Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
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 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 spring loaded breather connect and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
Worm reducers have already been the go-to answer for right-angle power transmitting for generations. Touted for his or her low-cost and robust building, worm reducers can be
found in nearly every industrial environment requiring this type of transmission. Sadly, they are inefficient at slower speeds and higher reductions, create a lot of warmth, take up a lot of space, and require regular maintenance.
Fortunately, there can be an alternative to worm gear pieces: 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. Available in smaller overall sizes and higher reduction potential, hypoid gearmotors possess a broader selection of feasible uses than their worm counterparts. This not only enables heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens possibilities 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 following 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 set there are two components: the input worm, and the output worm gear. The worm is definitely a screw-like equipment, that rotates perpendicular to its corresponding worm gear (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will comprehensive five revolutions while the output worm equipment is only going to complete one. With an increased ratio, for example 60:1, the worm will full 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 encounters sliding friction. There is absolutely no rolling element of the tooth contact (Number 2).
Sliding Friction
In high reduction applications, such as for example 60:1, there will be a large amount of sliding friction because of the high number of input revolutions necessary to spin the output equipment once. Low input rate applications have problems with the same friction issue, but for a different reason. Since there exists a lot of tooth contact, the initial energy to begin rotation is higher than that of a comparable hypoid reducer. When powered at low speeds, the worm requires more energy to keep its motion along the worm gear, and lots of that energy is lost to friction.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
However, 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 experience friction losses because of the meshing of the apparatus teeth, with minimal sliding included. These losses are minimized using the hypoid tooth pattern that allows torque to become transferred smoothly and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the biggest complications posed by worm equipment sets is their insufficient efficiency, chiefly in high reductions and low speeds. Typical efficiencies can vary 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
In the case of worm gear sets, they don’t operate at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of metal, with the worm equipment being made of bronze. Since bronze can be a softer metallic it is good at absorbing large shock loads but will not operate effectively until it’s been work-hardened. The high temperature generated from the friction of regular operating conditions really helps to harden the surface of the worm gear.
With hypoid gear models, there is absolutely no “break-in” period; they are typically made from steel which has already been carbonitride high temperature treated. This allows the drive to use at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is one of the most important things to consider whenever choosing a gearmotor. Since many have a very long service lifestyle, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for years to come. Additionally, a more efficient reducer allows for better reduction capacity and use of a motor that
consumes less electrical power. Single stage worm reducers are typically limited by ratios of 5:1 to 60:1, while hypoid gears possess a reduction 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 supplied by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This can be attributed to the excess processing techniques required to generate hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically make use of grease with severe pressure additives rather than oil that will incur higher costs. This price difference is composed for over the lifetime of the gearmotor because of increased efficiency and reduced maintenance.
A higher efficiency hypoid reducer will ultimately waste much less energy and maximize the energy being transferred from the motor to the driven shaft. Friction is certainly wasted energy that takes the form of warmth. Since worm gears produce more friction they run much hotter. Oftentimes, utilizing a hypoid reducer eliminates the need for cooling fins on the engine casing, additional reducing maintenance costs that would be required to keep carefully the fins clean and dissipating warmth 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 due to the inefficiencies of the worm reducer. The engine surface temperature of both devices began at 68°F, space temperature. After 100 mins of operating period, the temperature of both units began to level off, concluding the check. 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 just reached 125.0°F. A difference of about 26.4°F. Despite getting powered by the same electric motor, the worm unit not only produced less torque, but also wasted more energy. Bottom line, this can result in a much heftier electric bill 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 placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term exposure to high heat, these parts can fail, and oil changes are imminent because of lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance necessary to keep them operating at peak performance. Oil lubrication is not required: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the necessity for breather holes and any installation constraints posed by oil lubricated systems. It is also not necessary to replace lubricant since 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 motors can be used in hypoid gearmotors because of the more efficient Gearbox Worm Drive transfer of energy through the gearbox. In some instances, a 1 horsepower engine driving a worm reducer can create the same result as a comparable 1/2 horsepower electric motor traveling a hypoid reducer. In a single study by Nissei Company, 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 related 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 showing a comparison of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine 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 (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 sized than that of a similar worm gearmotor. This also makes working conditions safer since smaller sized gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is certainly 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 quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same power, hypoid drives significantly outperform their worm counterparts. One important aspect to consider is that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Figure 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably 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 research are clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to run 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 sized motor than a comparable worm gearmotor.
This can result in 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 better option in space-constrained applications. As shown, the overall footprint and symmetric style of hypoid gearmotors makes for a more aesthetically pleasing design while improving workplace safety; with smaller sized, much less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Clearly, hypoid gearmotors will be the most suitable choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that enhance operational efficiencies and reduce maintenance requirements and downtime. They provide premium efficiency models for long-term energy cost savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, reliable, and provide high torque at low quickness unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-restricted, chemically resistant units that withstand harsh circumstances. These gearmotors likewise have multiple standard specifications, options, and mounting positions to ensure compatibility.
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 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 Applied to Both Shaft Ends
Anti-Rust Primer Applied Outside and inside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Steel Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers a very wide range of worm gearboxes. Due to the modular design the standard programme comprises countless combinations when it comes to selection of equipment 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 easy and well proven. We only use high quality components such as houses in cast iron, aluminum and stainless, worms in the event hardened and polished steel and worm wheels in high-grade bronze of special alloys ensuring the maximum wearability. The seals of the worm gearbox are provided with a dirt lip which successfully resists dust and water. In addition, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in a single 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 equipment ratios and the same transferred power is definitely bigger than a worm gearing. Meanwhile, the worm gearbox is certainly in a more simple design.
A double reduction may be composed of 2 regular gearboxes or as a special gearbox.
Worm gearbox
Maximum output torque
Housing design
Series 35
5:1 – 90:1
Series 42
5:1 – 75:1
Cast iron
Series 52
7:1 – 60:1
Cast iron
Series 61
7:1 – 100:1
Cast iron
Series 79
7:1 – 60:1
Cast iron
Series 99
7:1 – 100:1
Cast iron
Other product benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is one of the key words of the typical gearboxes of the EP-Series. Further optimisation may be accomplished by using adapted gearboxes or unique gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is due to the very simple 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 gear. Therefore the general noise level of our gearbox is definitely reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This frequently proves to be a decisive advantage producing 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.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the gear house and is well suited for direct suspension for wheels, movable arms and other areas rather than having 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 a wide range of solutions.