Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Low friction coefficient on the gearing for high efficiency.
Powered by long-lasting worm gears.
Minimal 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 dual 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather connect and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Worm reducers have been the go-to option for right-angle power tranny for generations. Touted for their low-cost and robust structure, worm reducers can be
found in almost every industrial environment requiring this type of transmission. Sadly, they are inefﬁcient at slower speeds and higher reductions, produce a lot of warmth, take up a whole lot of space, and require regular maintenance.
Fortunately, there can be an option to worm gear pieces: the hypoid gear. Typically found in automotive applications, gearmotor businesses have begun integrating hypoid gearing into right-position gearmotors to solve the issues that arise with worm reducers. Available in smaller general sizes and higher reduction potential, hypoid gearmotors possess a broader range of feasible uses than their worm counterparts. This not only allows heavier Gearbox Worm Drive torque loads to be transferred at higher efﬁciencies, nonetheless it opens possibilities for applications where space is 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 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 arranged 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 instance, in a worm gearbox with a 5:1 ratio, the worm will full ﬁve revolutions as the output worm equipment is only going to complete one. With an increased ratio, for instance 60:1, the worm will full 60 revolutions per one output revolution. It is this fundamental set up that triggers the inefﬁciencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only encounters sliding friction. There is absolutely no rolling component to the tooth contact (Figure 2).
In high reduction applications, such as for example 60:1, you will have a big amount of sliding friction due to the high number of input revolutions required to spin the output gear once. Low input quickness applications suffer from the same friction issue, but for a different cause. Since there is a large amount of tooth contact, the original energy to begin rotation is higher than that of a similar hypoid reducer. When driven at low speeds, the worm needs more energy to continue its motion along the worm gear, and a lot of that energy is dropped to friction.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets contain the input hypoid equipment, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear arranged is a hybrid of bevel and worm gear technologies. They experience friction losses because of the meshing of the apparatus teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth design that allows torque to end up being transferred smoothly and evenly over 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 primary problems posed by worm equipment sets is their lack of efﬁciency, chieﬂy in high reductions and low speeds. Standard efﬁciencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid gear sets are typically 95% to 99% efﬁcient (Figure 4).
Worm vs Hypoid Efficiency
In the case of worm gear sets, they don’t run at peak efﬁciency until a certain “break-in” period has occurred. Worms are usually made of steel, with the worm gear being made of bronze. Since bronze is a softer steel it is proficient at absorbing heavy shock loads but does not operate successfully until it has been work-hardened. The temperature generated from the friction of regular working conditions helps to harden the surface of the worm gear.
With hypoid gear sets, there is no “break-in” period; they are usually 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 when choosing a gearmotor. Since the majority of employ a long service lifestyle, choosing a high-efﬁciency reducer will minimize costs related to procedure and maintenance for years to arrive. Additionally, a more efﬁcient reducer allows for better reduction capacity and usage of a motor that
consumes less electrical energy. Solitary stage worm reducers are typically limited to 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 supplied by another type of gearing, such as for example helical.
Hypoid drives can have a higher upfront cost than worm drives. This can be attributed to the additional processing techniques necessary to produce hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives rather than oil which will incur higher costs. This price difference is composed for over the lifetime of the gearmotor due to increased performance and reduced maintenance.
An increased 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 heat. Since worm gears produce more friction they operate much hotter. In many cases, using a hypoid reducer eliminates the need for cooling ﬁns on the engine casing, further reducing maintenance costs that might be required to keep the ﬁns clean and dissipating high temperature properly. A evaluation of motor surface area 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 created 204 in-lb of torque. This difference in torque is due to the inefﬁciencies of the worm reducer. The motor surface temperature of both products began at 68°F, room temperature. After 100 moments of operating period, the temperature of both units began to level off, concluding the check. The difference in temperature at this time was considerable: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A difference of about 26.4°F. Despite getting powered by the same motor, the worm device not only produced much less torque, but also wasted more energy. Important thing, this can result in a much heftier electrical bill for worm users.
As previously stated and proven, worm reducers operate 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 oil changes are imminent due to 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 required: the cooling potential of grease is enough to guarantee the reducer will run effectively. This eliminates the necessity for breather holes and any mounting constraints posed by oil lubricated systems. Additionally it is not necessary to replace lubricant since the grease is intended to last the life time use of the gearmotor, eliminating downtime and increasing efficiency.
More Power in a Smaller Package
Smaller sized motors can be utilized in hypoid gearmotors due to the more efﬁcient transfer of energy through the gearbox. In some instances, a 1 horsepower electric motor driving a worm reducer can generate the same output as a comparable 1/2 horsepower engine 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 reduction ratio of both gearboxes to 60:1 and compared electric motor power and result torque as it linked to power drawn. The analysis figured a 1/2 HP hypoid gearmotor can be used to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical price. A ﬁnal result showing a assessment of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease 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 consider up more space than hypoid gears (Physique 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is much smaller sized than that of a similar worm gearmotor. This also helps make working environments safer since smaller sized gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors is definitely that they are symmetrical along their centerline (Figure 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equivalent power, hypoid drives far 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 (Body 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors over 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 results in both studies are obvious: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As shown throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to perform more efﬁciently, cooler, and offer higher reduction ratios when compared to worm reducers. As confirmed using the studies presented 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 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 much better option in space-constrained applications. As shown, the entire footprint and symmetric style of hypoid gearmotors makes for a more aesthetically pleasing style while enhancing workplace safety; with smaller, much less cumbersome gearmotors there is a smaller potential for interference with workers or machinery. Obviously, hypoid gearmotors are the best choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that enhance operational efﬁciencies and reduce maintenance needs and downtime. They offer premium efﬁciency units for long-term energy 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 acceleration unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality ﬁnish that assures regularly tough, water-tight, chemically resistant models that withstand harsh conditions. These gearmotors also have multiple regular 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
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 Swiftness 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 Outside and inside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers a very wide selection of worm gearboxes. Due to the modular design the typical programme comprises countless combinations when it comes to selection of equipment housings, installation 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 only use high quality components such as homes in cast iron, aluminum and stainless, worms in case hardened and polished metal and worm wheels in high-grade bronze of special alloys ensuring the optimum wearability. The seals of the worm gearbox are given with a dust lip which successfully 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 allow for reductions of up to 100:1 in one single step or 10.000:1 in a double decrease. An equivalent gearing with the same gear 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 special gearbox.
Maximum output torque
5:1 – 90:1
5:1 – 75:1
7:1 – 60:1
7:1 – 100:1
7:1 – 60:1
7:1 – 100:1
Other product benefits of worm gearboxes in the EP-Series:
Compact design is one of the key terms of the standard gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or unique gearboxes.
Our worm gearboxes and actuators are extremely quiet. This is because of the very clean working of the worm equipment combined with the use of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we take extra treatment of any sound which can be interpreted as a murmur from the gear. So the general noise level of our gearbox can be reduced to an absolute minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This frequently proves to be a decisive advantage producing the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox can be an angle gear. This is 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 gear house and is well suited for direct suspension for wheels, movable arms and other parts rather than needing to create a separate suspension.
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking impact, which in many situations can be used as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them perfect for a wide variety of solutions.
Ever-Power Worm Gear Reducer