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.
Minimal 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 Right angle (HdR) series worm gearbox is due to 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 supplied with a brass springtime loaded breather plug and come pre-stuffed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to option for right-angle power transmitting for generations. Touted for their low-cost and robust structure, worm reducers can be
found in almost every industrial setting requiring this type of transmission. Sadly, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a lot of space, and require regular maintenance.
Fortunately, there can be an alternative to worm gear pieces: the hypoid gear. Typically used in auto applications, gearmotor businesses have begun integrating hypoid gearing into right-position gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller general sizes and higher decrease potential, hypoid gearmotors possess a broader selection of possible uses than their worm counterparts. This not merely allows heavier torque loads to end up being transferred at higher efficiencies, but it opens opportunities for applications where space is certainly a limiting factor. They are able to sometimes be costlier, however the savings in efficiency and maintenance are really 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 established 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 equipment (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will total five revolutions as the output worm equipment is only going to complete one. With a higher ratio, for example 60:1, the worm will total 60 revolutions per one result revolution. It really is this fundamental arrangement that triggers 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 (Body 2).
Sliding Friction
In high reduction applications, such as for example 60:1, there will be a large amount of sliding friction due to the lot of input revolutions required to spin the output gear once. Low input rate applications have problems with the same friction issue, but also for a different reason. Since there is a large amount 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 gear, and lots of that energy is lost to friction.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
However, hypoid gear sets contain the input hypoid equipment, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm equipment technologies. They experience friction losses due to the meshing of the gear teeth, with minimal sliding included. These losses are minimized using the hypoid tooth design that allows torque to become transferred easily and evenly across the interfacing surfaces. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary complications posed by worm gear sets is their insufficient efficiency, chiefly in high reductions and low speeds. Common efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment sets are typically 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
Regarding worm gear sets, they do not operate at peak efficiency until a specific “break-in” period has occurred. Worms are typically made of metal, with the worm gear being made of bronze. Since bronze is definitely a softer metallic it is proficient at absorbing heavy shock loads but will not operate efficiently until it has been work-hardened. The temperature generated from the friction of regular operating conditions really helps to harden the surface of the worm gear.
With hypoid gear models, there is no “break-in” period; they are usually made from metal which has recently been carbonitride heat treated. This enables the drive to use at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is one of the most important factors to consider when choosing a gearmotor. Since the majority of employ a long service lifestyle, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for a long time to come. Additionally, a more efficient reducer allows for better reduction ability and utilization of a motor that
consumes less electrical power. One stage worm reducers are typically limited by ratios of 5:1 to 60:1, while hypoid gears possess a reduction potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to decrease ratios of 10:1, and the additional reduction is provided 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 can be attributed to the additional processing techniques necessary to generate hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically use grease with severe pressure additives rather than oil that will incur higher costs. This price difference is made up for over the lifetime of the gearmotor because of increased overall performance and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste much less energy and maximize the energy getting transferred from the Gearbox Worm Drive electric motor to the driven shaft. Friction is certainly wasted energy that takes the form of temperature. Since worm gears generate more friction they operate much hotter. Oftentimes, using a hypoid reducer eliminates the need for cooling fins on the electric motor casing, additional reducing maintenance costs that might be required to keep carefully the fins clean and dissipating heat properly. A comparison of motor surface area 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 created 133 in-lb of torque while 
the hypoid gearmotor created 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The engine surface area temperature of both systems began at 68°F, space temperature. After 100 moments of operating period, the temperature of both devices started to level off, concluding the test. The difference in temperature at this stage was considerable: the worm unit reached a surface area temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A notable difference around 26.4°F. Despite becoming driven by the same electric motor, the worm device not only produced much less torque, but also wasted more energy. Bottom line, this can result in a much heftier electrical bill for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of the drives by putting extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these parts can fail, and essential oil changes are imminent due to lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance necessary to keep them running at peak performance. Essential oil lubrication is not required: the cooling potential of grease is enough to ensure the reducer will run effectively. This eliminates the necessity for breather holes and any installation constraints posed by oil lubricated systems. It is also not necessary to replace lubricant since the grease is meant to last the life time usage of the gearmotor, getting rid of downtime and increasing efficiency.
More Power in a Smaller Package
Smaller sized motors can be used in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor generating a worm reducer can generate the same result as a comparable 1/2 horsepower engine traveling a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer were compared for make use of on an equivalent app. This research fixed the decrease ratio of both gearboxes to 60:1 and compared motor power and result torque as it related to power drawn. The study figured a 1/2 HP hypoid gearmotor can be utilized to provide similar performance to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a comparison of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor size, comes the benefit 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 (Number 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the entire footprint of the hypoid gearmotor is a lot smaller sized than that of a comparable worm gearmotor. This also makes working conditions safer since smaller sized gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is definitely they are symmetrical along their centerline (Physique 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of the same power, hypoid drives much outperform their worm counterparts. One essential requirement to consider can be that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Number 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 results in both research are clear: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As shown throughout, the advantages of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As tested using the studies shown throughout, hypoid gearmotors can handle higher initial inertia loads and transfer more torque with a smaller motor than a comparable worm gearmotor.
This can result in upfront savings by allowing an individual to buy 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 proven, the overall footprint and symmetric design of hypoid gearmotors produces a more aesthetically pleasing design while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Obviously, hypoid gearmotors will be the best choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that boost operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency units for long-term energy cost savings. Besides being highly efficient, its hypoid/helical gearmotors are small in size and sealed forever. They are light, dependable, and offer high torque at low swiftness unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-restricted, chemically resistant devices that withstand harsh circumstances. These gearmotors also have multiple regular specifications, options, and installation positions to make sure compatibility.
Specifications
Material: 7005 aluminum gear 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
Take 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 Velocity 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 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 a very wide range of worm gearboxes. Because of the modular design the standard programme comprises countless combinations when it comes to selection of gear housings, mounting and connection options, flanges, shaft designs, kind of oil, surface treatments etc.
Sturdy and reliable
The look of the EP worm gearbox is easy and well proven. We only use high quality components such as homes in cast iron, aluminum and stainless steel, worms in the event hardened and polished metal and worm wheels in high-quality bronze of special alloys ensuring the optimum wearability. The seals of the worm gearbox are given with a dirt lip which successfully resists dust and water. Furthermore, the gearboxes are greased for life 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 reduction. An equivalent gearing with the same equipment ratios and the same transferred power is usually bigger when compared to a worm gearing. In the mean time, the worm gearbox can be in a far more simple design.
A double reduction could be composed of 2 regular gearboxes or as a special 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 advantages of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key phrases of the typical gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is because of the very soft running 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 consider extra care of any sound which can be interpreted as a murmur from the gear. So the general noise degree of our gearbox is certainly reduced to an absolute minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This frequently proves to be a decisive benefit making the incorporation of the gearbox significantly simpler and more compact.The worm gearbox is 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 apparatus house and is perfect for immediate suspension for wheels, movable arms and other areas rather than needing to create a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes will provide 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 ideal for an array of solutions.
