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 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 which range 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 plug and come pre-stuffed with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have been the go-to option for right-angle power tranny for generations. Touted for his or her low-cost and robust structure, worm reducers could be
found in almost every industrial establishing requiring this kind of transmission. Sadly, they are inefficient at slower speeds and higher reductions, create a lot of warmth, take up a lot of space, and need regular maintenance.
Fortunately, there is an alternative to worm gear models: the hypoid gear. Typically used 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 decrease potential, hypoid gearmotors have a broader selection of possible 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 can sometimes be costlier, but the cost savings in efficiency and maintenance are well 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.
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 is usually a screw-like gear, that rotates perpendicular to its corresponding worm gear (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will comprehensive five revolutions as the output worm equipment is only going to complete one. With an increased ratio, for instance 60:1, the worm will finish 60 revolutions per one output revolution. It is this fundamental arrangement that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, 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 60:1, there will be a huge amount of sliding friction because of the high number of input revolutions necessary to spin the output equipment once. Low input speed applications suffer from the same friction issue, but also for a different cause. Since there is a large amount of tooth contact, the initial energy to start rotation is greater than that of a comparable hypoid reducer. When powered at low speeds, the worm needs more energy to keep its motion along the worm equipment, and lots of that energy is dropped to friction.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
However, hypoid gear sets consist of 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 design which allows torque to be transferred easily and evenly across the interfacing surfaces. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest problems posed by worm gear sets is their lack of efficiency, chiefly in high reductions and low speeds. Regular efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment sets are usually 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 steel, with the worm equipment being manufactured from bronze. Since bronze is usually a softer steel it is good at absorbing weighty shock loads but will not operate effectively until it has been work-hardened. The warmth produced from the friction of regular operating conditions really helps to harden the top of worm gear.
With hypoid gear sets, there is no “break-in” period; they are usually made from steel which has recently been carbonitride heat treated. This enables the drive to use at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is one of the most Gearbox Worm Drive Important factors to consider when choosing a gearmotor. Since most employ a long service life, choosing a high-efficiency reducer will minimize costs related to procedure and maintenance for years to arrive. Additionally, a far more efficient reducer allows for 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 reduction potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to decrease ratios of 10:1, and the excess reduction is supplied 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 produce hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with extreme pressure additives rather than oil which will incur higher costs. This cost difference is made up for over the duration of the gearmotor because of increased overall performance and reduced maintenance.
A higher efficiency hypoid reducer will ultimately waste less energy and maximize the energy being transferred from the engine to the driven shaft. Friction is definitely wasted energy that takes the form of heat. Since worm gears produce more friction they run much hotter. Oftentimes, utilizing a hypoid reducer eliminates the necessity for cooling fins on the engine casing, additional reducing maintenance costs that would be required to keep carefully the fins clean and dissipating warmth properly. A assessment of motor surface 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 electric motor surface area temperature of both products began at 68°F, area temperature. After 100 moments of operating time, the temperature of both products started to level off, concluding the check. The difference in temperature at this time was substantial: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A difference of about 26.4°F. Despite getting run by the same engine, the worm device 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 mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This reduces the service life of these drives by putting 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 due to lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance necessary to keep them operating at peak performance. Essential oil lubrication is not needed: the cooling potential of grease is enough 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 displace lubricant because the grease is meant to last the life time usage of the gearmotor, removing 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 electric motor generating a worm reducer can produce the same result as a comparable 1/2 horsepower motor driving a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer were compared for make use of on an equivalent application. This study fixed the reduction ratio of both gearboxes to 60:1 and compared engine power and output torque as it linked to power drawn. The study figured a 1/2 HP hypoid gearmotor can be utilized to provide similar overall performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result showing a assessment of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor size, comes the benefit to use these drives in more applications where space is a constraint. Because of the way the axes of the gears intersect, worm gears consider up more space than hypoid gears (Determine 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the entire footprint of the hypoid gearmotor is a lot smaller sized than that of a similar worm gearmotor. This also helps make working environments safer since smaller gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors can be 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 quantity of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of the same power, hypoid drives much outperform their worm counterparts. One essential requirement to consider is usually that hypoid reducers can move loads from a dead stop with more relieve 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 outcomes in both research are obvious: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As shown throughout, the advantages of hypoid reducers speak for themselves. Their style allows them to run more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As confirmed 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 result in 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 better option in space-constrained applications. As proven, the overall footprint and symmetric design of hypoid gearmotors produces a more aesthetically pleasing style while improving workplace safety; with smaller, less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Obviously, hypoid gearmotors will be the most suitable 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 needs and downtime. They provide premium efficiency products for long-term energy cost savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in size and sealed forever. They are light, reliable, and offer high torque at low velocity 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 products that withstand harsh conditions. These gearmotors also have multiple regular specifications, options, and mounting positions to make sure 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
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 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 Used on Both Shaft Ends
Anti-Rust Primer Applied Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers a very wide variety of worm gearboxes. Due to the modular design the typical program comprises countless combinations when it comes to selection of gear housings, mounting 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 only use high quality components such as homes in cast iron, light weight aluminum and stainless, 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 dust lip which efficiently resists dust and water. In addition, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes allow for reductions of up to 100:1 in one 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 than a worm gearing. At the same time, the worm gearbox is usually in a 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 words of the typical gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or unique gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is due to the very even running of the worm gear combined with the use 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. Therefore the general noise degree of our gearbox can be reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This often proves to become a decisive benefit producing the incorporation of the gearbox substantially simpler and more compact.The worm gearbox can be an angle gear. This is 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 immediate suspension for wheels, movable arms and other areas rather than needing 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 utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for an array of solutions.