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.
Minimal 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 is due to how we dual up the bearings on the input shaft. HdR series reducers are available 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 versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to solution for right-angle power transmission for generations. Touted for their low-cost and robust building, worm reducers could be
found in nearly every industrial setting requiring this type of transmission. Sadly, they are inefficient at slower speeds and higher reductions, produce a lot of high temperature, take up a lot of space, and need regular maintenance.
Fortunately, there can be an alternative to worm gear units: the hypoid gear. Typically used in auto applications, gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the issues that occur with worm reducers. Available in smaller general sizes and higher reduction potential, hypoid gearmotors possess a broader range of feasible uses than their worm counterparts. This not merely enables heavier torque loads to become transferred at higher efficiencies, but it opens opportunities for applications where space is usually a limiting factor. They are able to sometimes be costlier, however the cost savings in efficiency and maintenance are well worth it.
The next 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.
Just 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 is certainly 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 comprehensive five revolutions while the output worm equipment is only going to complete one. With a higher ratio, for example 60:1, the worm will full 60 revolutions per one result revolution. It 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 absolutely no rolling component to the tooth contact (Shape 2).
Sliding Friction
In high reduction applications, such as 60:1, you will see a big amount of sliding friction because of the lot of input revolutions necessary 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 initial energy to begin rotation is higher than that of a comparable hypoid reducer. When powered at low speeds, the worm requires more energy to continue its motion along the worm gear, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
However, hypoid gear sets contain the input hypoid gear, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm gear technologies. They encounter friction losses because of the meshing of the gear teeth, with reduced sliding included. These losses are minimized using the hypoid tooth pattern that allows torque to be transferred smoothly and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the biggest complications posed by worm equipment sets is their lack of 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
Regarding worm gear sets, they do not operate at peak efficiency until a particular “break-in” period has occurred. Worms are typically made of metal, with the worm gear being manufactured from bronze. Since bronze is definitely a softer metallic it is proficient at absorbing large shock loads but does not operate efficiently until it has been work-hardened. The temperature generated from the friction of regular working conditions helps to harden the top of worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are usually made from metal which has recently been carbonitride heat treated. This allows the drive to operate at peak efficiency from the moment it is installed.
Why is Efficiency Important?
Efficiency is among the most important factors to consider when choosing a gearmotor. Since many have a very long service lifestyle, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for years to come. Additionally, a far more efficient reducer allows for better reduction capacity and utilization of a motor that
consumes less electrical power. Single stage worm reducers are usually limited to ratios of 5:1 to 60:1, while hypoid gears have a decrease 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 helical.
Minimizing Costs
Hypoid drives may have an increased upfront cost than worm drives. This is often attributed to the excess processing techniques required to generate hypoid gearing such as machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with extreme pressure additives instead of oil which will incur higher costs. This cost difference is made up for over the duration of the gearmotor because of increased efficiency and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste much less energy and maximize the energy getting transferred from the electric motor to the driven shaft. Friction is certainly wasted energy that takes the form of heat. Since worm gears generate more friction they operate much hotter. In many cases, utilizing a hypoid reducer eliminates the necessity for cooling fins on the motor casing, additional reducing maintenance costs that might be required to keep the fins clean and dissipating warmth properly. A assessment of motor surface area 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 as the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The engine surface temperature of both devices began at 68°F, room temperature. After 100 a few minutes of operating time, the temperature of both systems started to level off, concluding the check. The difference in temperature at this time was significant: the worm device reached a surface temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A notable difference of about 26.4°F. Despite being powered by the same electric motor, the worm device not only produced less torque, but also wasted more energy. Important thing, this can result in a much heftier electrical bill 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 contact with high heat, these components can fail, and essential oil changes are imminent because of lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance required to keep them running at peak performance. Essential oil lubrication is not needed: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the necessity for breather holes and any mounting Gearbox Worm Drive constraints posed by essential gearbox worm drive58024844276oil lubricated systems. It is also not necessary to displace lubricant since the grease is meant to last the lifetime usage of the gearmotor, getting rid of downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller sized motors can be utilized in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine driving a worm reducer can create the same output as a comparable 1/2 horsepower electric motor generating a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer were compared for make use of on an equivalent software. This research fixed the decrease ratio of both gearboxes to 60:1 and compared engine power and output torque as it linked to power drawn. The analysis figured a 1/2 HP hypoid gearmotor can be used to provide similar functionality to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a comparison of torque and power intake 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. 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 ability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is a lot smaller than that of a similar worm gearmotor. This also helps make working conditions safer since smaller 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 (Body 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 equal power, hypoid drives much outperform their worm counterparts. One essential requirement to consider is usually that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Determine 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably more torque than worm gearmotors above a 30:1 ratio due to 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 results in both research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As tested using the studies offered throughout, hypoid gearmotors are designed for higher preliminary 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 the user 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 shown, the overall footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing style while improving workplace safety; with smaller sized, much less cumbersome gearmotors there is 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 of gearmotors that increase operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency products for long-term energy cost savings. Besides being highly efficient, its hypoid/helical gearmotors are small in proportions and sealed for life. They are light, dependable, and offer high torque at low acceleration unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-limited, chemically resistant devices that withstand harsh conditions. These gearmotors likewise 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 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
Notice: The helical spur gear attaches to 4.7 mm D-shaft diameter. The worm gear attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Quickness 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 Versions for 56C and 145TC Motors
Ever-Power A/S offers a very wide variety of worm gearboxes. Due to the modular design the standard program comprises countless combinations when it comes to selection of equipment housings, installation and connection options, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We just use top quality components such as houses in cast iron, aluminium and stainless, worms in the event hardened and polished steel and worm tires in high-quality bronze of unique alloys ensuring the the best possible wearability. The seals of the worm gearbox are provided with a dirt lip which effectively resists dust and drinking water. In addition, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes enable reductions of up to 100:1 in one step or 10.000:1 in a double reduction. An comparative gearing with the same equipment ratios and the same transferred power can be bigger when compared to a worm gearing. Meanwhile, the worm gearbox is definitely 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 benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key phrases 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 really quiet. This is because of the very clean 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 treatment of any sound that can be interpreted as a murmur from the gear. Therefore the general noise level of our gearbox is definitely 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 benefit producing the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox can be an angle gear. This is often an edge for incorporation into constructions.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the gear house and is ideal for direct suspension for wheels, movable arms and other areas rather than needing to build a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking impact, which in many 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.