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.
Minimal 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 due to how we double 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 given a brass springtime loaded breather connect and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to alternative for right-angle power transmission for generations. Touted for their low-cost and robust building, worm reducers could be
found in almost every industrial establishing 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 is an option to worm gear units: the hypoid gear. Typically used in automotive applications, gearmotor businesses have begun integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller overall sizes and higher decrease potential, hypoid gearmotors have a broader range of feasible uses than their worm counterparts. This not only allows heavier torque loads to end up being transferred at higher efficiencies, but it opens options for applications where space can be a limiting factor. They are able to sometimes be costlier, but 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 established there are two components: the input worm, and the output worm gear. The worm is definitely a screw-like gear, that rotates perpendicular to its corresponding worm equipment (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will total five revolutions as the output worm gear is only going to complete one. With a higher ratio, for example 60:1, the worm will finish 60 revolutions per one output revolution. It really is this fundamental arrangement that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, 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 for example 60:1, there will be a big amount of sliding friction due to the lot of input revolutions necessary to spin the output equipment once. Low input quickness applications suffer from the same friction problem, but for a different cause. Since there exists a large amount of tooth contact, the original energy to begin 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 equipment, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets consist of the input hypoid equipment, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear set is a hybrid of bevel and worm equipment Gearbox Worm Drive technologies. They encounter friction losses due to the meshing of the apparatus 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 benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the primary problems posed by worm equipment 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 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 run 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 steel it is proficient at absorbing heavy shock loads but does not operate successfully until it has been work-hardened. The warmth produced from the friction of regular operating conditions really helps to harden the top of worm gear.
With hypoid gear pieces, there is absolutely no “break-in” period; they are usually made from metal which has recently been carbonitride high temperature treated. This allows the drive to use at peak efficiency as soon as it is installed.
Why is Efficiency Important?
Efficiency is among the most important things to consider whenever choosing a gearmotor. Since most employ a long service existence, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for a long time to come. Additionally, a far more efficient reducer permits better reduction capability and use of a motor that
consumes less electrical energy. One stage worm reducers are usually 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 reduction ratios of 10:1, and the excess reduction is provided 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 could be attributed to the excess processing techniques required to produce hypoid gearing such as for example 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 lifetime of the gearmotor because of increased performance and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste much less energy and maximize the energy being transferred from the engine to the driven shaft. Friction can be wasted energy that requires the form of temperature. Since worm gears produce more friction they run much hotter. In many cases, using a hypoid reducer eliminates the need for cooling fins on the electric motor casing, additional reducing maintenance costs that might be required to keep carefully the fins clean and dissipating heat 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 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 engine surface temperature of both units began at 68°F, space temperature. After 100 moments of operating time, the temperature of both models started to level off, concluding the test. The difference in temperature at this point was substantial: the worm device reached a surface temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A difference around 26.4°F. Despite being driven by the same motor, the worm device not only produced less torque, but also wasted more energy. Bottom line, this can result in a much heftier electric expenses for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This decreases the service life of the drives by placing extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term exposure to high heat, these parts 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 running at peak performance. Essential oil lubrication is not needed: the cooling potential of grease is enough 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 because the grease is intended to last the lifetime usage of the gearmotor, eliminating downtime and increasing efficiency.
More Power in a Smaller Package
Smaller motors can be used in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower engine generating a worm reducer can produce the same output as a comparable 1/2 horsepower electric motor traveling a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer were compared for use on an equivalent program. This research fixed the reduction 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 utilized to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result displaying a comparison of torque and power consumption 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. Due to the method the axes of the gears intersect, worm gears consider up more space than hypoid gears (Figure 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the entire footprint of the hypoid gearmotor is a lot smaller than that of a comparable worm gearmotor. This also makes working environments safer since smaller sized gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is usually they are symmetrical along their centerline (Body 9). Worm gearmotors are asymmetrical and lead to machines that aren’t as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same power, hypoid drives considerably outperform their worm counterparts. One essential requirement to consider is certainly that hypoid reducers can move loads from a lifeless 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 outcomes in both research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As shown throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to run more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As proven using the studies shown throughout, hypoid gearmotors are designed for higher initial inertia loads and transfer more torque with a smaller sized 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 far more aesthetically pleasing design while enhancing workplace safety; with smaller, much less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Obviously, hypoid gearmotors are the most suitable choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that enhance operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency units for long-term energy cost savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in size and sealed for life. 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 consistently tough, water-restricted, chemically resistant systems that withstand harsh circumstances. These gearmotors likewise have multiple regular specifications, options, and installation positions to make sure 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
Take note: The helical spur equipment attaches to 4.7 mm D-shaft diameter. The worm gear 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 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 range of worm gearboxes. Because of the modular design the standard program comprises countless combinations with regards to selection of gear housings, mounting and connection choices, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The look of the EP worm gearbox is simple and well proven. We only use top quality components such as houses in cast iron, aluminium and stainless steel, worms in the event hardened and polished metal and worm wheels in high-quality bronze of particular alloys ensuring the the best possible wearability. The seals of the worm gearbox are provided with a dust lip which efficiently resists dust and water. In addition, the gearboxes are greased forever 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 equipment ratios and the same transferred power is bigger when compared to a worm gearing. At the same time, the worm gearbox can be in a more simple design.
A double reduction may be composed of 2 regular 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 advantages of worm gearboxes in the EP-Series:
Compact design
Compact design is one of the key words of the standard 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 really quiet. This is because of the very soft running 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 take extra treatment of any sound that can be interpreted as a murmur from the apparatus. So the general noise level 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 often proves to be a decisive benefit making the incorporation of the gearbox considerably simpler and more compact.The worm gearbox can be an angle gear. This is often an edge 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 ideal for immediate suspension for wheels, movable arms and other parts rather than needing to build a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes will provide a self-locking effect, 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 well suited for an array of solutions.