Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient upon the gearing for high efficiency.
Powered by long-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 Right angle (HdR) series worm gearbox is because of how we double up the bearings on the input shaft. HdR series reducers can be found in speed ratios ranging 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 springtime loaded breather plug and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to alternative for right-angle power transmission for generations. Touted for his or her low-cost and robust structure, worm reducers could 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 warmth, take up a whole lot of space, and need regular maintenance.
Fortunately, there is an option to worm gear models: the hypoid gear. Typically used in automotive applications, Gearbox Worm Drive gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that arise with worm reducers. Obtainable in smaller overall sizes and higher reduction potential, hypoid gearmotors possess a broader range of possible uses than their worm counterparts. This not only enables heavier torque loads to become transferred at higher efficiencies, nonetheless it opens opportunities for applications where space is definitely a limiting factor. They can 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 arranged there are two components: the input worm, and the output worm gear. The worm is usually 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 complete five revolutions as the output worm gear is only going to complete one. With a higher ratio, for example 60:1, the worm will finish 60 revolutions per one result revolution. It is this fundamental arrangement that triggers 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 (Figure 2).
Sliding Friction
In high reduction applications, such as 60:1, there will be a huge amount of sliding friction because of the lot of input revolutions required to spin the output gear once. Low input acceleration applications suffer from the same friction issue, but for a different cause. Since there exists a lot of tooth contact, the initial energy to start rotation is greater than that of a similar hypoid reducer. When powered at low speeds, the worm needs more energy to keep its movement along the worm gear, and lots of that energy is lost to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
However, hypoid gear sets contain the input hypoid equipment, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear established 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 design that allows torque to be transferred easily and evenly over the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the primary complications posed by worm gear sets is their insufficient efficiency, chiefly at high reductions and low speeds. Normal efficiencies can vary 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 do not operate at peak efficiency until a particular “break-in” period has occurred. Worms are usually made of steel, with the worm gear being made of bronze. Since bronze is definitely a softer metallic it is proficient at absorbing heavy shock loads but does not operate efficiently until it’s been work-hardened. The temperature generated from the friction of regular operating conditions really helps to harden the surface of the worm gear.
With hypoid gear models, there is no “break-in” period; they are typically made from metal which has already been carbonitride heat 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 whenever choosing a gearmotor. Since many employ a long service life, choosing a high-efficiency reducer will minimize costs related to procedure and maintenance for years to arrive. Additionally, a far more efficient reducer allows for better reduction capacity and usage of a motor that
consumes less electrical power. 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 only go up to decrease ratios of 10:1, and the excess reduction is provided by a different type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This can be attributed to the excess processing techniques necessary to create hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically use grease with extreme pressure additives instead of oil which will incur higher costs. This cost difference is made up for over the lifetime of the gearmotor because of increased functionality and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste less energy and maximize the energy becoming transferred from the motor to the driven shaft. Friction is certainly wasted energy that takes the form of temperature. Since worm gears produce more friction they operate much hotter. Oftentimes, utilizing a hypoid reducer eliminates the necessity for cooling fins on the 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 both 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 due to the inefficiencies of the worm reducer. The engine surface temperature of both products began at 68°F, room temperature. After 100 a few minutes of operating period, the temperature of both models began to level off, concluding the check. 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 only reached 125.0°F. A notable difference around 26.4°F. Despite becoming run by the same electric motor, the worm unit not only produced much less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electric costs for worm users.
As previously stated and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This reduces the service life of the drives by putting extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term exposure to high heat, these parts can fail, and essential oil changes are imminent because of lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance required 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 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 intended to last the life time utilization of the gearmotor, removing downtime and increasing productivity.
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 motor driving a worm reducer can create the same output as a comparable 1/2 horsepower engine driving a hypoid reducer. In a single study by Nissei Corporation, both a worm and hypoid reducer had been compared for make use of on an equivalent program. This study 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 overall performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result displaying a evaluation of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in motor size, comes the benefit to use these drives in more applications where space is a constraint. Due to the method the axes of the gears intersect, worm gears consider up more space than hypoid gears (Number 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 than that of a similar worm gearmotor. This also makes working environments safer since smaller gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is definitely they are symmetrical along their centerline (Figure 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equivalent power, hypoid drives considerably outperform their worm counterparts. One important aspect to consider is definitely that hypoid reducers can move loads from a dead 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 because of 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 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 style allows them to perform more efficiently, cooler, and offer higher reduction ratios when compared to worm reducers. As verified using the studies offered 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 an individual 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 proven, the entire footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing design while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there exists a smaller chance of interference with employees or machinery. Clearly, hypoid gearmotors will be the most suitable choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family of gearmotors that enhance operational efficiencies and reduce maintenance needs and downtime. They offer premium efficiency models for long-term energy cost savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in size and sealed for life. They are light, dependable, and provide high torque at low acceleration unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-restricted, chemically resistant models that withstand harsh circumstances. These gearmotors also 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
Note: 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 Applied to 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 a very wide selection of worm gearboxes. Due to the modular design the typical program comprises countless combinations when it comes to selection of equipment housings, installation and connection options, 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 high quality components such as homes in cast iron, aluminium and stainless steel, worms in the event hardened and polished metal and worm wheels in high-quality bronze of special alloys ensuring the maximum wearability. The seals of the worm gearbox are given with a dust lip which successfully resists dust and water. Furthermore, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes enable reductions of up to 100:1 in one step or 10.000:1 in a double reduction. An equivalent gearing with the same equipment ratios and the same transferred power is certainly bigger than a worm gearing. In the mean time, the worm gearbox is usually in a far more simple design.
A double reduction may 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 one of the key terms of the typical 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 extremely quiet. This is due to the very clean operating of the worm equipment combined with the use of cast iron and high precision on component manufacturing and assembly. Regarding the our precision gearboxes, we take extra treatment of any sound that can be interpreted as a murmur from the gear. So the general noise level of our gearbox can be 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 be a decisive advantage producing 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.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the apparatus house and is perfect for immediate suspension for wheels, movable arms and other areas rather than having to create a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking effect, which in lots of situations can be used as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for an array of solutions.