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-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 Correct angle (HdR) series worm Gearbox Worm Drive gearbox is due to how we double 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 ranging from 1.33 to 3.25 inches. Also, our gearboxes are given a brass spring loaded breather connect and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have been the go-to alternative for right-angle power transmission for generations. Touted for their low-cost and robust structure, worm reducers can be
found in almost every industrial setting 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 units: the hypoid gear. Typically found in automotive applications, gearmotor companies have begun integrating hypoid gearing into right-angle gearmotors to solve the issues that arise with worm reducers. Available in smaller general sizes and higher reduction 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, nonetheless it opens options for applications where space can be a limiting factor. They can sometimes be costlier, however the cost savings in efficiency and maintenance are really worth it.
The following 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.
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 can be a screw-like gear, that rotates perpendicular to its corresponding worm gear (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will total five revolutions while the output worm gear is only going to complete one. With a higher ratio, for example 60:1, the worm will complete 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 gear, the worm only encounters sliding friction. There is no rolling element of the tooth contact (Number 2).
Sliding Friction
In high reduction applications, such as 60:1, there will be a huge amount of sliding friction due to the high number of input revolutions necessary to spin the output equipment once. Low input rate applications suffer from the same friction problem, but also for a different reason. Since there exists a lot 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 needs more energy to continue its motion along the worm gear, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
However, 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 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 pattern which allows torque to end up being transferred smoothly and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary complications posed by worm gear sets is their lack of efficiency, chiefly at high reductions and low speeds. Usual efficiencies can vary 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 typically made of steel, with the worm equipment being made of bronze. Since bronze is definitely a softer steel it is good at absorbing weighty shock loads but will not operate effectively until it has 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 sets, there is absolutely no “break-in” period; they are typically made from metal which has already been carbonitride warmth treated. This enables the drive to operate at peak efficiency as soon as 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 reduce costs related to operation and maintenance for years to arrive. Additionally, a more efficient reducer permits better reduction capability and utilization of a motor that
consumes less electrical power. Single stage worm reducers are typically limited by ratios of 5:1 to 60:1, while hypoid gears have a reduction potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the excess reduction is supplied by a different type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This is often attributed to the excess processing techniques required to create hypoid gearing such as for example machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with severe pressure additives rather than oil that may incur higher costs. This price difference is made up for over the duration of the gearmotor because of increased performance and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste less energy and maximize the energy being transferred from the electric motor to the driven shaft. Friction is wasted energy that takes the form of warmth. Since worm gears produce more friction they run much hotter. In many cases, utilizing a hypoid reducer eliminates the need for cooling fins on the electric motor casing, further reducing maintenance costs that might be required to keep the fins clean and dissipating high temperature properly. A evaluation of motor surface area 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 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 minutes of operating time, the temperature of both devices started to level off, concluding the check. The difference in temperature at this time was considerable: the worm unit reached a surface temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A difference of about 26.4°F. Despite getting powered by the same electric motor, the worm unit not only produced much less torque, but also wasted more energy. Important thing, this can result in a much heftier electric costs for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This decreases the service life of these drives by placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these parts can fail, and oil changes are imminent due to 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 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 lifetime use of the gearmotor, eliminating downtime and increasing productivity.
More Power in a Smaller Package
Smaller motors can be utilized in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine driving a worm reducer can create the same result as a comparable 1/2 horsepower engine generating a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer had been compared for make use of on an equivalent app. This study fixed the decrease ratio of both gearboxes to 60:1 and compared engine power and result torque as it related to power drawn. The study 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 showing a comparison of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction 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 take 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 much smaller sized than that of a comparable worm gearmotor. This also makes working conditions safer since smaller gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is definitely that they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and lead to machines that are not as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of the same power, hypoid drives considerably outperform their worm counterparts. One important aspect to consider is usually that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Figure 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 Output 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 obvious: 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 provide higher reduction ratios when compared to worm reducers. As confirmed using the studies provided 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 the user to purchase 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 overall footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing style while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there is a smaller chance of interference with employees or machinery. Clearly, 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 increase operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency devices for long-term energy cost 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 swiftness 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 units that withstand harsh conditions. These gearmotors likewise 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 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 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 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 an extremely wide range of worm gearboxes. Due to the modular design the typical programme comprises countless combinations with regards to selection of gear housings, installation 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 only use high quality components such as houses in cast iron, light weight aluminum and stainless, worms in the event hardened and polished metal and worm wheels in high-grade bronze of unique alloys ensuring the the best possible wearability. The seals of the worm gearbox are provided with a dirt lip which efficiently resists dust and drinking water. Furthermore, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in a single 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 equipment ratios and the same transferred power is usually bigger when compared to a worm gearing. In the meantime, the worm gearbox is in a more simple design.
A double reduction could 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 one of the key words 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 extremely quiet. This is because of the very easy working 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 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 often proves to be 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.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the gear house and is well suited for direct suspension for wheels, movable arms and other areas rather than having to create a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking effect, which in lots of situations can be utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for a wide range of solutions.