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-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 because of how we double up the bearings on the input shaft. HdR series reducers are available 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 spring loaded breather plug and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to answer for right-angle power tranny for generations. Touted because of their low-cost and robust construction, worm reducers could be
found in almost every industrial establishing requiring this type of transmission. Sadly, they are inefficient at slower speeds and higher reductions, produce a lot of warmth, take up a lot of space, and require regular maintenance.
Fortunately, there is an option to worm gear units: the hypoid gear. Typically found in auto applications, gearmotor businesses have started integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller general sizes and higher reduction potential, hypoid gearmotors have a broader selection of feasible uses than their worm counterparts. This not only allows heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens opportunities for applications where space is usually a limiting factor. They can sometimes be costlier, but the 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 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 total five revolutions while the output worm equipment will only complete one. With an increased ratio, for example 60:1, the worm will full 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 encounters sliding friction. There is no rolling component to the tooth contact (Figure 2).
Sliding Friction
In high reduction applications, such as 60:1, you will see a sizable amount of sliding friction due to the lot of input revolutions necessary to spin the output equipment once. Low input speed applications suffer from the same friction issue, but 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 needs more energy to continue its motion along the worm gear, and lots of that energy is dropped 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 equipment (Figure 3).
Hypoid Gear Set
The hypoid gear set is a hybrid of bevel and worm gear technologies. They experience friction losses because of the meshing of the apparatus teeth, with reduced sliding included. These losses are minimized using the hypoid tooth design which allows torque to be transferred efficiently and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary problems posed by worm equipment sets is their insufficient efficiency, chiefly at high reductions and low speeds. Regular efficiencies may differ 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
Regarding worm gear sets, they don’t operate at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of metal, with the worm gear being made of bronze. Since bronze can be a softer metal it is good at absorbing weighty shock loads but does not operate efficiently until it has been work-hardened. The warmth produced from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear pieces, there is absolutely 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 from the moment it is installed.
How come Efficiency Important?
Efficiency is one of the most Gearbox Worm Drive Important factors to consider when choosing a gearmotor. Since the majority of have a very long service life, choosing a high-efficiency reducer will minimize costs related to procedure and maintenance for years to come. Additionally, a more efficient reducer allows for better reduction capacity and usage of a motor that
consumes less electrical energy. One 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 only go up to decrease 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 is often attributed to the additional 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 extreme pressure additives rather than oil that will incur higher costs. This cost difference is composed for over the lifetime of the gearmotor because of increased overall performance and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste much less energy and maximize the energy getting transferred from the engine to the driven shaft. Friction can be wasted energy that takes the form of temperature. Since worm gears generate more friction they operate much hotter. In many cases, using a hypoid reducer eliminates the necessity for cooling fins on the electric motor casing, further reducing maintenance costs that would be required to keep the fins clean and dissipating warmth properly. A evaluation 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 created 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The engine surface temperature of both models began at 68°F, space temperature. After 100 mins of operating time, the temperature of both units began to level off, concluding the test. The difference in temperature at this point was substantial: the worm device reached a surface area temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A notable difference around 26.4°F. Despite being powered by the same motor, the worm unit not only produced much less torque, but also wasted more energy. Important thing, this can lead to a much heftier electric bill for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of these drives by putting extra thermal stress on the lubrication, bearings, seals, and gears. After long-term exposure to 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 working at peak performance. Oil lubrication is not needed: the cooling potential of grease is enough to guarantee the reducer will run effectively. This eliminates the necessity for breather holes and any mounting constraints posed by oil lubricated systems. It is also not necessary to replace lubricant because the grease is intended to last the lifetime utilization of the gearmotor, removing downtime and increasing efficiency.
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 electric motor driving a worm reducer can produce the same result as a comparable 1/2 horsepower electric motor driving a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer had been compared for make use of on an equivalent software. This study fixed the reduction ratio of both gearboxes to 60:1 and compared motor 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 performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result showing a comparison of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine 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 (Determine 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the overall footprint of the hypoid gearmotor is much smaller sized than that of a comparable worm gearmotor. This also helps make working environments safer since smaller gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is they are symmetrical along their centerline (Body 9). Worm gearmotors are asymmetrical and lead to machines that are not as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equal power, hypoid drives far outperform their worm counterparts. One essential requirement to consider is definitely that hypoid reducers can move loads from a lifeless stop with more relieve than worm reducers (Shape 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 more effectively.
The Hypoid Gear Advantage
As demonstrated throughout, the advantages of hypoid reducers speak for themselves. Their style allows them to run more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As proven using the studies offered throughout, hypoid gearmotors can handle higher preliminary inertia loads and transfer more torque with a smaller sized motor when compared to a comparable worm gearmotor.
This can result in 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 better option in space-constrained applications. As demonstrated, the entire footprint and symmetric design of hypoid gearmotors makes for a far more aesthetically pleasing style while enhancing workplace safety; with smaller, much less cumbersome gearmotors there exists a smaller chance of interference with employees or machinery. Obviously, hypoid gearmotors will be the most suitable choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that enhance operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency units for long-term energy financial savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in proportions and sealed for life. They are light, dependable, and offer 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-limited, chemically resistant devices that withstand harsh circumstances. These gearmotors likewise 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
Notice: The helical spur gear 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 a very wide selection of worm gearboxes. Due to the modular design the standard programme comprises countless combinations when it comes to selection of equipment housings, installation and connection choices, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The look of the EP worm gearbox is easy and well proven. We just use high quality components such as homes in cast iron, aluminium and stainless, worms in the event hardened and polished metal and worm tires in high-grade bronze of unique alloys ensuring the the best wearability. The seals of the worm gearbox are provided with a dirt lip which successfully resists dust and water. Furthermore, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes allow for reductions as high as 100:1 in one step or 10.000:1 in a double decrease. An equivalent gearing with the same equipment ratios and the same transferred power is definitely bigger than a worm gearing. In the meantime, 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 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 can be achieved through the use of adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very easy operating of the worm equipment 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 which can be interpreted as a murmur from the gear. 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 often proves to be a decisive advantage making the incorporation of the gearbox considerably simpler and more compact.The worm gearbox can be an angle gear. This is an advantage 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 direct 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 provides a self-locking effect, which in many situations can be used 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.