Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient upon the gearing for high efficiency.
Powered by 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 due to 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather connect and come pre-stuffed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
Introduction
Worm reducers have 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 environment requiring this type of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, produce a lot of high temperature, take up a whole lot of space, and need regular maintenance.
Fortunately, there can be an alternative to worm gear models: the hypoid gear. Typically found in auto applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller overall sizes and higher decrease potential, hypoid gearmotors have a broader selection of possible uses than their worm counterparts. This not only enables heavier torque loads to become transferred at higher efficiencies, nonetheless it opens options for applications where space is certainly a limiting factor. They are able to 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 number 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 can be 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 finish five revolutions as the output worm gear will only complete one. With an increased ratio, for example 60:1, the worm will total 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 equipment, the worm only encounters sliding friction. There is absolutely no rolling component to the tooth contact (Number 2).
Sliding Friction
In high reduction applications, such as for example 60:1, there will be a huge amount of sliding friction because of the lot of input revolutions necessary to spin the output equipment once. Low input acceleration applications suffer from the same friction issue, but for a different reason. Since there exists a large amount of tooth contact, the original energy to begin rotation is greater than that of a similar hypoid reducer. When driven at low speeds, the worm needs more energy to keep its movement along the worm equipment, and a lot of that energy is lost to friction.
Hypoid vs. 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 established is a hybrid of bevel and worm equipment technologies. They encounter friction losses because of the meshing of the apparatus teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth pattern which allows torque to be transferred efficiently and evenly over the interfacing areas. This is what gives the 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 lack of 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 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 do not run at peak efficiency until a specific “break-in” period has occurred. Worms are typically made of metal, with the worm equipment being manufactured from bronze. Since bronze is usually a softer steel it is proficient at absorbing large shock loads but does not operate effectively until it’s been work-hardened. The warmth produced from the friction of regular working conditions helps to harden the surface of the worm gear.
With hypoid gear pieces, there is no “break-in” period; they are typically made from metal which has already been carbonitride warmth 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 things to consider whenever choosing a gearmotor. Since most employ a long service life, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for years to come. Additionally, a more efficient reducer permits better reduction capability and use of a motor that
consumes less electrical energy. Single stage worm reducers are usually limited by ratios of 5:1 to 60:1, while hypoid gears possess 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 excess reduction is supplied by a different type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives may have a higher upfront cost than worm drives. This could be attributed to the additional processing techniques required to generate hypoid gearing such as for example machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives rather than oil that may incur higher costs. This price difference is composed for over the lifetime of the gearmotor because of increased functionality and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste less energy and maximize the energy becoming transferred from the motor to the driven shaft. Friction can be wasted energy that requires the form of high 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 motor casing, additional reducing maintenance costs that might be required to keep the fins clean and dissipating warmth 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 due to the inefficiencies of the worm reducer. The motor surface temperature of both products began at 68°F, room temperature. After 100 moments of operating time, the temperature of both devices started to level off, concluding the check. The difference in temperature at this time was significant: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A difference around 26.4°F. Despite becoming driven by the same motor, the worm unit not only produced much less torque, but also wasted more energy. Important thing, this can result in a much heftier electrical costs 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 placing extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these components can fail, and oil changes are imminent due to 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 guarantee the reducer will run effectively. This eliminates the need for breather holes and any mounting constraints posed by essential oil lubricated systems. Additionally it is not necessary to displace lubricant since the grease is meant to last the life time use of the gearmotor, getting rid of 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. Occasionally, a 1 horsepower motor generating a worm reducer can produce the same result as a comparable 1/2 horsepower motor traveling a hypoid reducer. In a single study by Nissei Corporation, both a worm and hypoid reducer had been compared for make use of on an equivalent app. This research 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 analysis concluded that a 1/2 HP hypoid gearmotor can be utilized 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 usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in motor size, comes the advantage to use these drives in more applications where space is a constraint. Because of the method the axes of the gears intersect, worm gears take up more space than hypoid gears (Physique 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 sized than that of a similar worm gearmotor. This also helps make working conditions safer since smaller sized gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is definitely they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and lead to machines that aren’t as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equal power, hypoid drives considerably outperform their worm counterparts. One essential requirement to consider is certainly that hypoid reducers can move loads from a lifeless stop with more relieve than worm reducers (Body 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors over 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 outcomes in both studies are clear: hypoid reducers transfer power more effectively.
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 tested using the studies shown throughout, hypoid gearmotors are designed for higher preliminary inertia loads and transfer more torque with a smaller sized motor than a comparable worm gearmotor.
This can lead to upfront savings by allowing the user to purchase 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 style of hypoid gearmotors makes for a more aesthetically pleasing design while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there is a smaller chance of interference with workers or machinery. Obviously, hypoid gearmotors will be the best choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that increase Gearbox Worm Drive operational efficiencies and reduce maintenance requirements and downtime. They provide premium efficiency systems for long-term energy cost savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in proportions and sealed for life. They are light, reliable, and provide high torque at low rate unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-tight, chemically resistant units that withstand harsh circumstances. These gearmotors also have multiple standard specifications, options, and installation positions to ensure 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
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 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 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 Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide selection of worm gearboxes. Due to the modular design the standard programme comprises countless combinations with regards to selection of gear housings, mounting and connection choices, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The look of the EP worm gearbox is easy 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 metal and worm tires in high-grade bronze of particular alloys ensuring the optimum wearability. The seals of the worm gearbox are provided with a dirt lip which successfully 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 allow for reductions of up to 100:1 in one single step or 10.000:1 in a double decrease. An equivalent gearing with the same equipment ratios and the same transferred power is certainly bigger when compared to a worm gearing. At the same time, the worm gearbox is usually in a more simple design.
A double reduction may be composed of 2 regular 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 words 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 because of the very smooth operating 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 gear. So the general noise level of our gearbox can be reduced to an absolute minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to each other. 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 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 perfect for immediate suspension for wheels, movable arms and other parts rather than having to create a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking impact, which in lots of situations can be used as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them perfect for an array of solutions.
