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-lasting worm gears.
Minimal 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 because of 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather connect and come pre-stuffed 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 transmission for generations. Touted for their low-cost and robust construction, worm reducers could be
found in nearly every industrial setting requiring this type of transmission. Unfortunately, they are inefficient at slower speeds and Gearbox Worm Drive higher reductions, create a lot of temperature, take up a lot of space, and require regular maintenance.
Fortunately, there can be an option to worm gear units: the hypoid gear. Typically used in automotive applications, gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the issues that occur with worm reducers. Obtainable in smaller general sizes and higher decrease 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, nonetheless it opens possibilities for applications where space can be a limiting factor. They can sometimes be costlier, but the financial savings in efficiency and maintenance are really worth it.
The following 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.
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 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 finish five revolutions while the output worm gear is only going to complete one. With a higher ratio, for instance 60:1, the worm will complete 60 revolutions per one result revolution. It really 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 no rolling element of the tooth contact (Physique 2).
Sliding Friction
In high reduction applications, such as 60:1, there will be a big amount of sliding friction due to the lot of input revolutions necessary to spin the output equipment once. Low input rate applications suffer from the same friction issue, but 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 similar hypoid reducer. When powered at low speeds, the worm requires more energy to continue its motion along the worm gear, and a lot of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective 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 set is a hybrid of bevel and worm equipment technologies. They experience friction losses due to the meshing of the apparatus teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth pattern which allows torque to be transferred smoothly and evenly across the interfacing surfaces. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the primary problems posed by worm equipment sets is their insufficient efficiency, chiefly at high reductions and low speeds. Regular efficiencies can vary 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
In the case of 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 made of bronze. Since bronze can be a softer steel it is proficient at absorbing large shock loads but will not operate effectively until it’s been work-hardened. The temperature produced from the friction of regular operating conditions really helps to harden the top of worm gear.
With hypoid gear pieces, there is no “break-in” period; they are usually made from metal which has recently been carbonitride temperature treated. This allows the drive to operate at peak efficiency from the moment it is installed.
Why is Efficiency Important?
Efficiency is one of the most 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 operation and maintenance for years to come. Additionally, a more efficient reducer permits better reduction capability and usage of a motor that
consumes less electrical energy. 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 just go up to decrease ratios of 10:1, and the additional reduction is provided by another type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This could be attributed to the additional processing techniques required to create hypoid gearing such as machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives rather than oil that will incur higher costs. This cost difference is made up for over the lifetime of the gearmotor because of increased functionality and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste less energy and maximize the energy becoming transferred from the electric motor to the driven shaft. Friction can be wasted energy that requires the form of warmth. Since worm gears produce more friction they operate much hotter. Oftentimes, utilizing a hypoid reducer eliminates the necessity for cooling fins on the electric motor casing, further reducing maintenance costs that might be required to keep carefully the fins clean and dissipating temperature properly. A evaluation of motor surface area temperature between worm and hypoid gearmotors are available 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 as the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The engine surface area temperature of both products began at 68°F, area temperature. After 100 mins of operating time, the temperature of both models began to level off, concluding the check. The difference in temperature at this time was considerable: the worm unit reached a surface area temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A notable difference around 26.4°F. Despite getting powered by the same motor, the worm device not only produced much less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electric costs for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of the 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 run cooler, there is little to no maintenance required to keep them running at peak performance. Oil lubrication is not needed: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the need for breather holes and any installation constraints posed by essential oil lubricated systems. It is also not necessary to replace lubricant since the grease is intended to last the lifetime utilization of the gearmotor, eliminating downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller sized motors can be utilized in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor generating a worm reducer can produce 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 had been compared for use on an equivalent program. This study fixed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and result torque as it related to power drawn. The analysis figured a 1/2 HP hypoid gearmotor can be utilized to provide similar performance to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a assessment 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 take up more space than hypoid gears (Number 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the entire footprint of the hypoid gearmotor is a lot smaller sized than that of a comparable worm gearmotor. This also makes working environments safer since smaller gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is usually they are symmetrical along their centerline (Body 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 Shape Comparison
In motors of the same power, hypoid drives far outperform their worm counterparts. One essential requirement to consider is that hypoid reducers can move loads from a dead stop with more relieve than worm reducers (Shape 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably 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 studies are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As proven throughout, the advantages 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 proven using the studies provided throughout, hypoid gearmotors can handle higher initial inertia loads and transfer more torque with a smaller sized 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 better option in space-constrained applications. As shown, the overall footprint and symmetric design of hypoid gearmotors makes for a more aesthetically pleasing style while enhancing workplace safety; with smaller, much less cumbersome gearmotors there exists a smaller chance of interference with employees or machinery. Clearly, hypoid gearmotors will be the most suitable choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that boost operational efficiencies and reduce maintenance needs 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, reliable, and provide high torque at low swiftness 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 devices that withstand harsh circumstances. These gearmotors also have multiple regular specifications, options, and installation positions to make sure compatibility.
Specifications
Material: 7005 aluminum equipment box, SAE 841 bronze worm gear, 303/304 stainless steel 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 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 Rate 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 range of worm gearboxes. Due to the modular design the standard programme comprises countless combinations with regards to selection of gear housings, installation and connection choices, 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 top quality components such as homes in cast iron, aluminum and stainless steel, worms in case hardened and polished metal and worm wheels 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 effectively resists dust and water. Furthermore, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes allow for reductions as high as 100:1 in one step or 10.000:1 in a double reduction. An equivalent gearing with the same equipment ratios and the same transferred power is certainly bigger when compared to a worm gearing. In the meantime, the worm gearbox is usually 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 phrases of the typical gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is because of the very soft working of the worm equipment combined with the use of cast iron and high precision on element manufacturing and assembly. In connection with our precision gearboxes, we take extra treatment of any sound that can be interpreted as a murmur from the gear. So 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 one another. This often proves to be a decisive advantage producing the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox is 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 quite firmly embedded in the apparatus house and is well suited for direct suspension for wheels, movable arms and other parts rather than needing to create a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking effect, which in lots of situations can be used as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for an array of solutions.