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-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 Correct angle (HdR) series worm gearbox is because of how we double 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 ranging from 1.33 to 3.25 inches. Also, our gearboxes are given a brass spring loaded breather plug and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to solution for right-angle power tranny for generations. Touted for his or her low-cost and robust building, worm reducers could be
found in almost every industrial environment requiring this type of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, produce a lot of heat, take up a whole lot of space, and need regular maintenance.
Fortunately, there can be an option to worm gear pieces: the hypoid gear. Typically found in auto applications, gearmotor businesses have begun integrating hypoid gearing into right-position gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller general sizes and higher decrease potential, hypoid gearmotors have a broader selection of possible uses than their worm counterparts. This not only enables heavier torque loads to end up being transferred at higher efficiencies, but it opens opportunities for applications where space is certainly a limiting factor. They can sometimes be costlier, but the financial savings in efficiency and maintenance are really 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 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 equipment (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will finish five revolutions as the output worm gear is only going to complete one. With an increased ratio, for example 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 no rolling element of the tooth contact (Figure 2).
Sliding Friction
In high reduction applications, such as 60:1, there will be a big amount of sliding friction because of the lot of input revolutions required to spin the output gear once. Low input quickness applications suffer from the same friction problem, but also 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 powered at low speeds, the worm needs more energy to keep its movement along the worm equipment, and a lot of that energy is lost to friction.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
However, hypoid gear sets contain the input hypoid gear, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear set is a hybrid of bevel and worm gear technologies. They experience friction losses due to the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth pattern that allows torque to end up being transferred smoothly and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the primary problems posed by worm equipment sets is their lack of efficiency, chiefly at 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 usually 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
In the case of 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 gear being made of bronze. Since bronze is definitely a softer steel it is good at absorbing heavy shock loads but will not operate efficiently until it has been work-hardened. The warmth produced 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 typically made from steel which has already been carbonitride heat treated. This allows the drive to use at peak efficiency from the moment it is installed.
Why is Efficiency Important?
Efficiency is one of the most important factors to consider when choosing a gearmotor. Since most employ a long service life, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for years to come. Additionally, a far more efficient reducer allows for better reduction capability 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 just go up to reduction ratios of 10:1, and the excess reduction is supplied by a different type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This can be attributed to the additional processing techniques required to create hypoid gearing such as machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with severe 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 ultimately waste much less energy and maximize the energy getting transferred from the engine to the driven shaft. Friction can be wasted energy that takes the form of warmth. Since worm gears produce more friction they operate much hotter. Oftentimes, utilizing a hypoid reducer eliminates the necessity for cooling fins on the engine casing, further reducing maintenance costs that would 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 created 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 products began at 68°F, space temperature. After 100 a few minutes of Gearbox Worm Drive operating period, the temperature of both devices started to level off, concluding the check. The difference in temperature at this time was considerable: the worm unit reached a surface temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A difference around 26.4°F. Despite being run by the same motor, the worm unit not only produced much less torque, but also wasted more energy. Important thing, this can lead to a much heftier electric costs for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This decreases the service life of these drives by putting extra thermal stress on the lubrication, bearings, seals, and gears. After long-term exposure to high heat, these parts can fail, and essential oil changes are imminent due to lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance required to keep them operating at peak performance. Oil lubrication is not needed: the cooling potential of grease is enough to guarantee the reducer will run effectively. This eliminates the need for breather holes and any mounting constraints posed by oil lubricated systems. Additionally it is not necessary to displace lubricant since the grease is intended to last the life time use 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 through the gearbox. Occasionally, a 1 horsepower electric motor generating a worm reducer can produce the same result as a comparable 1/2 horsepower engine driving a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer were compared for make use of on an equivalent app. This study fixed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and result 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 price. A final result displaying a evaluation of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in motor size, comes the benefit 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 (Figure 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 comparable worm gearmotor. This also makes working environments safer since smaller gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is certainly they are symmetrical along their centerline (Determine 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of the same power, hypoid drives far 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 (Shape 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably more torque than worm gearmotors over a 30:1 ratio because of 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 studies are clear: hypoid reducers transfer power more effectively.
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 proven using the studies offered throughout, hypoid gearmotors can handle 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 the user to buy 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 far more aesthetically pleasing design while enhancing workplace safety; with smaller, much less cumbersome gearmotors there is a smaller chance of interference with workers or machinery. Clearly, hypoid gearmotors are the most suitable choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that enhance operational efficiencies and reduce maintenance needs and downtime. They offer premium efficiency devices for long-term energy cost savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in size and sealed forever. They are light, dependable, and offer high torque at low rate 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 models that withstand harsh conditions. These gearmotors also have multiple standard specifications, options, and mounting positions to ensure 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 gear attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Rate 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 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 an extremely wide selection of worm gearboxes. Due to the modular design the standard program comprises countless combinations when it comes to selection of gear 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 top quality components such as houses in cast iron, aluminium and stainless, worms in the event hardened and polished metal and worm wheels in high-quality bronze of special alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dirt lip which efficiently resists dust and drinking water. Furthermore, the gearboxes are greased forever 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. Meanwhile, the worm gearbox can be in a far more simple design.
A double reduction could be composed of 2 regular 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 one of the key terms of the typical gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or unique gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very clean 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 consider extra care of any sound which can be interpreted as a murmur from the gear. So the general noise degree of our gearbox can be 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 producing the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox is 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 very firmly embedded in the apparatus house and is ideal for immediate suspension for wheels, movable arms and other parts rather than having to create a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes provides a self-locking effect, which in lots of situations can be utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them perfect for a wide range of solutions.