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-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 because of 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 given a brass springtime loaded breather connect and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More Cost Effective 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 almost 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 option to worm gear pieces: the hypoid gear. Typically found in auto applications, gearmotor companies have begun integrating hypoid gearing into right-position gearmotors to solve the issues that occur with worm reducers. Available in smaller general sizes and higher reduction potential, hypoid gearmotors have a broader range 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 can be a limiting factor. They are able to 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 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 arranged 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 instance, in a worm gearbox with a 5:1 ratio, the worm will full five revolutions as the output worm equipment will only complete one. With a higher ratio, for example 60:1, the worm will full 60 revolutions per one result revolution. It really is this fundamental set up that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm gear, 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 for example 60:1, there will be a big amount of sliding friction because of the high number of input revolutions necessary to spin the output gear once. Low input swiftness applications have problems with the same friction issue, but also for a different cause. Since there exists a large amount of tooth contact, the initial energy to begin rotation is higher than that of a comparable hypoid reducer. When driven at low speeds, the worm requires more energy to keep its movement along the worm gear, and a lot of that energy is lost to friction.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets contain 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 experience friction losses because of the meshing of the apparatus teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth design that allows torque to end up being transferred smoothly and Gearbox Worm Drive evenly over the interfacing areas. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Performance Actually Differ?
One of the primary problems posed by worm equipment sets is their lack of efficiency, chiefly at high reductions and low speeds. Typical efficiencies may differ 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
Regarding 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 equipment being made of bronze. Since bronze is definitely a softer steel it is proficient at absorbing weighty shock loads but will not operate successfully until it’s been work-hardened. The warmth generated from the friction of regular working conditions really helps to harden the surface of the worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are typically made from steel which has recently been carbonitride temperature 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 whenever choosing a gearmotor. Since many have a very long service lifestyle, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for a long time to arrive. Additionally, a more efficient reducer allows for better reduction capability and use of a motor that
consumes less electrical power. Solitary stage worm reducers are typically limited by 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 decrease ratios of 10:1, and the additional reduction is provided by another type of gearing, such as helical.
Minimizing Costs
Hypoid drives may have an increased upfront cost than worm drives. This could be attributed to the additional processing techniques required to produce hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with intense pressure additives rather than oil which will incur higher costs. This price difference is composed for over the lifetime of the gearmotor because of increased efficiency and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste less energy and maximize the energy getting transferred from the motor to the driven shaft. Friction is definitely wasted energy that takes the form of warmth. Since worm gears produce more friction they operate much hotter. In many cases, utilizing a hypoid reducer eliminates the need for cooling fins on the electric motor casing, additional reducing maintenance costs that might be required to keep carefully the fins clean and dissipating heat properly. A assessment of motor surface area 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 while the hypoid gearmotor created 204 in-lb of torque. This difference in torque is because of the inefficiencies of the worm reducer. The engine surface area temperature of both systems began at 68°F, area temperature. After 100 a few minutes of operating time, the temperature of both devices started to level off, concluding the check. The difference in temperature at this time was substantial: the worm unit reached a surface temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A difference of about 26.4°F. Despite becoming run by the same engine, the worm device not only produced less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electric expenses for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This decreases the service life of the drives by placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these components 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 operating at peak performance. Essential oil lubrication is not needed: the cooling potential of grease is enough 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 intended to last the life time use of the gearmotor, getting rid of downtime and increasing productivity.
More Power in a Smaller Package
Smaller sized motors can be utilized in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine traveling a worm reducer can produce the same output as a comparable 1/2 horsepower electric motor generating a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer were compared for make use of on an equivalent program. This research 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 analysis concluded that a 1/2 HP hypoid gearmotor can be utilized to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a evaluation of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in engine size, comes the advantage 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 (Body 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is much smaller sized than that of a similar worm gearmotor. This also helps make working environments safer since smaller sized gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is certainly that they are symmetrical along their centerline (Body 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of the same power, hypoid drives considerably outperform their worm counterparts. One essential requirement to consider is usually that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Determine 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors above 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 studies are clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to perform more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As verified using the studies offered throughout, hypoid gearmotors can handle higher preliminary inertia loads and transfer more torque with a smaller sized motor when compared to a comparable worm gearmotor.
This can lead to 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 much better option in space-constrained applications. As shown, the entire footprint and symmetric style of hypoid gearmotors produces a far more aesthetically pleasing style while enhancing workplace safety; with smaller, much less cumbersome gearmotors there is a smaller chance of interference with workers or machinery. Obviously, hypoid gearmotors are the best choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that increase 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 proportions and sealed forever. They are light, dependable, and provide high torque at low velocity unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant models that withstand harsh conditions. These gearmotors likewise 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 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 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 Outside and inside 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 variety of worm gearboxes. Because of the modular design the typical programme comprises countless combinations when it comes to selection of gear housings, mounting and connection options, flanges, shaft designs, type of oil, surface treatments etc.
Sturdy and reliable
The look of the EP worm gearbox is simple and well proven. We just use top quality components such as homes in cast iron, aluminum and stainless steel, worms in case hardened and polished steel and worm tires in high-quality bronze of particular alloys ensuring the the best wearability. The seals of the worm gearbox are provided with a dust lip which efficiently resists dust and water. In addition, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in a single 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 decrease. An equivalent gearing with the same equipment ratios and the same transferred power can be bigger than a worm gearing. In the meantime, 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 benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is one of the key terms of the standard 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 because of the very simple running of the worm gear combined with the use of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we take extra care of any sound which can be interpreted as a murmur from the apparatus. So the general noise degree of our gearbox is certainly 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 substantially simpler and more compact.The worm gearbox is an angle gear. This is often an edge for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is very firmly 
embedded in the gear house and is perfect for immediate 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 provides 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 perfect for a wide selection of solutions.
