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-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 due to how we double up the bearings on the input shaft. HdR series reducers can be found 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 given a brass spring loaded breather connect and come pre-stuffed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to alternative for right-angle power transmitting for generations. Touted because of their low-cost and robust structure, worm reducers can be
found in nearly every industrial environment requiring this type of transmission. However, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a whole lot of space, and need regular maintenance.
Fortunately, there is an alternative to worm gear models: the hypoid gear. Typically found in auto applications, gearmotor companies have begun integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller general sizes and higher decrease potential, hypoid gearmotors possess a broader range of feasible uses than their worm counterparts. This not merely enables heavier torque loads to be transferred at higher efficiencies, but it opens options for applications where space is certainly a limiting factor. They can sometimes be costlier, but the savings in efficiency and maintenance are well worth it.
The next 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 set there are two components: the input worm, and the output worm gear. The worm is definitely 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 total five revolutions while the output worm gear is only going to complete one. With an increased ratio, for instance 60:1, the worm will complete 60 revolutions per one output revolution. It is this fundamental arrangement that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only encounters sliding friction. There is no rolling element of the tooth contact (Body 2).
Sliding Friction
In high reduction applications, such as for example 60:1, there will be a large amount of sliding friction due to the high number of input revolutions necessary to spin the output equipment once. Low input swiftness applications suffer from the same friction problem, but for a different cause. Since there is a lot of tooth contact, the initial energy to start rotation is higher than that of a comparable hypoid reducer. When powered at low speeds, the worm needs more energy to continue its motion along the worm equipment, and a lot 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 gear, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear arranged is a hybrid of bevel and worm gear technologies. They encounter friction losses due to the meshing of the apparatus teeth, with reduced sliding included. These losses are minimized using the hypoid tooth design which allows torque to become transferred efficiently and evenly over the interfacing areas. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the primary problems posed by worm gear sets is their insufficient efficiency, chiefly in high reductions and low speeds. Regular 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 do not run at peak efficiency until a certain “break-in” period has occurred. Worms are typically made of metal, with the worm gear being made of bronze. Since bronze is definitely a softer metal it is good at absorbing heavy shock loads but will not operate effectively until it’s been work-hardened. The high temperature generated from the friction of regular operating conditions really helps to harden the surface of the worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are usually made from steel which has already been carbonitride heat treated. This allows the drive to use at peak efficiency as soon as it is installed.
Why is Efficiency Important?
Efficiency is among the most important things to consider whenever choosing a gearmotor. Since most have a very long service existence, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for years to arrive. Additionally, a far more efficient reducer permits better reduction ability and usage of a motor that
consumes less electrical energy. One stage worm reducers are typically limited to 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 just go up to reduction ratios of 10:1, and the excess reduction is provided by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives may have an increased upfront cost than worm drives. This can be attributed to the additional processing techniques required to generate hypoid gearing such as for example machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with intense pressure additives rather than oil that may incur higher costs. This cost difference is Gearbox Worm Drive composed for over the lifetime of the gearmotor because of increased efficiency and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste much less energy and maximize the energy becoming transferred from the motor to the driven shaft. Friction is certainly wasted energy that requires the form of temperature. Since worm gears generate more friction they operate much hotter. Oftentimes, utilizing a hypoid reducer eliminates the need for cooling fins on the electric motor casing, additional 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 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 electric motor surface area temperature of both devices began at 68°F, area temperature. After 100 a few minutes of operating time, the temperature of both products began to level off, concluding the test. The difference in temperature at this point was considerable: the worm unit reached a surface area temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A difference around 26.4°F. Despite becoming powered by the same engine, the worm device not only produced less torque, but also wasted more energy. Bottom line, this can result in a much heftier electric costs for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This decreases 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 components can fail, and essential oil changes are imminent because of lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance necessary to keep them working at peak performance. Essential oil lubrication is not required: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the necessity for breather holes and any installation constraints posed by oil lubricated systems. Additionally it is not necessary to displace lubricant because 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 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 traveling a worm reducer can generate the same output as a comparable 1/2 horsepower electric motor generating a hypoid reducer. In a single study by Nissei Corporation, both a worm and hypoid reducer were compared for make use of on an equivalent app. This study fixed the reduction ratio of both gearboxes to 60:1 and compared motor power and output torque as it linked to power drawn. The study concluded that a 1/2 HP hypoid gearmotor can be used to provide similar overall performance to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a assessment of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine size, comes the benefit 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 (Determine 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 sized than that of a comparable worm gearmotor. This also makes working conditions safer since smaller sized gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is usually that they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and lead to machines that aren’t as aesthetically pleasing 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 important aspect to consider is definitely that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Determine 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 outcomes in both studies are obvious: 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 provide higher reduction ratios when compared to worm reducers. As verified using the studies presented throughout, hypoid gearmotors are designed for higher initial 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 style of hypoid gearmotors makes for a more aesthetically pleasing style while enhancing workplace safety; with smaller, less cumbersome gearmotors there exists a smaller potential for interference with employees or machinery. Clearly, hypoid gearmotors are the best choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that boost operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency units for long-term energy cost savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in size and sealed forever. They are light, reliable, and provide high torque at low swiftness 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 conditions. These gearmotors likewise have multiple regular specifications, options, and mounting 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 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 Acceleration 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 Steel Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers a very wide range of worm gearboxes. Due to the modular design the typical program comprises countless combinations with regards to selection of equipment housings, installation and connection choices, flanges, shaft designs, kind of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We just use top quality components such as houses in cast iron, aluminium and stainless steel, worms in the event hardened and polished steel and worm tires in high-quality bronze of special alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dirt lip which efficiently resists dust and drinking 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 of up to 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 can be bigger when compared to a worm gearing. At the same time, the worm gearbox is certainly in a far 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 phrases of the typical gearboxes of the EP-Series. Further optimisation may be accomplished by using adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is due to the very easy working of the worm gear 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. Therefore the general noise degree of our gearbox is definitely reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This often proves to become a decisive advantage making the incorporation of the gearbox considerably simpler and more compact.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 apparatus house and is perfect for direct 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 will provide a self-locking effect, which in lots of situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for an array of solutions.