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-long lasting 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 Right angle (HdR) series worm gearbox is because of how we dual up the bearings on the input shaft. HdR series reducers can be found in speed ratios which range 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 spring loaded breather plug and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
Introduction
Worm reducers have already been the go-to remedy for right-angle power tranny for generations. Touted because of their low-cost and robust building, worm reducers can be
found in nearly every industrial environment requiring this type of transmission. However, they are inefficient at slower speeds and higher reductions, create a lot of warmth, take up a whole lot of space, and need regular maintenance.
Fortunately, there can be an option to worm gear units: the hypoid gear. Typically used in auto applications, gearmotor companies have begun integrating hypoid gearing into right-position gearmotors to solve the problems that occur with worm reducers. Available in smaller overall sizes and higher decrease potential, hypoid gearmotors possess a broader selection of possible uses than their worm counterparts. This not merely enables heavier torque loads to be transferred at higher efficiencies, nonetheless it opens possibilities for applications where space is a limiting factor. They can sometimes be costlier, but the cost 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 arranged there are two components: the input worm, and the output worm gear. The worm is usually a screw-like equipment, that rotates perpendicular to its corresponding worm gear (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will complete five revolutions while the output worm gear will only complete one. With an increased ratio, for example 60:1, the worm will comprehensive 60 revolutions per one result revolution. It really is this fundamental set up that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only experiences sliding friction. There is no rolling component to the tooth contact (Shape 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will have a huge amount of sliding friction due to the lot of input revolutions required to spin the output gear once. Low input swiftness applications have problems with the same friction problem, but also for a different cause. Since there is a lot of tooth contact, the original energy to begin rotation is greater than that of a comparable hypoid reducer. When powered at low speeds, the worm requires more energy to continue its movement along the worm equipment, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
However, hypoid gear sets Gearbox Worm Drive contain 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 experience 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 efficiently and evenly over the interfacing areas. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest problems posed by worm equipment sets is their lack of 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 gear sets are typically 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
Regarding worm gear sets, they don’t operate at peak efficiency until a particular “break-in” period has occurred. Worms are usually made of metal, with the worm gear being made of bronze. Since bronze is usually a softer metal it is proficient at absorbing large shock loads but will not operate efficiently until it has been work-hardened. The heat generated from the friction of regular operating conditions helps to harden the surface of the worm gear.
With hypoid gear units, there is absolutely no “break-in” period; they are typically made from metal which has recently been carbonitride heat treated. This allows the drive to use at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is one of the most important things to consider whenever choosing a gearmotor. Since the majority of employ a long service life, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for years to arrive. Additionally, a more efficient reducer allows for better reduction ability and utilization of a motor that
consumes less electrical energy. Single stage worm reducers are typically limited to ratios of 5:1 to 60:1, while hypoid gears have a decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the excess 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 additional processing techniques required to produce hypoid gearing such as machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with extreme pressure additives instead of oil which will incur higher costs. This price difference is made up for over the lifetime of the gearmotor due to increased performance and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste much less energy and maximize the energy getting transferred from the engine to the driven shaft. Friction is wasted energy that requires the form of warmth. Since worm gears produce more friction they run much hotter. Oftentimes, using a hypoid reducer eliminates the need for cooling fins on the motor casing, further reducing maintenance costs that might be required to keep carefully the fins clean and dissipating high temperature properly. A assessment of motor surface area 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 as the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The motor surface temperature of both devices began at 68°F, area temperature. After 100 mins of operating period, the temperature of both systems started to level off, concluding the test. The difference in temperature at this time was considerable: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A difference around 26.4°F. Despite getting run by the same electric motor, the worm unit not only produced less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical expenses for worm users.
As previously mentioned and proven, worm reducers operate 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 components can fail, and oil changes are imminent because of lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance required to keep them working at peak performance. Oil lubrication is not required: the cooling potential of grease will do to guarantee the reducer will run effectively. This eliminates the necessity 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 lifetime usage of the gearmotor, removing downtime and increasing productivity.
More Power in a Smaller Package
Smaller sized motors can be used in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine generating 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 Corporation, both a worm and hypoid reducer had been compared for use on an equivalent application. This study fixed the reduction ratio of both gearboxes to 60:1 and compared engine 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 motor size, comes the advantage to use these drives in more applications where space is a constraint. Because of the method the axes of the gears intersect, worm gears consider up more space than hypoid gears (Shape 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized motor, the overall footprint of the hypoid gearmotor is a lot smaller than that of a comparable worm gearmotor. This also helps make working conditions safer since smaller sized gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is usually they are symmetrical along their centerline (Physique 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equivalent power, hypoid drives far outperform their worm counterparts. One important aspect to consider can be that hypoid reducers can move loads from a lifeless 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 above a 30:1 ratio due to their higher efficiency (Figure 11).
Worm vs Hypoid Result 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 better.
The Hypoid Gear Advantage
As shown throughout, the benefits 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 confirmed using the studies provided throughout, hypoid gearmotors can handle 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 demonstrated, the entire footprint and symmetric style of hypoid gearmotors makes for a more aesthetically pleasing style while improving workplace safety; with smaller, much less cumbersome gearmotors there is a smaller potential for interference with workers or machinery. Clearly, hypoid gearmotors are the best choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that enhance operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency units for long-term energy savings. Besides being highly efficient, its hypoid/helical gearmotors are small in proportions and sealed forever. They are light, reliable, and offer high torque at low speed unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-tight, chemically resistant models that withstand harsh conditions. These gearmotors likewise have multiple standard specifications, options, and installation positions to make sure compatibility.
Specifications
Material: 7005 aluminum gear 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 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 Style for OEM Replacement
Double Bearings Applied to 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 programme comprises countless combinations when it comes to selection of equipment housings, mounting and connection choices, flanges, shaft designs, type of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We just use high quality components such as houses in cast iron, aluminium and stainless, worms in case hardened and polished steel and worm tires in high-quality bronze of particular alloys ensuring the ideal 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 enable reductions of up to 100:1 in one single step or 10.000:1 in a double reduction. An equivalent gearing with the same gear ratios and the same transferred power is bigger when compared to a worm gearing. Meanwhile, the worm gearbox can be in a far more simple design.
A double reduction may be composed of 2 standard 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 terms of the typical gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or special gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is because of the very simple working of the worm equipment combined with the use of cast iron and high precision on component manufacturing and assembly. Regarding the our precision gearboxes, we take extra treatment of any sound that can be interpreted as a murmur from the gear. So the general noise level of our gearbox is definitely reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This frequently proves to become 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 edge for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the apparatus house and is well suited for immediate suspension for wheels, movable arms and other areas rather than having to build a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking impact, which in lots of situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for an array of solutions.