Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Low friction coefficient on 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 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 spring loaded breather connect and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Worm reducers have already been the go-to remedy for right-angle power transmitting for generations. Touted for their low-cost and robust building, worm reducers could be
found in nearly every industrial establishing requiring this kind of transmission. However, they are inefﬁcient at slower speeds and higher reductions, produce a lot of temperature, take up a lot of space, and require regular maintenance.
Fortunately, there can be an option to worm gear sets: 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 overall sizes and higher reduction potential, hypoid gearmotors have a broader selection of feasible uses than their worm counterparts. This not merely enables heavier torque loads to end up being transferred at higher efﬁciencies, but it opens opportunities for applications where space is certainly a limiting factor. They are able to sometimes be costlier, but the 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.
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 is definitely a screw-like equipment, 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 equipment is only going to complete one. With a higher ratio, for instance 60:1, the worm will complete 60 revolutions per one output revolution. It really is this fundamental set up that causes the inefﬁciencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only experiences sliding friction. There is no rolling component to the tooth contact (Determine 2).
In high reduction applications, such as for example 60:1, you will have a large amount of sliding friction because of the lot of input revolutions necessary to spin the output gear once. Low input Gearbox Worm Drive velocity applications suffer from the same friction problem, but also for a different cause. Since there exists a lot of tooth contact, the initial energy to start rotation is greater than that of a comparable hypoid reducer. When driven at low speeds, the worm requires more energy to continue its motion along the worm gear, and lots of that energy is dropped to friction.
Hypoid vs. Worm Gears: A 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 set is a hybrid of bevel and worm equipment technologies. They experience friction losses due to the meshing of the gear teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth design which allows torque to become transferred efficiently and evenly over the interfacing areas. This is what gives the hypoid reducer a mechanical advantage 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 in high reductions and low speeds. Regular 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
Regarding worm gear sets, they don’t run at peak efﬁciency until a certain “break-in” period has occurred. Worms are typically made of steel, with the worm gear being made of bronze. Since bronze is usually a softer metallic it is proficient at absorbing heavy shock loads but does not operate efficiently until it has been work-hardened. The warmth generated from the friction of regular working conditions helps to harden the top of worm gear.
With hypoid gear pieces, there is no “break-in” period; they are typically made from metal which has already been carbonitride heat treated. This enables the drive to use at peak efﬁciency from the moment 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 reduce costs related to procedure and maintenance for years to come. Additionally, a far more efﬁcient reducer allows for better reduction capability and use of a motor that
consumes less electrical energy. Solitary 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 reduction ratios of 10:1, and the additional reduction is provided by a different type of gearing, such as for example helical.
Hypoid drives can have an increased upfront cost than worm drives. This can be attributed to the excess processing techniques required to create hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with severe pressure additives instead of oil that may incur higher costs. This cost difference is composed for over the lifetime of the gearmotor due to increased overall performance and reduced maintenance.
An increased efﬁciency hypoid reducer will eventually waste less energy and maximize the energy becoming transferred from the engine to the driven shaft. Friction can be wasted energy that takes the form of high temperature. Since worm gears create more friction they run much hotter. Oftentimes, utilizing a hypoid reducer eliminates the necessity 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 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 created 133 in-lb of torque while the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is because of the inefﬁciencies of the worm reducer. The motor surface area temperature of both models began at 68°F, space temperature. After 100 a few minutes of operating period, the temperature of both products started to level off, concluding the check. The difference in temperature at this stage was substantial: the worm device reached a surface temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A difference of about 26.4°F. Despite getting powered 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 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 these drives by placing extra thermal pressure 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 operate cooler, there is little to no maintenance necessary to keep them running at peak performance. Essential oil lubrication is not needed: the cooling potential of grease will do to guarantee the reducer will operate effectively. This eliminates the necessity for breather holes and any mounting constraints posed by essential oil lubricated systems. It is also not necessary to replace lubricant since the grease is intended to last the lifetime 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 motor traveling a worm reducer can create the same result as a comparable 1/2 horsepower engine generating a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer were compared for make use of on an equivalent app. This research ﬁxed the reduction ratio of both gearboxes to 60:1 and compared motor power and result torque as it related to power drawn. The study concluded that a 1/2 HP hypoid gearmotor can be used to provide similar overall performance to a 1 HP worm gearmotor, at a fraction of the electrical price. A ﬁnal result showing a assessment of torque and power consumption 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. Due to the way the axes of the gears intersect, worm gears take up more space than hypoid gears (Physique 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized motor, the overall footprint of the hypoid gearmotor is much smaller than that of a comparable worm gearmotor. This also helps make working environments safer since smaller sized gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors can be they are symmetrical along their centerline (Body 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equivalent power, hypoid drives considerably outperform their worm counterparts. One important aspect to consider is that hypoid reducers can move loads from a dead stop with more relieve than worm reducers (Figure 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors above 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 more effectively.
The Hypoid Gear Advantage
As demonstrated 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 proven 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 lead to upfront savings by allowing an individual 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 makes for a more aesthetically pleasing style while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there is a smaller potential for 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 offers a family of gearmotors that increase operational efﬁciencies and reduce maintenance needs and downtime. They offer premium efﬁciency units for long-term energy savings. Besides being highly efﬁcient, its hypoid/helical gearmotors are small in size and sealed for life. They are light, reliable, and offer high torque at low rate unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality ﬁnish that assures regularly tough, water-tight, chemically resistant systems that withstand harsh circumstances. These gearmotors also have multiple standard speciﬁcations, options, and installation positions to ensure compatibility.
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
Take note: The helical spur gear 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 Versions for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide variety of worm gearboxes. Due to the modular design the standard program comprises countless combinations when it comes to selection of gear housings, mounting and connection choices, flanges, shaft designs, kind 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 houses 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 the best possible 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 for life with synthetic oil.
Large reduction 100:1 in a single step
As default the worm gearboxes enable reductions as high as 100:1 in one step or 10.000:1 in a double decrease. An equivalent gearing with the same gear ratios and the same transferred power is definitely bigger when compared to a worm gearing. In the mean time, the worm gearbox is usually in a far more simple design.
A double reduction could be composed of 2 regular gearboxes or as a special gearbox.
Maximum output torque
5:1 – 90:1
5:1 – 75:1
7:1 – 60:1
7:1 – 100:1
7:1 – 60:1
7:1 – 100:1
Other product advantages of worm gearboxes in the EP-Series:
Compact design is among the key words of the typical gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or particular gearboxes.
Our worm gearboxes and actuators are really quiet. This is because of the very simple running of the worm equipment combined with the use of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we consider extra care of any sound that can be interpreted as a murmur from the apparatus. So the general noise degree of our gearbox is usually reduced to an absolute minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This frequently proves to become a decisive benefit producing the incorporation of the gearbox significantly simpler and more compact.The worm gearbox can be an angle gear. This is often an advantage 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 well suited for direct suspension for wheels, movable arms and other parts rather than having to create a separate suspension.
For larger gear ratios, Ever-Power worm gearboxes will provide 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 perfect for an array of solutions.
Ever-Power Worm Gear Reducer