Ever-Power Worm Gear Reducer
High-efficiency, high-strength 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 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 springtime loaded breather connect and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. 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 could be
found in nearly every industrial establishing requiring this type of transmission. Sadly, they are inefficient at slower speeds and higher reductions, produce a lot of heat, take up a whole lot of space, and require regular maintenance.
Fortunately, there is an option to worm gear sets: the hypoid gear. Typically found in automotive applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the issues that arise with worm reducers. Obtainable in smaller general sizes and higher reduction potential, hypoid gearmotors possess a broader range of feasible uses than their worm counterparts. This not merely allows heavier torque loads to become transferred at higher efficiencies, nonetheless it opens possibilities for applications where space is certainly a limiting factor. They can sometimes be costlier, however the cost savings in efficiency and maintenance are well 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.
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 instance, in a worm gearbox with a 5:1 ratio, the worm will comprehensive five revolutions as the output worm equipment will only complete one. With an increased ratio, for example 60:1, the worm will total 60 revolutions per one result revolution. It really is this fundamental set up 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, you will have a sizable amount of sliding friction due to the lot of input revolutions necessary to spin the output gear once. Low input speed applications have problems with the same friction issue, but for a different reason. Since there exists a lot of tooth contact, the initial energy to begin rotation is higher than that of a similar hypoid reducer. When driven at low speeds, the worm needs more energy to continue its movement along the worm equipment, and lots of that energy is lost to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets consist of the input hypoid gear, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm gear technologies. They experience friction losses due to the meshing of the gear teeth, with reduced sliding included. These losses are minimized using the hypoid tooth pattern which allows torque to end up being transferred smoothly and evenly across 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 primary 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 usually 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
In the case of worm gear sets, they don’t operate at peak efficiency until a specific “break-in” period has occurred. Worms are typically made of metal, with the worm gear being made of bronze. Since bronze is a softer steel it is good at absorbing heavy shock loads but will not operate effectively until it has been work-hardened. The heat generated from the friction of regular working conditions really 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 already been carbonitride temperature treated. This allows the drive to operate at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is among the most important factors to consider when choosing a gearmotor. Since the majority of have a very long service existence, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for a long time to come. Additionally, a more efficient reducer permits better reduction ability and usage of a motor that
consumes less electrical power. One 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 excess reduction is provided 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 create hypoid gearing such as machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with extreme pressure additives rather than oil that may incur higher costs. This price difference is composed for over the lifetime of the gearmotor due to increased performance and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste less energy and maximize the energy becoming transferred from the engine to the driven shaft. Friction is usually wasted energy that takes the form of heat. Since worm gears generate more friction they run much hotter. Oftentimes, using a hypoid reducer eliminates the need for cooling fins on the electric motor casing, further reducing maintenance costs that might be required to keep the fins clean and dissipating 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 as the hypoid gearmotor produced 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 units began at 68°F, room temperature. After 100 moments of operating period, the temperature of both systems began to level off, concluding the test. The difference in temperature at this point was significant: the worm device reached a surface temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A notable difference around 26.4°F. Despite becoming run by the same engine, the worm device 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 the drives by placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these components 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 working at peak performance. Oil lubrication is not needed: the cooling potential of grease will do to guarantee the reducer will run effectively. This eliminates the necessity for breather holes and any mounting constraints posed by oil lubricated systems. Additionally it is not necessary to replace lubricant because the grease is intended to last the lifetime utilization of the gearmotor, eliminating downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller motors can be utilized in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor driving a worm reducer can create the same output as a comparable 1/2 horsepower electric motor generating a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer had been compared for use on an equivalent app. This study fixed the decrease ratio of both gearboxes to 60:1 and compared engine power and output torque as it related to power drawn. The analysis 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 cost. A final result displaying a evaluation of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric 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 take up more space than hypoid gears (Number 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized 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 lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the quantity 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 usually that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Body 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 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 clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As shown throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to run more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As tested using the studies presented 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 result in 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 much better option in space-constrained applications. As shown, the overall 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 exists a smaller potential for interference with workers or machinery. Clearly, hypoid gearmotors will be the most suitable choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that increase operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency devices for long-term energy 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 speed unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant models that withstand harsh conditions. These gearmotors likewise have multiple standard specifications, options, and installation positions to ensure 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
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 Quickness 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 Outside and inside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Steel Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide variety of worm gearboxes. Because of the modular design the standard programme comprises countless combinations with regards to selection of equipment housings, installation and connection options, flanges, shaft designs, kind 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, light weight aluminum and stainless steel, 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 dirt lip which effectively resists dust and drinking 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 as high as 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 is bigger when compared to a worm gearing. At the same time, the worm gearbox is in a more simple design.
A double reduction could be composed of 2 standard 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 among the key terms of the typical gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is because of the very smooth operating of the worm gear combined with the usage 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 apparatus. Therefore the general noise degree of our gearbox is reduced to an absolute minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This frequently proves to become a decisive advantage making the incorporation of the gearbox considerably simpler and smaller sized.The worm gearbox can be an angle gear. This is often an edge 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 perfect for immediate suspension for wheels, movable arms and other areas rather than needing to create a Gearbox Worm Drive separate suspension.
Self locking
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 a wide variety of solutions.