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-lasting worm gears.
Minimum 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 dual 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass spring loaded breather connect and come pre-packed 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 transmission for generations. Touted for his or her low-cost and robust building, worm reducers can be
found in nearly every industrial environment requiring this kind of transmission. Sadly, they are inefficient at slower speeds and higher reductions, create a lot of high temperature, take up a lot of space, and need regular maintenance.
Fortunately, there is an alternative to worm gear pieces: the hypoid gear. Typically used in automotive applications, gearmotor businesses 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 reduction potential, hypoid gearmotors possess a broader range of possible uses than their worm counterparts. This not only allows heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens opportunities for applications where space is certainly 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 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 certainly a screw-like equipment, that rotates perpendicular to its corresponding worm equipment (Figure 1). For example, 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 an increased ratio, for instance 60:1, the worm will finish 60 revolutions per one result revolution. It is this fundamental arrangement that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only experiences sliding friction. There is absolutely no rolling component to the tooth contact (Determine 2).
Sliding Friction
In high reduction applications, such as 60:1, you will have a big amount of sliding friction because of the high number of input revolutions necessary to spin the output gear once. Low input swiftness applications have problems with the same friction issue, but for a different cause. Since there is a lot of tooth contact, the initial energy to start rotation is higher than that of a comparable hypoid reducer. When powered at low speeds, the worm requires more energy to continue its motion along the worm gear, and lots of that energy is dropped to friction.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets contain the input hypoid equipment, 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 because of 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 easily and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary complications posed by worm gear sets is their lack of efficiency, chiefly in high reductions and low speeds. Common 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
In the case of worm gear sets, they do not run at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of steel, with the worm equipment being manufactured from bronze. Since bronze is usually a softer metallic it is good at absorbing large shock loads but does not operate effectively until it has been work-hardened. The heat produced from the friction of regular operating conditions helps to harden the top of worm gear.
With hypoid gear units, there is absolutely no “break-in” period; they are usually made from metal which has recently been carbonitride heat treated. This allows the drive to use at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is one of the most important things to consider when choosing a gearmotor. Since many 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 allows for better reduction capability and utilization 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 decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the additional reduction is provided by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives may have an increased upfront cost than worm drives. This is often attributed to the additional processing techniques necessary to create hypoid gearing such as machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically use grease with intense pressure additives rather than oil that will incur higher costs. This price difference is composed for over the lifetime of the gearmotor due to increased functionality and reduced maintenance.
A higher 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 temperature. Since worm gears create more friction they operate much hotter. In many cases, utilizing a hypoid reducer eliminates the necessity for cooling fins on the electric motor casing, further reducing maintenance costs that would be required to keep the fins clean and dissipating high temperature properly. A evaluation 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 created 133 in-lb of torque while the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is because of the inefficiencies of the worm reducer. The motor surface temperature of both systems began at 68°F, space temperature. After 100 mins of operating period, the temperature of both products started to level off, concluding the test. The difference in temperature at this point was considerable: the worm unit reached a surface temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A notable difference around 26.4°F. Despite becoming driven by the same motor, the worm unit not only produced much 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 placing extra thermal stress 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 required to keep them operating at peak performance. Oil lubrication is not required: the cooling potential of grease will do to ensure the reducer will operate effectively. This eliminates the necessity for breather holes and any installation constraints posed by essential 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 efficiency.
More Power in a Smaller Package
Smaller sized motors can be used in hypoid gearmotors because of the more efficient transfer of energy Gearbox Worm Drive through the gearbox. In some instances, a 1 horsepower motor driving a worm reducer can generate the same output as a comparable 1/2 horsepower motor traveling a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer had been compared for make use of on an equivalent app. 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 analysis figured a 1/2 HP hypoid gearmotor can be utilized to provide similar functionality to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a comparison 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. Because of the way the axes of the gears intersect, worm gears consider up more space than hypoid gears (Body 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the entire footprint of the hypoid gearmotor is much smaller than that of a similar worm gearmotor. This also helps make working environments safer since smaller gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is certainly that they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equivalent power, hypoid drives much outperform their worm counterparts. One important aspect to consider is usually that hypoid reducers can move loads from a dead stop with more ease 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 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 research are obvious: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As demonstrated throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to perform more efficiently, cooler, and offer higher reduction ratios when compared to worm reducers. As proven using the studies provided throughout, hypoid gearmotors can handle higher preliminary 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 proven, the overall footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing design while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there is a smaller potential for interference with workers or machinery. Clearly, hypoid gearmotors will be the best choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that enhance operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency products for long-term energy savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in proportions and sealed for life. They are light, reliable, and offer high torque at low speed unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-tight, chemically resistant products that withstand harsh conditions. These gearmotors likewise have multiple regular 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 equipment attaches to 4.7 mm D-shaft diameter. The worm equipment attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Velocity 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 Steel Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide selection of worm gearboxes. Because of the modular design the standard programme comprises countless combinations when it comes to selection of gear housings, mounting 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 just use high quality components such as houses in cast iron, aluminium and stainless steel, worms in the event hardened and polished steel and worm tires in high-quality bronze of unique alloys ensuring the ideal wearability. The seals of the worm gearbox are given with a dust lip which effectively resists dust and drinking 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 single step or 10.000:1 in a double decrease. An equivalent gearing with the same gear ratios and the same transferred power is certainly bigger than a worm gearing. Meanwhile, the worm gearbox is in a far more simple design.
A double reduction may 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 advantages of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key phrases of the standard 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 due to the very clean working of the worm equipment combined with the usage of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we consider extra care of any sound that can be interpreted as a murmur from the apparatus. So the general noise level of our gearbox is certainly reduced to an absolute 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 considerably simpler and more compact.The worm gearbox is an angle gear. This is often an advantage 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 perfect for immediate suspension for wheels, movable arms and other parts rather than having to create a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking impact, which in many situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for a wide variety of solutions.