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-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 due to 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 ranging from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather connect and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to alternative for right-angle power tranny for generations. Touted for his or her low-cost and robust construction, worm reducers can be
found in nearly every industrial establishing requiring this kind of transmission. Unfortunately, they are inefficient at slower speeds and higher reductions, produce a lot of warmth, take up a lot of space, and require regular maintenance.
Fortunately, there can be an option to worm gear sets: the hypoid gear. Gearbox Worm Drive typically found in auto applications, gearmotor businesses have begun integrating hypoid gearing into right-angle gearmotors to solve the problems that arise with worm reducers. Obtainable in smaller general sizes and higher decrease potential, hypoid gearmotors possess a broader range of possible uses than their worm counterparts. This not merely allows heavier torque loads to be transferred at higher efficiencies, nonetheless it opens options for applications where space is a limiting factor. They can sometimes be costlier, however the financial savings in efficiency and maintenance are well worth it.
The next 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 established 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 is only going to complete one. With a higher 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 gear, the worm only experiences sliding friction. There is absolutely no rolling element of the tooth contact (Shape 2).
Sliding Friction
In high reduction applications, such as 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 speed applications have problems with the same friction problem, but for a different reason. Since there is a lot of tooth contact, the initial energy to start rotation is higher than that of a similar hypoid reducer. When driven at low speeds, the worm requires more energy to keep its motion along the worm gear, and a lot of that energy is dropped to friction.
Hypoid vs. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets consist of 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 encounter friction losses due to the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth design that allows torque to be transferred efficiently 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 biggest problems posed by worm gear sets is their insufficient efficiency, chiefly in high reductions and low speeds. Typical efficiencies may differ 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 metal, with the worm gear being manufactured from bronze. Since bronze is usually a softer steel it is good at absorbing large shock loads but will not operate effectively until it has been work-hardened. The heat produced from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear pieces, there is no “break-in” period; they are typically made from steel which has already been carbonitride temperature treated. This allows the drive to use at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is among the most important factors to consider whenever choosing a gearmotor. Since most employ a long service lifestyle, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for a long time to arrive. Additionally, a far more efficient reducer allows for better reduction capacity and usage 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 have a decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to decrease ratios of 10:1, and the additional reduction is supplied by another type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives may have an increased upfront cost than worm drives. This could be attributed to the excess processing techniques required to generate hypoid gearing such as machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with intense pressure additives instead of oil which will incur higher costs. This price difference is made up for over the duration of the gearmotor because of increased performance and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste less energy and maximize the energy becoming transferred from the engine to the driven shaft. Friction is usually wasted energy that requires the form of heat. Since worm gears produce 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 might be required to keep carefully the fins clean and dissipating high temperature properly. A evaluation of motor surface 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 created 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 temperature of both systems began at 68°F, area temperature. After 100 minutes of operating time, the temperature of both systems began to level off, concluding the check. The difference in temperature at this time was substantial: the worm device reached a surface temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A difference around 26.4°F. Despite getting powered by the same electric motor, the worm unit not only produced much less torque, but also wasted more energy. Bottom line, this can result in a much heftier electrical bill for worm users.
As previously mentioned 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 essential oil changes are imminent because of 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 guarantee the reducer will operate effectively. This eliminates the need for breather holes and any mounting constraints posed by oil lubricated systems. It is also not necessary to replace lubricant since the grease is intended to last the lifetime use of the gearmotor, getting rid of downtime and increasing efficiency.
More Power in a Smaller Package
Smaller motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor generating a worm reducer can create the same output as a comparable 1/2 horsepower motor traveling a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer had been compared for use on an equivalent application. This study fixed the decrease ratio of both gearboxes to 60:1 and compared electric motor power and output torque as it linked to power drawn. The analysis concluded that a 1/2 HP hypoid gearmotor can be utilized 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 benefit to use these drives in more applications where space is a constraint. Due to 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 much smaller than that of a similar worm gearmotor. This also makes working conditions safer since smaller 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 are not as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same power, hypoid drives much outperform their worm counterparts. One important aspect to consider is that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Shape 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors above a 30:1 ratio because of 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 more effectively.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to run more efficiently, cooler, and offer higher reduction ratios when compared to worm reducers. As confirmed using the studies shown throughout, hypoid gearmotors are designed for higher initial inertia loads and transfer more torque with a smaller motor than a comparable worm gearmotor.
This can lead to upfront savings by allowing an individual to buy 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 overall footprint and symmetric style of hypoid gearmotors makes for a more aesthetically pleasing style while improving workplace safety; with smaller, less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Obviously, hypoid gearmotors will be the best choice for long-term cost benefits and reliability in comparison 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 products for long-term energy savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, reliable, and offer high torque at low velocity unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant products that withstand harsh circumstances. These gearmotors also have multiple standard specifications, options, and mounting 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
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 Acceleration 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 Applied to Both Shaft Ends
Anti-Rust Primer Applied Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide selection of worm gearboxes. Because of the modular design the typical program comprises countless combinations when it comes to selection of equipment housings, installation and connection choices, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We just use high quality components such as homes in cast iron, aluminium and stainless, worms in case hardened and polished metal and worm tires in high-quality bronze of particular alloys ensuring the maximum 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 reduction. An comparative gearing with the same equipment ratios and the same transferred power is bigger than a worm gearing. In the meantime, the worm gearbox is 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 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 because of the very soft working of the worm equipment combined with the usage of cast iron and high precision on element manufacturing and assembly. In connection with our precision gearboxes, we consider extra treatment of any sound that can be interpreted as a murmur from the apparatus. Therefore the general noise level 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 each other. This often proves to become a decisive advantage producing the incorporation of the gearbox substantially simpler and more compact.The worm gearbox can be 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 very firmly embedded in the apparatus house and is well suited for direct suspension for wheels, movable arms and other areas rather than having to create a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes will provide a self-locking impact, which in many situations can be utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for a wide variety of solutions.