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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 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-loaded with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to answer for right-angle power transmitting for generations. Touted for his or her low-cost and robust structure, worm reducers could be
found in nearly every industrial setting requiring this kind of transmission. However, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a lot of space, and require regular maintenance.
Fortunately, there can be an alternative to worm gear sets: the hypoid gear. Typically used in automotive applications, gearmotor businesses have started 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 selection of possible uses than their worm counterparts. This not only enables heavier torque loads to become transferred at higher efficiencies, nonetheless it opens possibilities for applications where space is a limiting factor. They can sometimes be costlier, but the cost savings in efficiency and maintenance are really 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 established there are two components: the input worm, and the output worm gear. The worm is 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 full five revolutions as the output worm equipment will only complete one. With an increased ratio, for instance 60:1, the worm will full 60 revolutions per one result revolution. It is this fundamental arrangement that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only experiences sliding friction. There is absolutely no rolling element of the tooth contact (Determine 2).
Sliding Friction
In high reduction applications, such as 60:1, you will see a large amount of sliding friction because of the high number of input revolutions necessary to spin the output equipment once. Low input rate applications have problems with the same friction problem, but for a different reason. Since there is a large amount of tooth contact, the initial energy to start rotation is greater than that of a comparable 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 lost to friction.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets consist of the input hypoid equipment, and the output hypoid bevel equipment (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 included. These losses are minimized using the hypoid tooth pattern which allows torque to become transferred smoothly and evenly across 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. Typical efficiencies can vary 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
In the case of worm gear sets, they don’t run at peak efficiency until a certain “break-in” period has occurred. Worms are typically made of steel, with the worm equipment being manufactured from bronze. Since bronze is certainly a softer metallic it is proficient at absorbing weighty shock loads but will not operate effectively until it has been work-hardened. The warmth generated from the friction of regular operating conditions helps to harden the surface of the worm gear.
With hypoid gear pieces, there is absolutely no “break-in” period; they are usually made from metal which has recently been Gearbox Worm Drive carbonitride high temperature treated. This allows the drive to operate at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is among the most important factors to consider when choosing a gearmotor. Since the majority of employ a long service existence, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for years to arrive. Additionally, a far more efficient reducer permits better reduction ability and utilization of a motor that
consumes less electrical energy. Single stage worm reducers are typically 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 only go up to reduction 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 could be attributed to the excess processing techniques required to generate hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with intense pressure additives instead of oil which will 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 being transferred from the electric motor to the driven shaft. Friction is definitely wasted energy that requires the form of warmth. 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, further reducing maintenance costs that would be required to keep the fins clean and dissipating temperature properly. A comparison of motor surface 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 because of the inefficiencies of the worm reducer. The electric motor surface temperature of both models began at 68°F, room temperature. After 100 mins of operating period, the temperature of both systems started to level off, concluding the check. The difference in temperature at this time was considerable: the worm device reached a surface temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A notable difference around 26.4°F. Despite getting driven by the same motor, the worm unit 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 pressure 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 run cooler, there is little to no maintenance necessary to keep them operating at peak performance. Essential 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 installation constraints posed by oil lubricated systems. It is also not necessary to replace lubricant since the grease is meant to last the lifetime usage of the gearmotor, removing downtime and increasing efficiency.
More Power in a Smaller sized 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 driving 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 use on an equivalent application. This study fixed the reduction ratio of both gearboxes to 60:1 and compared engine power and result torque as it linked to power drawn. The analysis 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 comparison 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. Because of the way the axes of the gears intersect, worm gears take up more space than hypoid gears (Body 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the overall footprint of the hypoid gearmotor is a lot smaller than that of a similar 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 definitely that they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and lead to machines that are not as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same power, hypoid drives far outperform their worm counterparts. One essential requirement to consider is usually that hypoid reducers can move loads from a dead stop with more relieve than worm reducers (Physique 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 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 run more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As verified 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 result in 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 much better option in space-constrained applications. As shown, the overall 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. Clearly, hypoid gearmotors are the best choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that increase operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency products for long-term energy financial savings. Besides being highly efficient, its hypoid/helical gearmotors are small in size and sealed forever. They are light, reliable, and offer high torque at low velocity 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 models that withstand harsh circumstances. These gearmotors likewise have multiple regular specifications, options, and installation positions to make sure compatibility.
Specifications
Material: 7005 aluminum equipment 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 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 Metal Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide range of worm gearboxes. Due to the modular design the typical program comprises countless combinations with regards to selection of equipment housings, mounting and connection choices, flanges, shaft designs, type of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We only use high quality components such as houses in cast iron, aluminium and stainless, worms in case hardened and polished metal and worm wheels in high-grade bronze of particular alloys ensuring the the best possible wearability. The seals of the worm gearbox are provided with a dirt lip which efficiently resists dust and water. Furthermore, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in a single 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 is definitely 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 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 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 by using adapted gearboxes or special gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very clean operating of the worm gear combined with the usage 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 apparatus. Therefore 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 producing the incorporation of the gearbox substantially simpler and more compact.The worm gearbox can be an angle gear. This is often an advantage for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the apparatus house and is well suited for immediate suspension for wheels, movable arms and other parts rather than having 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 an array of solutions.