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-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 Right 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 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 springtime loaded breather connect and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to answer for right-angle power tranny for generations. Touted because of their low-cost and robust building, worm reducers can be
found in nearly every industrial environment requiring this kind of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, create a lot of warmth, take up a whole lot of space, and need regular maintenance.
Fortunately, there can be an alternative to worm gear pieces: the hypoid gear. Typically found in automotive applications, gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the issues that arise with worm reducers. Available in smaller general sizes and higher decrease potential, hypoid gearmotors have a broader selection of possible uses than their worm counterparts. This not merely allows heavier torque loads to become transferred at higher efficiencies, nonetheless it opens options for applications where space is definitely a limiting factor. They can sometimes be costlier, however the financial 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 usually 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 complete five revolutions while the output worm equipment will only complete one. With an increased ratio, for instance 60:1, the worm will comprehensive 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 encounters sliding friction. There is absolutely no rolling element of the tooth contact (Body 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will see a huge 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 cause. Since there is a large amount of tooth contact, the original energy to begin rotation is higher than that of a similar hypoid reducer. When powered at low speeds, the worm needs more energy to continue its movement along the worm equipment, and lots of that energy is lost to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE 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 arranged is a hybrid of bevel and worm gear technologies. They encounter friction losses because of the meshing of the apparatus teeth, with minimal sliding included. These losses are minimized using the hypoid tooth pattern that allows torque to be transferred efficiently and evenly across the interfacing areas. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the biggest complications posed by worm equipment sets is their insufficient efficiency, chiefly at high reductions and low speeds. Normal efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid gear sets are usually 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
Regarding worm gear sets, they do not operate at peak efficiency until a certain “break-in” period has occurred. Worms are typically made of steel, with the worm gear being manufactured from bronze. Since bronze can be a softer steel it is good at absorbing large shock loads but will not operate effectively until it has been work-hardened. The heat produced from the friction of regular operating conditions really helps to harden the top of worm gear.
With hypoid gear units, there is absolutely no “break-in” period; they are typically made from steel which has recently been carbonitride heat treated. This allows the drive to operate at peak efficiency as soon as it is installed.
Why is Efficiency Important?
Efficiency is among the most important things to consider when choosing a gearmotor. Since the majority of employ a long service life, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for a long time to arrive. Additionally, a more efficient reducer permits better reduction capability and use of a motor that
consumes less electrical power. Single stage worm reducers are usually 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 decrease 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 a higher upfront cost than worm drives. This could be attributed to the excess processing techniques necessary to produce hypoid gearing such as for example machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically use grease with extreme pressure additives rather than oil that may incur higher costs. This price difference is made up for over the duration of the gearmotor due to increased performance and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste less energy and maximize the energy being transferred from the engine to the driven shaft. Friction is definitely wasted energy that takes the form of high temperature. Since worm gears produce more friction they operate much hotter. Oftentimes, using a hypoid reducer eliminates the need for cooling fins on the electric motor casing, further reducing maintenance costs that would be required to keep carefully 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 both 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 electric motor surface temperature of both systems began at 68°F, room temperature. After 100 mins of operating time, the temperature of both devices began to level off, concluding the check. The difference in temperature at this time was significant: the worm unit reached a surface area temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A notable difference of about 26.4°F. Despite becoming driven by the same electric motor, the worm device not only produced less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical expenses for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of the drives by placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term exposure to 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 working at peak performance. Oil lubrication is not required: the cooling potential of grease will do to ensure the reducer will operate effectively. This eliminates the need for breather holes and any installation constraints posed by oil lubricated systems. Additionally it is not necessary to displace lubricant since the grease is meant to last the life time utilization of the gearmotor, removing downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller sized motors can be utilized in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower electric motor generating a worm reducer can produce the same result as a comparable 1/2 horsepower motor generating 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 decrease ratio of both gearboxes to 60:1 and compared electric 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 comparison of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in electric motor 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 consider 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 sized than that of a similar worm gearmotor. This also makes 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 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 equivalent power, hypoid drives much outperform their worm counterparts. One essential requirement to consider is certainly that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Body 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 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 research are clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As shown throughout, the benefits 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 verified using the studies presented 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 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 overall footprint and symmetric style of hypoid gearmotors produces a far more aesthetically pleasing design while improving workplace safety; with smaller sized, much less cumbersome gearmotors there exists a smaller chance of interference with employees or machinery. Obviously, hypoid gearmotors are the most suitable choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family of gearmotors that increase operational efficiencies and reduce maintenance needs and downtime. They offer premium efficiency systems for long-term energy financial savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, reliable, and offer high torque at low speed unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-restricted, chemically resistant products that withstand harsh conditions. These gearmotors likewise have multiple Gearbox Worm Drive standard specifications, options, and mounting positions to make sure 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 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 Style 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 Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide range of worm gearboxes. Because of the modular design the typical programme comprises countless combinations with regards to selection of gear housings, mounting and connection options, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We only use high quality components such as homes in cast iron, light weight aluminum and stainless steel, worms in the event hardened and polished steel and worm tires in high-grade bronze of particular alloys ensuring the the best wearability. The seals of the worm gearbox are given with a dust 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 single step or 10.000:1 in a double reduction. An comparative gearing with the same gear ratios and the same transferred power is usually bigger when compared to a worm gearing. Meanwhile, 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 one of the key phrases of the typical gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very soft operating of the worm gear combined with the utilization of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we take extra treatment of any sound which can be interpreted as a murmur from the gear. Therefore the general noise level of our gearbox is certainly 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 producing the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox is an angle gear. This is an edge for incorporation into constructions.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the gear house and is perfect for immediate suspension for wheels, movable arms and other areas rather than needing to build a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking impact, 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 ideal for a wide selection of solutions.