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-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 due to how we dual 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 ranging from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather connect and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have already been the go-to solution for right-angle power transmitting for generations. Touted because of their low-cost and robust construction, worm reducers can be
found in almost every industrial establishing requiring this type of transmission. Unfortunately, they are inefficient at slower speeds and higher reductions, create a lot of heat, 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 used in auto applications, Gearbox Worm Drive gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the issues that arise with worm reducers. Obtainable in smaller overall sizes and higher reduction potential, hypoid gearmotors possess a broader selection of feasible uses than their worm counterparts. This not only allows heavier torque loads to be transferred at higher efficiencies, but it opens options for applications where space is a limiting factor. They are able to sometimes be costlier, but the financial savings in efficiency and maintenance are really worth it.
The next 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.
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 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 while the output worm gear is only going to complete one. With a higher ratio, for instance 60:1, the worm will full 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 equipment, the worm only experiences sliding friction. There is absolutely no rolling element of the tooth contact (Physique 2).
Sliding Friction
In high reduction applications, such as for example 60:1, there will be a large amount of sliding friction due to the lot of input revolutions required to spin the output gear once. Low input velocity applications have problems with the same friction issue, but also for a different reason. Since there exists a large amount of tooth contact, the original energy to begin rotation is higher than that of a comparable hypoid reducer. When powered at low speeds, the worm needs more energy to keep its motion along the worm gear, and lots of that energy is dropped to friction.
Hypoid vs. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets contain the input hypoid gear, 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 encounter friction losses due to the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth pattern which allows torque to become transferred efficiently and evenly over the interfacing areas. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Efficiency Actually Differ?
One of the primary problems posed by worm equipment sets is their insufficient efficiency, chiefly at high reductions and low speeds. Normal efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment 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 specific “break-in” period has occurred. Worms are usually made of steel, with the worm equipment being made of bronze. Since bronze can be a softer metal it is good at absorbing large shock loads but does not operate efficiently until it’s been work-hardened. The high temperature produced from the friction of regular operating conditions really helps to harden the top of worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are typically made from steel which has recently been carbonitride high temperature treated. This enables the drive to operate at peak efficiency as soon as it is installed.
Why is Efficiency Important?
Efficiency is one of the most important factors to consider whenever choosing a gearmotor. Since many have a very long service existence, choosing a high-efficiency reducer will minimize costs related to procedure and maintenance for a long time 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 by 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 decrease ratios of 10:1, and the additional reduction is supplied 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 excess processing techniques necessary to generate hypoid gearing such as machining, heat therapy, and special grinding methods. 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 overall performance and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste much less energy and maximize the energy getting transferred from the engine to the driven shaft. Friction is certainly wasted energy that requires the form of warmth. Since worm gears produce more friction they run much hotter. In many cases, using a hypoid reducer eliminates the need for cooling fins on the electric motor casing, additional reducing maintenance costs that would be required to keep the fins clean and dissipating warmth properly. A evaluation of motor surface area 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 because of the inefficiencies of the worm reducer. The engine surface temperature of both systems began at 68°F, room 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 time was significant: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A notable difference of about 26.4°F. Despite getting run by the same motor, the worm unit not only produced much less torque, but also wasted more energy. Bottom line, this can result in a much heftier electrical bill 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 placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with 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 necessary to keep them working at peak performance. Oil lubrication is not required: the cooling potential of grease is enough to guarantee the reducer will run 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 usage of the gearmotor, removing 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. Occasionally, a 1 horsepower motor traveling a worm reducer can generate the same result as a comparable 1/2 horsepower engine driving a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer were compared for use on an equivalent application. This research fixed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and result torque as it linked to power drawn. The study concluded that a 1/2 HP hypoid gearmotor can be used to provide similar performance 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 reduction in 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 (Shape 7).
Worm vs Hypoid Axes
Coupled with the ability 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 makes 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 they are symmetrical along their centerline (Figure 9). Worm gearmotors are asymmetrical and result in machines that are not 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 can be that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Physique 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 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 more effectively.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to perform more efficiently, cooler, and provide higher reduction ratios in comparison with worm reducers. As verified 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 lead to 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 demonstrated, the entire footprint and symmetric style of hypoid gearmotors produces a more aesthetically pleasing design while enhancing workplace safety; with smaller, much less cumbersome gearmotors there exists a smaller chance of interference with employees or machinery. Obviously, hypoid gearmotors will be the best choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that enhance operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency units for long-term energy cost savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in proportions and sealed for life. They are light, dependable, and provide high torque at low quickness unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-restricted, chemically resistant systems 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
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 Speed 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 Steel Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers a very wide selection of worm gearboxes. Because of the modular design the typical program comprises countless combinations with regards to selection of gear housings, installation and connection choices, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The look of the EP worm gearbox is easy and well proven. We just use top quality components such as homes in cast iron, aluminum and stainless, worms in case hardened and polished steel and worm tires in high-quality bronze of particular alloys ensuring the the best possible wearability. The seals of the worm gearbox are given with a dirt lip which effectively 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 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 is definitely bigger when compared to a worm gearing. In the meantime, the worm gearbox can be in a far more simple design.
A double reduction could be composed of 2 regular 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 one of 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 really quiet. This is due to the very easy operating of the worm equipment combined with the utilization 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 apparatus. 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 one another. This often proves to become a decisive benefit producing the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox can be an angle gear. This is an edge for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the gear house and is well suited for immediate suspension for wheels, movable arms and other parts rather than having to create a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes will provide a self-locking impact, which in many situations can be used as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for a wide selection of solutions.