Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient on the gearing for high efficiency.
Powered by long-enduring 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 due to how we double 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 ranging 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 FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have already been the go-to option for right-angle power transmission for generations. Touted for their low-cost and robust structure, worm reducers can be
found in almost every industrial environment requiring this kind of transmission. Unfortunately, they are inefficient at slower speeds and higher reductions, produce a lot of heat, take up a whole lot of space, and require regular maintenance.
Fortunately, there can be an option to worm gear units: the hypoid gear. Typically used in automotive applications, gearmotor companies have begun integrating hypoid gearing into right-position gearmotors to solve the problems that arise with worm reducers. Available in smaller general sizes and higher decrease potential, hypoid gearmotors have a broader range of feasible uses than their worm Gearbox Worm Drive counterparts. This not merely enables heavier torque loads to end up being transferred at higher efficiencies, but it opens options for applications where space is certainly a limiting factor. They are able to sometimes be costlier, however the cost savings in efficiency and maintenance are well 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 certainly a screw-like gear, that rotates perpendicular to its corresponding worm equipment (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will finish five revolutions as the output worm equipment is only going to complete one. With a higher ratio, for instance 60:1, the worm will full 60 revolutions per one output revolution. It is this fundamental arrangement 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 (Physique 2).
Sliding Friction
In high reduction applications, such as 60:1, you will have a huge amount of sliding friction because of the high number of input revolutions necessary to spin the output equipment once. Low input quickness applications have problems with the same friction issue, but also for a different reason. Since there is a large amount of tooth contact, the original energy to start rotation is greater than that of a comparable hypoid reducer. When powered at low speeds, the worm requires more energy to keep its motion along the worm equipment, and lots of that energy is dropped to friction.
Hypoid versus. 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 set is a hybrid of bevel and worm equipment technologies. They encounter friction losses due to the meshing of the gear teeth, with minimal sliding included. These losses are minimized using the hypoid tooth design which allows torque to be transferred easily and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the primary complications posed by worm equipment sets is their insufficient efficiency, chiefly in high reductions and low speeds. Regular 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 don’t operate at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of steel, with the worm equipment being made of bronze. Since bronze is usually a softer steel it is proficient at absorbing heavy shock loads but will not operate successfully until it’s been work-hardened. The heat produced from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear sets, there is no “break-in” period; they are usually made from steel which has already been carbonitride heat treated. This enables the drive to use at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is among the most important things to consider when choosing a gearmotor. Since many have a very long service life, 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 utilization of a motor that
consumes less electrical energy. 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 supplied by another type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This can be attributed to the excess processing techniques necessary to generate hypoid gearing such as machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with extreme pressure additives rather than oil that will 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 motor to the driven shaft. Friction is definitely wasted energy that takes the form of heat. Since worm gears generate more friction they operate much hotter. In many cases, utilizing a hypoid reducer eliminates the necessity for cooling fins on the motor casing, additional reducing maintenance costs that would be required to keep carefully the fins clean and dissipating high temperature properly. A assessment 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 while 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 area temperature of both products began at 68°F, area temperature. After 100 a few minutes of operating time, the temperature of both products started to level off, concluding the check. The difference in temperature at this point was significant: 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 becoming powered by the same engine, the worm unit not only produced less torque, but also wasted more energy. Bottom line, this can result in a much heftier electric bill for worm users.
As previously mentioned and proven, worm reducers run 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 elements can fail, and oil changes are imminent because of lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance required to keep them running at peak performance. Essential oil lubrication is not required: the cooling potential of grease is enough to guarantee the reducer will operate effectively. This eliminates the need for breather holes and any mounting constraints posed by oil lubricated systems. Additionally it is not necessary to replace lubricant since the grease is intended to last the lifetime usage of the gearmotor, removing downtime and increasing productivity.
More Power in a Smaller Package
Smaller sized motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower electric motor traveling a worm reducer can produce the same output as a comparable 1/2 horsepower electric motor generating a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer were compared for make use of on an equivalent app. This research fixed the decrease ratio of both gearboxes to 60:1 and compared engine power and output torque as it linked to power drawn. The analysis figured 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 cost. A final result displaying a assessment of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor size, comes the benefit to use these drives in more applications where space is a constraint. Due to the way the axes of the gears intersect, worm gears consider up more space than hypoid gears (Figure 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller 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 environments safer since smaller gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors can be that they are symmetrical along their centerline (Number 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 Form Comparison
In motors of equal power, hypoid drives much outperform their worm counterparts. One essential requirement to consider is certainly that hypoid reducers can move loads from a dead stop with more relieve than worm reducers (Figure 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably more torque than worm gearmotors above a 30:1 ratio because of 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 research are obvious: hypoid reducers transfer power better.
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 confirmed using the studies shown throughout, hypoid gearmotors are designed for 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 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 proven, the entire footprint and symmetric design of hypoid gearmotors makes for a more aesthetically pleasing style while enhancing workplace safety; with smaller sized, much less cumbersome gearmotors there exists a smaller potential for interference with employees or machinery. Obviously, hypoid gearmotors are the most suitable choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that boost operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency models for long-term energy savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in size and sealed forever. They are light, dependable, and provide high torque at low velocity 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 products that withstand harsh conditions. These gearmotors also 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 worm
Weight: 105.5 g per gear box
Size: 64 mm x 32 mm x 32 mm
Thickness: 2 mm
Gear Ratios: 4:1
Take note: 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 Swiftness 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 Steel Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers a very wide variety of worm gearboxes. Due to the modular design the typical program 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 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, worms in case hardened and polished steel and worm wheels in high-grade bronze of special alloys ensuring the maximum wearability. The seals of the worm gearbox are given with a dirt lip which efficiently resists dust and drinking water. Furthermore, the gearboxes are greased for life 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 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. At the same time, the worm gearbox is usually 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 benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key terms of the standard gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or special gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is due to the very simple working of the worm gear combined with the use of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we take extra care of any sound which can be interpreted as a murmur from the gear. Therefore the general noise degree of our gearbox can be 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 benefit producing the incorporation of the gearbox considerably simpler and smaller sized.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 perfect for direct 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 will provide a self-locking effect, which in many situations can be utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for a wide range of solutions.