Ever-Power Worm Gear Reducer
High-efficiency, high-strength 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 in accordance with its high load capacity.
The structural strength of our cast iron, Heavy-duty Correct angle (HdR) series worm gearbox is because of how we double up the bearings on the input shaft. HdR series reducers can be found in speed ratios which range 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-stuffed with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
Introduction
Worm reducers have already been the go-to alternative for right-angle power transmission for generations. Touted because of their low-cost and robust structure, worm reducers could be
found in almost every industrial setting 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 need regular maintenance.
Fortunately, there can be an option to worm gear units: the hypoid gear. Typically used in auto applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the issues that arise with worm reducers. Available in Gearbox Worm Drive Smaller general sizes and higher decrease potential, hypoid gearmotors possess a broader range of possible uses than their worm counterparts. This not only allows heavier torque loads to be transferred at higher efficiencies, nonetheless it opens opportunities for applications where space is certainly a limiting factor. They can sometimes be costlier, but the financial savings in efficiency and maintenance are well worth it.
The following analysis is targeted towards engineers specifying worm gearmotors in the range of 1/50 to 3 horsepower, and in applications where speed and torque are controlled.
Just how do Worm Gears and Hypoid Gears Differ?
In a worm gear arranged there are two components: the input worm, and the output worm gear. The worm is a screw-like equipment, that rotates perpendicular to its corresponding worm gear (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will complete five revolutions while the output worm gear will only complete one. With a higher ratio, for example 60:1, the worm will complete 60 revolutions per one output revolution. It really is this fundamental set up that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only encounters sliding friction. There is no rolling element of the tooth contact (Figure 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will have a big amount of sliding friction due to the high number of input revolutions required to spin the output gear once. Low input velocity applications have problems with the same friction problem, but also for a different cause. Since there exists a large amount of tooth contact, the original energy to start rotation is greater 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 a lot of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets consist of 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 experience friction losses due to the meshing of the apparatus teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth pattern which allows torque to become transferred smoothly and evenly over the interfacing surfaces. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest complications posed by worm gear sets is their lack of efficiency, chiefly in high reductions and low speeds. Regular efficiencies can vary 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
Regarding worm gear sets, they don’t operate at peak efficiency until a specific “break-in” period has occurred. Worms are typically made of steel, with the worm gear being made of bronze. Since bronze is usually a softer steel it is good at absorbing weighty shock loads but does not operate successfully until it’s been work-hardened. The heat generated 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 metal which has recently been carbonitride high temperature treated. This allows the drive to operate at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is among the most important things to consider when choosing a gearmotor. Since most employ a long service existence, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for a long time to arrive. Additionally, a more efficient reducer allows for better reduction ability and use of a motor that
consumes less electrical power. Solitary stage worm reducers are usually limited by ratios of 5:1 to 60:1, while hypoid gears possess a decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the additional reduction is supplied by a different type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This could be attributed to the excess processing techniques necessary to create hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically make use of grease with severe pressure additives rather than oil that will incur higher costs. This price difference is composed for over the lifetime of the gearmotor because of increased performance and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste much less energy and maximize the energy being transferred from the electric motor to the driven shaft. Friction is 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 motor casing, further reducing maintenance costs that would be required to keep carefully the fins clean and dissipating temperature properly. A comparison of motor surface temperature between worm and hypoid gearmotors are available in Figure 5.
In testing both gearmotors had equally sized motors and carried the same load; the worm gearmotor produced 133 in-lb of torque while the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is because of the inefficiencies of the worm reducer. The electric motor surface area temperature of both products began at 68°F, area temperature. After 100 mins of operating period, the temperature of both systems began to level off, concluding the check. The difference in temperature at this stage was significant: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A notable difference of about 26.4°F. Despite being driven by the same electric motor, the worm unit not only produced much less torque, but also wasted more energy. Important thing, this can lead to a much heftier electric costs for worm users.
As previously mentioned 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 exposure to high heat, these parts can fail, and oil changes are imminent because of lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance required to keep them working at peak performance. Essential oil lubrication is not needed: the cooling potential of grease is enough to ensure 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 displace lubricant since the grease is intended to last the lifetime utilization of the gearmotor, removing downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller motors can be utilized in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine generating a worm reducer can create the same output as a comparable 1/2 horsepower motor driving a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer had been compared for make use of on an equivalent app. This study fixed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and output torque as it related to power drawn. The study figured a 1/2 HP hypoid gearmotor can be used to provide similar performance to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result showing a comparison of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in motor size, comes the advantage to use these drives in more applications where space is a constraint. Due to the method the axes of the gears intersect, worm gears take up more space than hypoid gears (Determine 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized motor, the overall footprint of the hypoid gearmotor is a lot smaller sized than that of a comparable worm gearmotor. This also makes working environments safer since smaller sized gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is that they are symmetrical along their centerline (Figure 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equivalent power, hypoid drives significantly outperform their worm counterparts. One essential requirement to consider is certainly that hypoid reducers can move loads from a dead stop with more relieve 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 studies are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to run more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As verified using the studies presented throughout, hypoid gearmotors can handle higher initial inertia loads and transfer more torque with a smaller sized motor than a comparable worm gearmotor.
This can lead to upfront savings by allowing the user to purchase a smaller motor, and long-term savings in electrical and maintenance costs.
This also allows hypoid gearmotors to be a better option in space-constrained applications. As shown, the entire footprint and symmetric design of hypoid gearmotors produces a far more aesthetically pleasing design while improving workplace safety; with smaller sized, less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Clearly, hypoid gearmotors are the best choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that boost operational efficiencies and reduce maintenance needs and downtime. They offer premium efficiency units for long-term energy savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in size and sealed for life. They are light, dependable, and provide high torque at low speed unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant products that withstand harsh circumstances. These gearmotors also have multiple regular specifications, options, and installation positions to make sure compatibility.
Specifications
Material: 7005 aluminum equipment box, SAE 841 bronze worm gear, 303/304 stainless steel 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 Acceleration 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 Style for OEM Replacement
Double Bearings Used on Both Shaft Ends
Anti-Rust Primer Applied Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide selection of worm gearboxes. Because of the modular design the typical programme comprises countless combinations when it comes to selection of equipment housings, mounting and connection options, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The look of the EP worm gearbox is easy and well proven. We just use high quality components such as houses in cast iron, aluminum and stainless, worms in the event hardened and polished metal and worm wheels in high-quality bronze of particular alloys ensuring the maximum wearability. The seals of the worm gearbox are given 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 a single 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 decrease. An equivalent gearing with the same equipment ratios and the same transferred power is bigger when compared to a worm gearing. In the meantime, the worm gearbox can be in a more simple design.
A double reduction could be composed of 2 standard 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 special gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very simple operating of the worm gear combined with the use of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we take extra care of any sound that can be interpreted as a murmur from the apparatus. Therefore the general noise degree of our gearbox can be reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This frequently proves to become a decisive advantage producing the incorporation of the gearbox significantly simpler and smaller sized.The worm gearbox can be an angle gear. This is an edge for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the gear house and is ideal for immediate suspension for wheels, movable arms and other areas rather than having to create a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes provides a self-locking effect, which in lots of situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them perfect for an array of solutions.
