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-lasting 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 Correct 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 ranging 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 springtime loaded breather connect and come pre-loaded 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 answer for right-angle power transmission for generations. Touted for their low-cost and robust building, worm reducers can be
found in nearly every industrial environment requiring this kind of transmission. However, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a lot of space, and require regular maintenance.
Fortunately, there can be an option to worm gear pieces: the hypoid gear. Typically used 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 overall sizes and higher decrease potential, hypoid gearmotors possess a broader selection of feasible uses than their worm counterparts. This not merely allows heavier torque loads to be transferred at higher efficiencies, but it opens opportunities for applications where space is definitely a limiting factor. They can sometimes be costlier, but the cost savings in efficiency and maintenance are really worth it.
The following 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.
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 can be a screw-like equipment, that rotates perpendicular to its corresponding worm gear (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will finish five revolutions while the output worm equipment is only going to complete one. With an increased ratio, for example 60:1, the worm will total 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 equipment, the worm only experiences sliding friction. There is absolutely no rolling component to the tooth contact (Physique 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 necessary to spin the output gear once. Low input acceleration applications suffer from the same friction problem, but for a different reason. Since there is a large amount of tooth contact, the initial energy to start rotation is higher than that of a comparable hypoid reducer. When driven at low speeds, the worm needs more energy to continue its movement along the worm gear, and a lot of that energy is lost to friction.
Hypoid vs. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
However, hypoid gear sets contain 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 equipment technologies. They experience friction losses due to the meshing of the gear teeth, with reduced sliding included. These losses are minimized using the hypoid tooth design that allows torque to be transferred efficiently and evenly across the interfacing surfaces. This is what provides 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 lack of efficiency, chiefly in high reductions and low speeds. Usual 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
In the case of worm gear sets, they do not operate at peak efficiency until a particular “break-in” period has occurred. Worms are usually made of metal, with the worm equipment being made of bronze. Since bronze can be a softer steel it is proficient at absorbing heavy shock loads but does not operate efficiently until it’s been work-hardened. The warmth generated from the friction of regular operating conditions helps to harden the top of worm gear.
With hypoid gear pieces, there is no “break-in” period; they are typically made from steel which has recently been carbonitride temperature treated. This allows the drive to operate at peak efficiency as soon as it is installed.
Why is Efficiency Important?
Efficiency is one of 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 a long time to arrive. Additionally, a far more efficient reducer permits better reduction capacity and usage of a motor that
consumes less electrical power. Single stage worm reducers are typically limited to 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 just go up to reduction ratios of 10:1, and the additional reduction is provided 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 required to generate hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with extreme pressure additives instead of oil which will incur higher costs. This cost difference is composed for over the lifetime of the gearmotor because of increased performance and reduced maintenance.
A higher efficiency hypoid reducer will ultimately waste less energy and maximize the energy becoming transferred from the motor to the driven shaft. Friction is definitely wasted energy that requires the form of warmth. Since worm gears generate more friction they run much hotter. In many cases, 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 created 133 in-lb of torque while the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The motor surface temperature of both systems began at 68°F, room temperature. After 100 moments of operating period, the temperature of both units began to level off, concluding the test. The difference in temperature at this point was substantial: the worm unit reached a surface area temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A notable difference of about 26.4°F. Despite being run by the same motor, the worm unit not only produced less torque, but also wasted more energy. Important thing, this can result in a much heftier electric bill for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This decreases the service life of the drives by placing extra thermal pressure 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 run cooler, there is little to no maintenance required to keep them running at peak performance. Oil lubrication is not required: the cooling potential of grease will do to guarantee the reducer will operate effectively. This eliminates the necessity for breather holes and any installation constraints posed by oil lubricated systems. It is also not necessary to replace lubricant since the grease is intended to last the life time utilization of the gearmotor, eliminating 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 motor traveling a worm reducer can create the same result as a comparable 1/2 horsepower engine traveling a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer were compared for make use of on an equivalent software. This study fixed the reduction ratio of both gearboxes to 60:1 and compared engine power and result torque as it related to power drawn. The analysis concluded that a 1/2 HP hypoid gearmotor can be used to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result showing a evaluation of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in electric motor size, comes the benefit 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 (Figure 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the overall footprint of the hypoid gearmotor is a lot smaller than that of a similar worm gearmotor. This also helps make working environments safer since smaller sized gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is definitely they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in 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 much outperform their worm counterparts. One essential requirement to consider is that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Physique 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially 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 results in both studies are clear: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As confirmed using the studies shown throughout, hypoid gearmotors can handle higher initial inertia loads and transfer more torque with a smaller motor when compared to 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 demonstrated, the overall footprint and symmetric design of hypoid gearmotors produces a far more aesthetically pleasing design while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Obviously, hypoid gearmotors are the most suitable choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that enhance operational efficiencies and reduce maintenance requirements and downtime. They provide premium efficiency units 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, reliable, and provide high torque at low rate unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a Gearbox Worm Drive high-quality finish that assures consistently tough, water-limited, chemically resistant products that withstand harsh circumstances. These gearmotors also have multiple standard specifications, options, and mounting positions to make sure compatibility.
Specifications
Material: 7005 aluminum equipment 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 gear attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Rate 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 range of worm gearboxes. Because of the modular design the typical program comprises countless combinations with regards to selection of equipment housings, installation and connection options, flanges, shaft designs, type of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We just use top quality components such as houses in cast iron, aluminum and stainless steel, 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 provided with a dirt lip which successfully resists dust and water. In addition, the gearboxes are greased forever 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 decrease. An equivalent gearing with the same equipment ratios and the same transferred power is bigger than a worm gearing. At the same time, the worm gearbox is in a far more simple design.
A double reduction may be composed of 2 standard 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 benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key words of the standard 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 consider extra care of any sound that can be interpreted as a murmur from the gear. So 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 each other. This frequently proves to be 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.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the gear house and is ideal for immediate suspension for wheels, movable arms and other parts rather than having to build a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide 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 well suited for an array of solutions.