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-enduring 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 Right 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 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 supplied with a brass spring loaded breather connect and come pre-filled 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 remedy for right-angle power transmitting for generations. Touted for his or her low-cost and robust structure, worm reducers can be
found in nearly every industrial setting requiring this kind of transmission. Unfortunately, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a whole lot of space, and require regular maintenance.
Fortunately, there is an alternative to worm gear units: the hypoid gear. Typically used in auto applications, gearmotor businesses have begun integrating 
hypoid gearing into right-angle gearmotors to solve the problems that arise with worm reducers. Obtainable in smaller general sizes and higher reduction potential, hypoid gearmotors have a broader range of possible uses than their worm counterparts. This not merely enables heavier torque loads to become transferred at higher efficiencies, but it opens possibilities for applications where space is a limiting factor. They can sometimes be costlier, but the financial 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 usually a screw-like gear, that rotates perpendicular to its corresponding worm gear (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will total five revolutions as the output worm equipment will only complete one. With a higher ratio, for example 60:1, the worm will total 60 revolutions per one output revolution. It really is this fundamental arrangement that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only experiences sliding friction. There is absolutely no rolling element of the tooth contact (Physique 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will have a big amount of sliding friction because of the high number of input revolutions necessary to spin the output gear once. Low input rate applications suffer from the same friction problem, but also for a different reason. Since there is a large amount of tooth contact, the initial energy to begin rotation is greater than that of a similar hypoid reducer. When powered at low speeds, the worm requires more energy to continue its movement along the worm equipment, and lots of that energy is lost to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets contain the input hypoid equipment, 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 experience friction losses due to the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth design which allows torque to end up being transferred smoothly and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Efficiency Actually Differ?
One of the primary problems posed by worm equipment sets is their insufficient efficiency, chiefly at high reductions and low speeds. Common 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
Regarding worm gear sets, they don’t run 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 a softer metallic it is good at absorbing weighty shock loads but does not operate effectively until it’s been work-hardened. The warmth generated from the friction of regular operating 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 heat treated. This allows 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 when choosing a gearmotor. Since many have a very long service existence, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for years to arrive. Additionally, a more efficient reducer permits better reduction capacity and utilization of a motor that
consumes less electrical energy. Gearbox Worm Drive Solitary stage worm reducers are typically limited to 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 only go up to decrease ratios of 10:1, and the excess reduction is supplied by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This could be attributed to the excess processing techniques necessary to generate hypoid gearing such as for example machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives instead of oil that may incur higher costs. This price difference is composed for over the lifetime of the gearmotor due to increased efficiency and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste less energy and maximize the energy becoming transferred from the electric motor to the driven shaft. Friction is definitely wasted energy that requires the form of temperature. Since worm gears generate more friction they operate much hotter. In many cases, utilizing a hypoid reducer eliminates the need for cooling fins on the motor casing, additional reducing maintenance costs that would be required to keep carefully the fins clean and dissipating high temperature properly. A comparison of motor surface area temperature between worm and hypoid gearmotors can be found 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 produced 204 in-lb of torque. This difference in torque is because of the inefficiencies of the worm reducer. The motor surface temperature of both models began at 68°F, room temperature. After 100 a few minutes of operating period, the temperature of both systems started to level off, concluding the test. The difference in temperature at this time was considerable: the worm device reached a surface temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A notable difference around 26.4°F. Despite being driven by the same engine, the worm device not only produced less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical bill for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of these drives by placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these parts can fail, and oil changes are imminent due to lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance necessary to keep them operating at peak performance. Essential oil lubrication is not required: the cooling potential of grease will do to ensure the reducer will operate effectively. This eliminates the need for breather holes and any installation constraints posed by oil lubricated systems. Additionally it is not necessary to replace lubricant because the grease is meant to last the lifetime usage of the gearmotor, removing downtime and increasing efficiency.
More Power in a Smaller Package
Smaller motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor traveling a worm reducer can create the same output as a comparable 1/2 horsepower motor traveling a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer were compared for use on an equivalent application. This study fixed the reduction ratio of both gearboxes to 60:1 and compared electric 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 cost. A final result showing a evaluation of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in engine 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 (Figure 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the overall footprint of the hypoid gearmotor is much smaller than that of a similar 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 can be that they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equal power, hypoid drives far outperform their worm counterparts. One essential requirement to consider is usually that hypoid reducers can move loads from a lifeless stop with more relieve 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 due to 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 clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to perform more efficiently, cooler, and offer higher reduction ratios when compared to worm reducers. As tested using the studies offered throughout, hypoid gearmotors can handle higher initial inertia loads and transfer more torque with a smaller motor than a comparable worm gearmotor.
This can lead to 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 shown, the entire footprint and symmetric design of hypoid gearmotors makes for a more aesthetically pleasing design while enhancing workplace safety; with smaller, much less cumbersome gearmotors there exists a smaller chance of interference with workers or machinery. Obviously, hypoid gearmotors are the best choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that increase operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency systems for long-term energy savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in size and sealed for life. They are light, reliable, and provide high torque at low rate unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-limited, 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 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 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 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. Due to the modular design the typical programme comprises countless combinations with regards to selection of equipment housings, installation and connection choices, flanges, shaft designs, type of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We only use high quality components such as homes in cast iron, aluminium and stainless, worms in the event hardened and polished steel and worm wheels in high-grade bronze of particular alloys ensuring the the best wearability. The seals of the worm gearbox are given with a dirt lip which efficiently resists dust and drinking water. Furthermore, 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 single step or 10.000:1 in a double decrease. An equivalent gearing with the same gear ratios and the same transferred power can be bigger than a worm gearing. In the mean time, the worm gearbox is usually 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 advantages 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 by using adapted gearboxes or special gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is due to the very soft working of the worm gear combined with the use of cast iron and high precision on component manufacturing and assembly. Regarding the our precision gearboxes, we consider extra care of any sound that can be interpreted as a murmur from the apparatus. So the general noise level of our gearbox is usually reduced to an absolute 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 benefit making 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 apparatus house and is ideal for immediate suspension for wheels, movable arms and other parts rather than needing to build a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides 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 ideal for a wide range of solutions.
