Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient on the gearing for high efficiency.
Powered by long-enduring worm gears.
Minimum 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 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 given a brass springtime loaded breather plug and come pre-loaded 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 transmitting for generations. Touted because of their low-cost and robust construction, worm reducers can be
found in almost every industrial setting 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 require regular maintenance.
Fortunately, there can be an alternative to worm gear sets: the hypoid gear. Typically used in automotive applications, gearmotor businesses have begun integrating hypoid gearing into right-position gearmotors to solve the problems that arise with worm reducers. Available in smaller general sizes and higher reduction potential, hypoid gearmotors have a broader range of feasible uses than their worm counterparts. This not only allows heavier torque loads to be transferred at higher efficiencies, nonetheless it opens possibilities for applications where space can be a limiting factor. They are able to sometimes be costlier, but the financial 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 set 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 equipment (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will comprehensive five revolutions while the output worm equipment is only going to complete one. With an increased 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 absolutely no rolling element of the tooth contact (Determine 2).
Sliding Friction
In high reduction applications, such as for example 60:1, there will be a sizable amount of sliding friction because of the high number of input revolutions necessary to spin the output equipment once. Low input acceleration applications have problems with the same friction problem, but for a different reason. Since there exists a lot of tooth contact, the initial energy to start rotation is greater than that of a similar hypoid reducer. When driven at low speeds, the worm needs more energy to continue its motion along the worm equipment, and a lot of that energy is lost to friction.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
However, 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 gear technologies. They encounter 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 easily and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest complications posed by worm gear sets is their insufficient efficiency, chiefly in high reductions and low speeds. Typical efficiencies can vary 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 operate at peak efficiency until a particular “break-in” period has occurred. Worms are usually made of steel, with the worm equipment being made of bronze. Since bronze is a softer metal it is good at absorbing large shock loads but will not operate successfully until it’s been work-hardened. The high temperature generated from the friction of regular working conditions really helps to harden the surface of the worm gear.
With hypoid gear units, there is no “break-in” period; they are usually made from metal which has recently been carbonitride high temperature treated. This allows the drive to use at peak efficiency from the moment it is installed.
Why is Efficiency Important?
Efficiency is among the most important things to consider when choosing a gearmotor. Since many employ a long service life, choosing a high-efficiency reducer will minimize costs related to procedure and maintenance for a long time to come. Additionally, a more efficient reducer permits better reduction capability and utilization of a motor that
consumes less electrical energy. Single stage worm reducers are usually limited to 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 just go up to decrease ratios of 10:1, and the excess reduction is provided by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives may have a higher upfront cost than worm drives. This can be attributed to the additional processing techniques required to generate hypoid gearing such as machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with severe pressure additives instead of oil which will incur higher costs. This price Gearbox Worm Drive difference is composed for over the lifetime of the gearmotor due to increased efficiency and reduced maintenance.
A higher efficiency hypoid reducer will ultimately waste much less energy and maximize the energy getting transferred from the electric motor to the driven shaft. Friction is certainly wasted energy that requires the form of high temperature. Since worm gears generate more friction they run much hotter. Oftentimes, utilizing a hypoid reducer eliminates the need for cooling fins on the electric motor casing, additional reducing maintenance costs that might be required to keep the fins clean and dissipating high temperature properly. A assessment of motor surface 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 created 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The motor surface area temperature of both systems began at 68°F, area temperature. After 100 mins of operating time, the temperature of both devices started to level off, concluding the test. The difference in temperature at this time was substantial: the worm device reached a surface area temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A notable difference around 26.4°F. Despite being powered by the same engine, the worm unit not only produced less torque, but also wasted more energy. Important thing, 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 decreases the service life of the drives by putting extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term exposure to 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 necessary to keep them working at peak performance. Oil lubrication is not required: the cooling potential of grease is enough to ensure 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 replace lubricant since the grease is meant to last the lifetime usage of the gearmotor, eliminating downtime and increasing efficiency.
More Power in a Smaller Package
Smaller sized motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine traveling a worm reducer can produce the same output as a comparable 1/2 horsepower engine driving a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer had been compared for use on an equivalent program. This research fixed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and output torque as it linked to power drawn. The study figured 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 cost. A final result displaying a assessment of torque and power intake 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. Because of 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 similar worm gearmotor. This also makes working environments safer since smaller sized 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 aren’t as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same 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 (Number 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 outcomes in both studies are clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the advantages of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and provide higher reduction ratios in comparison with worm reducers. As confirmed using the studies presented throughout, hypoid gearmotors are designed for 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 better option in space-constrained applications. As proven, the overall footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing style while improving workplace safety; with smaller sized, less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Clearly, hypoid gearmotors will be the best choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family of gearmotors that enhance operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency units for long-term energy savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, dependable, and provide high torque at low quickness unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-limited, chemically resistant models that withstand harsh conditions. 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 Swiftness 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 Metal 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 standard programme comprises countless combinations with regards to selection of gear housings, mounting and connection choices, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We only use top quality components such as homes in cast iron, light weight aluminum and stainless steel, worms in the event hardened and polished steel and worm tires in high-grade bronze of special alloys ensuring the optimum wearability. The seals of the worm gearbox are provided with a dirt lip which effectively 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 of up to 100:1 in one single step or 10.000:1 in a double decrease. An equivalent gearing with the same gear ratios and the same transferred power can be bigger than a worm gearing. Meanwhile, the worm gearbox is certainly 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 advantages of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key words of the typical 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 really quiet. This is because of the very easy working of the worm gear 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 which can be interpreted as a murmur from the gear. So the general noise degree of our gearbox is certainly 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 benefit making the incorporation of the gearbox substantially simpler and more compact.The worm gearbox can be an angle gear. This is an advantage for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the apparatus house and is ideal for direct suspension for wheels, movable arms and other areas rather than having to build a separate suspension.
Self locking
For larger equipment 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 perfect for an array of solutions.