Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient on 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 due to how we double up the bearings on the input shaft. HdR series reducers are available 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-filled with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to answer for right-angle power transmission for generations. Touted for their low-cost and robust building, worm reducers could be
found in nearly every industrial environment requiring this type of transmission. Unfortunately, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a lot of space, and require regular maintenance.
Fortunately, there is an alternative to worm gear units: the hypoid gear. Typically found in auto applications, gearmotor companies have started integrating hypoid gearing into right-position gearmotors to solve the problems that occur with worm reducers. Available in Gearbox Worm Drive smaller general sizes and higher reduction potential, hypoid gearmotors possess a broader range of possible uses than their worm counterparts. This not only enables heavier torque loads to be transferred at higher efficiencies, nonetheless it opens possibilities for applications where space is definitely a limiting factor. They are able to sometimes be costlier, however the financial 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.
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 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 total five revolutions while the output worm equipment is only going to complete one. With an increased ratio, for instance 60:1, the worm will total 60 revolutions per one output revolution. It is this fundamental arrangement that causes 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, there will be a big amount of sliding friction due to the lot of input revolutions required to spin the output equipment once. Low input swiftness applications suffer from the same friction problem, but also for a different reason. Since there is a large amount of tooth contact, the original energy to start rotation is higher than that of a comparable hypoid reducer. When driven at low speeds, the worm needs more energy to keep its motion along the worm equipment, and lots of that energy is dropped to friction.
Hypoid vs. 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 equipment (Figure 3).
Hypoid Gear Set
The hypoid gear arranged is a hybrid of bevel and worm equipment technologies. They encounter friction losses because of the meshing of the apparatus teeth, with reduced sliding involved. 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 Efficiency Actually Differ?
One of the primary complications posed by worm gear sets is their lack of efficiency, chiefly at high reductions and low speeds. Regular efficiencies may differ 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
Regarding worm gear sets, they do not run at peak efficiency until a particular “break-in” period has occurred. Worms are typically made of metal, with the worm gear being manufactured from bronze. Since bronze can be a softer steel it is proficient at absorbing large shock loads but will not operate effectively until it’s been work-hardened. The high temperature 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 usually made from metal which has already been carbonitride heat treated. This enables the drive to operate at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is one of the most important things to consider when choosing a gearmotor. Since the majority of 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 more efficient reducer permits better reduction capability and use of a motor that
consumes less electrical power. Solitary 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 only go up to decrease ratios of 10:1, and the additional reduction is provided by another type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This is often attributed to the additional processing techniques necessary to generate hypoid gearing such as for example machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically make use of grease with intense pressure additives instead of oil which will incur higher costs. This cost difference is composed for over the duration of the gearmotor because of increased functionality and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste much less energy and maximize the energy becoming transferred from the motor to the driven shaft. Friction is certainly wasted energy that requires the form of heat. Since worm gears generate more friction they operate much hotter. In many cases, using a hypoid reducer eliminates the necessity for cooling fins on the motor casing, additional reducing maintenance costs that might be required to keep the fins clean and dissipating warmth properly. A assessment of motor surface area temperature between worm and hypoid gearmotors are available 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 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 models began at 68°F, room temperature. After 100 mins of operating time, the temperature of both devices began to level off, concluding the test. The difference in temperature at this time was significant: the worm unit reached a surface area temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A notable difference around 26.4°F. Despite becoming run by the same motor, the worm unit not only produced much less torque, but also wasted more energy. Important thing, this can result in a much heftier electric bill 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 elements 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 running at peak performance. Essential oil lubrication is not needed: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the need for breather holes and any installation constraints posed by oil lubricated systems. It is also not necessary to replace lubricant because the grease is meant to last the lifetime use of the gearmotor, getting rid of downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller sized motors can be used in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower electric motor driving a worm reducer can create the same output as a comparable 1/2 horsepower motor driving a hypoid reducer. In a single study by Nissei Corporation, both a worm and hypoid reducer had been compared for use on an equivalent program. This research fixed the decrease ratio of both gearboxes to 60:1 and compared electric motor power and output torque as it related to power drawn. The analysis figured a 1/2 HP hypoid gearmotor can be utilized to provide similar performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result displaying a evaluation of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in electric 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 take up more space than hypoid gears (Determine 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the overall 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 lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is they are symmetrical along their centerline (Determine 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 Form Comparison
In motors of the same power, hypoid drives far outperform their worm counterparts. One essential requirement to consider can be that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Figure 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors over 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 outcomes in both research are obvious: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As demonstrated throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to run more efficiently, cooler, and provide higher reduction ratios in comparison with worm reducers. As verified using the studies provided throughout, hypoid gearmotors are designed for higher preliminary inertia loads and transfer more torque with a smaller sized motor when compared to a comparable worm gearmotor.
This can lead to 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 chance of interference with employees or machinery. Obviously, hypoid gearmotors will be the most suitable choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that increase operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency devices for long-term energy cost savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in proportions and sealed forever. They are light, reliable, and provide high torque at low swiftness 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 devices that withstand harsh circumstances. These gearmotors also have multiple regular specifications, options, and installation positions to ensure compatibility.
Specifications
Material: 7005 aluminum gear box, SAE 841 bronze worm gear, 303/304 stainless 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 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 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 variety of worm gearboxes. Because of the modular design the typical programme comprises countless combinations with regards to selection of gear housings, mounting and connection options, flanges, shaft designs, type of oil, surface treatments etc.
Sturdy and reliable
The look of the EP worm gearbox is simple and well proven. We only use high quality components such as homes in cast iron, aluminium and stainless steel, worms in case hardened and polished metal and worm wheels in high-grade bronze of unique alloys ensuring the optimum wearability. The seals of the worm gearbox are given with a dirt lip which successfully resists dust and drinking water. In addition, 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 step or 10.000:1 in a double decrease. An comparative gearing with the same equipment ratios and the same transferred power is certainly 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 benefits 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 can be achieved through the use of adapted gearboxes or special gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is because of the very smooth operating of the worm gear combined with the use of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we consider extra treatment of any sound that can be interpreted as a murmur from the apparatus. Therefore the general noise degree of our gearbox is usually reduced to an absolute minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This often proves to be a decisive advantage making the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox is an angle gear. This is an advantage 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 direct 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 will provide a self-locking effect, which in many 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 selection of solutions.