutions per one output revolution. It really is this fundamental set up that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only experiences sliding friction. There is no rolling component to the tooth contact (Shape 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will see a huge amount of sliding friction because of the high number of input revolutions required to spin the output gear once. Low input quickness applications suffer from the same friction problem, but also for a different cause. Since there exists a lot of tooth contact, the original energy to begin rotation is higher than that of a similar hypoid reducer. When powered at low speeds, the worm requires more energy to keep its movement along the worm equipment, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets contain the input hypoid gear, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear arranged is a hybrid of bevel and worm gear technologies. They encounter friction losses due to the meshing of the gear teeth, with reduced sliding included. These losses are minimized using the hypoid tooth design which allows torque to end up being transferred easily and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest problems posed by worm equipment sets is their lack of efficiency, chiefly at high reductions and low speeds. Standard efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid gear sets are typically 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
In the case of worm gear sets, they don’t run at peak efficiency until a particular “break-in” period has occurred. Worms are typically made of steel, with the worm equipment being manufactured from bronze. Since bronze is certainly a softer steel it is proficient at absorbing large shock loads but will not operate successfully until it has been work-hardened. The temperature produced from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear pieces, there is no “break-in” period; they are usually made from steel which has already been carbonitride high temperature treated. This enables the drive to operate at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is one of the most important factors to consider whenever choosing a gearmotor. Since many employ a long service existence, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for years to arrive. Additionally, a far more efficient reducer permits better reduction ability and usage of a motor that
consumes less electrical power. One stage worm reducers are usually limited by ratios of 5:1 to 60:1, while hypoid gears have a reduction potential of 5:1 up to 120:1. Typically, hypoid gears themselves just go up to decrease ratios of 10:1, and the additional reduction is provided by another type of gearing, such as helical.
Minimizing Costs
Hypoid drives may have a higher upfront cost than worm drives. This is often attributed to the additional processing techniques required to generate hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically make use of grease with intense pressure additives rather than oil that may incur higher costs. This price difference is made up for over the lifetime of the gearmotor due to increased performance and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste much less energy and maximize the energy being transferred from the engine to the driven shaft. Friction is certainly wasted energy that requires the form of heat. Since worm gears produce more friction they run much hotter. In many cases, utilizing a hypoid reducer eliminates the necessity for cooling fins on the electric motor casing, further reducing maintenance costs that would be required to keep the fins clean and dissipating temperature properly. A comparison of motor surface temperature between worm and hypoid gearmotors can be found in Figure 5.
In testing the two gearmotors had equally sized motors and carried the same load; the worm gearmotor produced 133 in-lb of torque while the hypoid gearmotor created 204 in-lb of torque. This difference in torque is because of the inefficiencies of the worm reducer. The motor surface temperature of both products began at 68°F, room temperature. After 100 mins of operating time, the temperature of both products began to level off, concluding the check. The difference in temperature at this point was substantial: the worm unit reached a surface temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A difference of about 26.4°F. Despite becoming run by the same electric motor, the worm unit not only produced less torque, but also wasted more energy. Important thing, this can lead to a much heftier electrical bill for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This decreases the service life of these drives by putting extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these elements can fail, and oil changes are imminent due to lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance required to keep them operating at peak performance. Oil lubrication is not required: the cooling potential of grease is enough to guarantee the reducer will run effectively. This eliminates the need for breather holes and any mounting constraints posed by oil lubricated systems. It is also not necessary to replace lubricant since the grease is meant to last the life time use of the gearmotor, removing downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower engine driving a worm reducer can produce the same output as a comparable 1/2 horsepower engine generating a hypoid reducer. In one study by Nissei 
Company, both a worm and hypoid reducer had been compared for make use of on an equivalent application. This study fixed the decrease ratio of both gearboxes to 60:1 and compared engine power and output torque as it related to power drawn. The analysis concluded that a 1/2 HP hypoid gearmotor can be utilized to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a evaluation of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine size, comes the benefit to use these drives in more applications where space is a constraint. Because of the way the axes of the gears intersect, worm gears take up more space than hypoid gears (Figure 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is a lot smaller than that of a comparable worm gearmotor. This also helps make working conditions safer since smaller sized gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors can be that they are symmetrical along their centerline (Determine 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of the same power, hypoid drives significantly outperform their worm counterparts. One important aspect to consider is certainly that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Shape 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably more torque than worm gearmotors above a 30:1 ratio because of their higher efficiency (Figure 11).
Worm vs Hypoid Result Torque
Both comparisons, of allowable inertia and torque produced, were performed using equally sized motors with both hypoid and worm reducers. The outcomes in both research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to perform more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As verified using the studies offered throughout, hypoid gearmotors are designed for higher initial inertia loads and transfer more torque with a smaller motor when compared to a comparable worm gearmotor.
This can result in upfront savings by allowing an individual to purchase a smaller motor, and long-term savings in electrical and maintenance costs.
This also allows hypoid gearmotors to be a much better option in space-constrained applications. As proven, the overall footprint and symmetric style of hypoid gearmotors makes for a more aesthetically pleasing design while improving workplace safety; with smaller, much less cumbersome gearmotors there is a smaller chance of interference with workers or machinery. Obviously, hypoid gearmotors are the best choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that increase operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency systems for long-term energy financial savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in proportions and sealed forever. They are light, dependable, and offer high torque at low acceleration unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant systems that withstand harsh circumstances. These gearmotors also have multiple regular specifications, options, and mounting positions to ensure compatibility.
Specifications
Material: 7005 aluminum equipment box, SAE 841 bronze worm gear, 303/304 stainless worm
Weight: 105.5 g per gear box
Size: 64 mm x 32 mm x 32 mm
Thickness: 2 mm
Gear Ratios: 4:1
Note: The helical spur equipment attaches to 4.7 mm D-shaft diameter. The worm equipment attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Speed Reducers is rated 5.0 out of 5 by 1.
8 Ratios Available from 5:1 to 60:1
7 Gear Box Sizes from 1.33 to 3.25″
Universally Interchangeable Design for OEM Replacement
Double Bearings Applied to Both Shaft Ends
Anti-Rust Primer Applied Outside and inside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide variety of worm gearboxes. Due to the modular design the typical program comprises countless combinations with regards to selection of equipment housings, installation and connection options, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The look of the EP worm gearbox is simple and well proven. We only use top quality components such as homes in cast iron, aluminium and stainless steel, worms in case hardened and polished steel and worm tires in high-grade bronze of unique alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dirt lip which successfully resists dust and water. In addition, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes allow for reductions as high as 100:1 in one single step or 10.000:1 in a double reduction. An equivalent gearing with the same gear ratios and the same transferred power is bigger than a worm gearing. In the mean time, the worm gearbox is certainly in a more simple design.
A double reduction could be composed of 2 regular gearboxes or as a particular gearbox.
Worm gearbox
Ratios
Maximum output torque
[Nm]
Housing design
Series 35
5:1 – 90:1
25
Aluminium
Series 42
5:1 – 75:1
50
Cast iron
Series 52
7:1 – 60:1
130
Cast iron
Series 61
7:1 – 100:1
200
Cast iron
Series 79
7:1 – 60:1
300
Cast iron
Series 99
7:1 – 100:1
890
Cast iron
Other product benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is one of the key words of the standard gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very smooth operating of the worm gear combined with the use of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we take extra care of any sound which can be interpreted as a murmur from the apparatus. So the general noise level of our gearbox can be reduced to an absolute minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This often proves to become a decisive advantage producing the incorporation of the gearbox considerably simpler and more compact.The worm gearbox is an angle gear. This is often an advantage for incorporation into constructions.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the gear house and is perfect for immediate suspension for wheels, movable arms and other areas rather than having to build a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes provides a self-locking impact, which in many situations can be used as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for an array of solutions.