Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient on the gearing for high efficiency.
Powered by 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 because of how we dual up the bearings on the input shaft. HdR series reducers can be found 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 springtime loaded breather connect and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to remedy for right-angle power transmitting for generations. Touted for their low-cost and robust structure, worm reducers can be
found in almost every industrial environment requiring this type of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, produce a lot of heat, take up a lot of space, and need regular maintenance.
Fortunately, there is an option to worm gear units: the hypoid gear. Typically used in automotive applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the issues that occur with worm reducers. Available in smaller overall sizes and higher decrease potential, hypoid gearmotors have a broader range of feasible uses than their worm counterparts. This not merely allows heavier torque loads to become transferred at higher efficiencies, but it opens opportunities for applications where space is definitely a limiting factor. They are able to sometimes be costlier, but the cost 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.
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 definitely 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 full five revolutions as the output worm gear is only going to complete one. With a higher ratio, for example 60:1, the worm will complete 60 revolutions per one output revolution. It is this fundamental set up that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only experiences sliding friction. There is no rolling element of the tooth contact (Figure 2).
Sliding Friction
In high reduction applications, such as 60:1, you will have a large amount of sliding friction due to the lot of input revolutions required to spin the output equipment once. Low input swiftness applications have problems with the same friction issue, but for a different reason. Since there is a lot of tooth contact, the initial energy to start rotation is greater than that of a similar hypoid reducer. When powered at low speeds, the worm needs more energy to continue its motion along the worm gear, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR 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 experience friction losses because of the meshing of the gear teeth, with minimal sliding included. These losses are minimized using the hypoid tooth pattern that allows torque to become transferred efficiently and evenly over the interfacing surfaces. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Performance Actually Differ?
One of the primary problems posed by worm equipment sets is their lack of efficiency, chiefly at high reductions and low speeds. Usual efficiencies can vary from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment sets are usually 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
In the case of worm gear sets, they don’t run at peak efficiency until a particular “break-in” period has occurred. Worms are usually made of steel, with the worm gear being manufactured from bronze. Since bronze is a softer metal it is good at absorbing heavy shock loads but will not operate successfully until it’s been work-hardened. The high temperature generated from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear units, there is absolutely no “break-in” period; they are usually made from metal which has recently been carbonitride heat 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 things to consider whenever choosing a gearmotor. Since most 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 far more efficient reducer permits better reduction capability and use of a motor that
consumes less electrical power. Single stage worm reducers are typically limited by 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 only go up to decrease ratios of 10:1, and the additional reduction is supplied by another 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 create hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives instead of oil that will incur higher costs. This price difference is made up for over the lifetime of the gearmotor due to increased efficiency and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste less energy and maximize the energy being transferred from the motor to the driven shaft. Friction is wasted energy that takes the form of high temperature. Since worm gears generate 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 warmth properly. A evaluation of motor surface area 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 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 units began at 68°F, room temperature. After 100 a few minutes of operating period, the temperature of both models started to level off, concluding the check. The difference in temperature at this point was significant: the worm unit reached a surface area temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A difference of about 26.4°F. Despite getting powered by the same motor, the worm device not only produced less torque, but also wasted more energy. Important thing, this can lead to a much heftier electrical costs for worm users.
As previously stated and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This decreases the service life of the 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 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 need for breather holes and any mounting constraints posed by oil lubricated systems. It is also not necessary to displace lubricant because 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 because of the more efficient transfer of energy through the gearbox. In some instances, a 1 Gearbox Worm Drive horsepower motor traveling a worm reducer can create the same output as a comparable 1/2 horsepower engine generating a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer were compared for make use of on an equivalent software. This research fixed the reduction ratio of both gearboxes to 60:1 and compared engine power and output torque as it related to power drawn. The study concluded that a 1/2 HP hypoid gearmotor can be utilized to provide similar overall performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result showing a assessment of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease 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 (Determine 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is much smaller than that of a comparable worm gearmotor. This also makes working environments 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 (Physique 9). Worm gearmotors are asymmetrical and lead to machines that aren’t as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equal power, hypoid drives much outperform their worm counterparts. One important aspect to consider is usually that hypoid reducers can move loads from a dead 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 over 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 proven 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 verified using the studies offered throughout, hypoid gearmotors can handle higher preliminary inertia loads and transfer more torque with a smaller motor than 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 demonstrated, the entire footprint and symmetric design of hypoid gearmotors produces a far more aesthetically pleasing style while enhancing workplace safety; with smaller, much less cumbersome gearmotors there is a smaller chance of interference with employees or machinery. Clearly, hypoid gearmotors will be the most suitable choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that boost operational efficiencies and reduce maintenance needs and downtime. They offer premium efficiency products for long-term energy savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in size and sealed forever. They are light, dependable, and provide high torque at low quickness 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 products 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 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 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 Style for OEM Replacement
Double Bearings Applied to 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 program comprises countless combinations with regards to selection of gear housings, mounting and connection options, flanges, shaft designs, type of oil, surface treatments etc.
Sturdy and reliable
The look of the EP worm gearbox is simple and well proven. We just use high quality components such as homes in cast iron, aluminum and stainless, worms in case 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 dirt lip which successfully resists dust and 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 as high as 100:1 in one single step or 10.000:1 in a double reduction. An equivalent gearing with the same gear ratios and the same transferred power is definitely bigger when compared to a worm gearing. In the mean time, the worm gearbox is in a 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 among 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 even operating of the worm equipment combined with the utilization of cast iron and high precision on element manufacturing and assembly. In connection with 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 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 be a decisive benefit producing the incorporation of the gearbox considerably simpler and smaller sized.The worm gearbox is an angle gear. This is an advantage for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the gear house and is well suited for direct suspension for wheels, movable arms and other parts rather than needing to build a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes provides a self-locking impact, which in lots of situations can be used as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them perfect for a wide variety of solutions.