Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient on 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 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 ranging 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 versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have already been the go-to answer for right-angle power transmission for generations. Touted because of their low-cost and robust building, worm reducers could be
found in nearly every industrial environment requiring this kind of transmission. However, they are inefficient at slower speeds and higher reductions, produce a lot of warmth, take up a whole lot of space, and require regular maintenance.
Fortunately, there is an option to worm gear sets: the hypoid gear. Typically used in auto applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Available 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, nonetheless it opens possibilities for applications where space is definitely a limiting factor. They are able to sometimes be costlier, but the financial savings in efficiency and maintenance are well worth it.
The next 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.
How do Worm Gears and Hypoid Gears Differ?
In a worm gear set there are two components: the input worm, and the output worm gear. The worm can be a screw-like gear, 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 as the output worm equipment is only going to complete one. With an increased ratio, for instance 60:1, the worm will full 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 absolutely no rolling element of the tooth contact (Shape 2).
Sliding Friction
In high reduction applications, such as 60:1, you will see a big amount of sliding friction due to the lot of input revolutions necessary to spin the output gear once. Low input swiftness applications have problems with the same friction problem, but for a different cause. Since there exists a lot of tooth contact, the initial energy to start rotation is higher than that of a comparable hypoid reducer. When powered at low speeds, the worm requires more energy to keep its motion along the worm equipment, and a lot of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
However, hypoid gear sets consist of the input hypoid equipment, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear set is a hybrid of bevel and worm gear technologies. They experience friction losses because of the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth pattern that allows torque to end up being transferred efficiently and evenly across the interfacing surfaces. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the biggest problems posed by worm equipment sets is their insufficient efficiency, chiefly in high reductions and low speeds. Typical 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
In the case of worm gear sets, they don’t operate at peak efficiency until a certain “break-in” period has occurred. Worms are usually made of steel, with the worm equipment being made of bronze. Since bronze is certainly a softer metallic it is good at absorbing heavy shock loads but will not operate effectively until it has been work-hardened. The high temperature generated from the friction of regular operating conditions helps to harden the Gearbox Worm Drive surface of the worm gear.
With hypoid gear pieces, there is absolutely no “break-in” period; they are typically made from steel which has recently been carbonitride warmth treated. This enables the drive to operate at peak efficiency as soon as it is installed.
Why is Efficiency Important?
Efficiency is one of the most important factors to consider when choosing a gearmotor. Since many have a very long service life, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for a long time to arrive. Additionally, a far more efficient reducer permits better reduction capability and use of a motor that
consumes less electrical energy. Solitary stage worm reducers are usually limited to 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 just 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 a higher upfront cost than worm drives. This can be attributed to the additional processing techniques required to produce hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with severe pressure additives rather than oil which will incur higher costs. This price difference is made up for over the duration of the gearmotor due to increased functionality and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste less energy and maximize the energy becoming transferred from the engine to the driven shaft. Friction is usually wasted energy that takes the form of temperature. Since worm gears create more friction they run much hotter. In many cases, utilizing a hypoid reducer eliminates the need for cooling fins on the electric motor casing, further reducing maintenance costs that would be required to keep carefully the fins clean and dissipating warmth properly. A comparison of motor surface temperature between worm and hypoid gearmotors are available 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 electric motor surface temperature of both systems began at 68°F, area temperature. After 100 a few minutes of operating time, the temperature of both units began to level off, concluding the check. The difference in temperature at this stage was substantial: the worm unit reached a surface temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A difference around 26.4°F. Despite being powered 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 electrical expenses for worm users.
As previously stated and proven, worm reducers run 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 parts can fail, and oil changes are imminent because of lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance required to keep them working at peak performance. Oil lubrication is not needed: the cooling potential of grease will do to ensure the reducer will operate effectively. This eliminates the necessity for breather holes and any mounting constraints posed by oil lubricated systems. Additionally it is not necessary to replace lubricant because the grease is intended to last the lifetime usage of the gearmotor, removing downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller motors can be used in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine traveling a worm reducer can generate the same result as a comparable 1/2 horsepower motor generating a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer had been compared for use on an equivalent software. This research fixed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and output torque as it linked to power drawn. The study concluded that a 1/2 HP hypoid gearmotor can be used to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result showing a assessment 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. Because of the way 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 similar worm gearmotor. This also makes working conditions safer since smaller gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equivalent power, hypoid drives considerably outperform their worm counterparts. One important aspect to consider is definitely that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Physique 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 Output 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 advantages of hypoid reducers speak for themselves. Their style allows them to run more efficiently, cooler, and offer higher reduction ratios when compared to worm reducers. As confirmed using the studies presented throughout, hypoid gearmotors can handle higher preliminary inertia loads and transfer more torque with a 
smaller motor than a comparable worm gearmotor.
This can lead to upfront savings by allowing the user to buy 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 demonstrated, the overall footprint and symmetric design of hypoid gearmotors makes for a far more aesthetically pleasing style while improving workplace safety; with smaller, much 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 savings and reliability compared to worm gearmotors.
Brother Gearmotors provides a family of gearmotors that enhance operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency models for long-term energy financial savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in size and sealed forever. They are light, reliable, and offer high torque at low quickness unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-tight, chemically resistant units that withstand harsh circumstances. These gearmotors likewise have multiple standard specifications, options, and mounting 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
Note: The helical spur equipment attaches to 4.7 mm D-shaft diameter. The worm gear 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 Outside and inside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Steel Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide range of worm gearboxes. Because of the modular design the typical program comprises countless combinations with regards to selection of gear housings, mounting and connection choices, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We only use top quality components such as houses in cast iron, aluminium and stainless, worms in the event hardened and polished metal and worm wheels in high-grade bronze of special alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dust 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 of up to 100:1 in one single step or 10.000:1 in a double reduction. An comparative gearing with the same gear ratios and the same transferred power is certainly bigger when compared to a worm gearing. At the same time, the worm gearbox is in a far more simple design.
A double reduction may be composed of 2 standard 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 one of the key terms of the standard gearboxes of the EP-Series. Further optimisation may be accomplished by using adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very even running of the worm gear combined with the use of cast iron and high precision on element 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. Therefore the general noise level of our gearbox is certainly reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This often proves to be a decisive advantage producing the incorporation of the gearbox significantly simpler and more compact.The worm gearbox is an angle gear. This is often an edge for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the apparatus house and is ideal for direct 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 impact, which in many situations can be used as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for an array of solutions.