Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Low friction coefficient on the gearing for high efficiency.
Powered by long-enduring 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 Right angle (HdR) series worm gearbox is because of how we dual 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather connect and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
Worm reducers have already been the go-to alternative for right-angle power tranny for generations. Touted because of their low-cost and robust construction, worm reducers can be
found in nearly every industrial environment requiring this kind of transmission. However, they are inefﬁcient at slower speeds and higher reductions, create a lot of high temperature, take up a lot of space, and require regular maintenance.
Fortunately, there can be an alternative to worm gear units: the hypoid gear. Typically used in auto applications, gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the problems that arise with worm reducers. Available in smaller general sizes and higher decrease potential, hypoid gearmotors possess a broader range of feasible uses than their worm counterparts. This not merely enables heavier torque loads to end up being transferred at higher efﬁciencies, nonetheless it opens opportunities for applications where space is usually a limiting factor. They can sometimes be costlier, however the financial savings in efﬁciency and maintenance are well 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 set 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 instance, in a worm gearbox with a 5:1 ratio, the worm will finish ﬁve revolutions while the output worm equipment will only complete one. With an increased ratio, for instance 60:1, the worm will complete 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 experiences sliding friction. There is no rolling element of the tooth contact (Number 2).
In high reduction applications, such as 60:1, there will be a sizable amount of sliding friction because of the high number of input revolutions required to spin the output gear once. Low input quickness applications have problems with the same friction issue, but also for a different cause. Since there exists a large amount of tooth contact, the original energy to start rotation is greater than that of a similar hypoid reducer. When powered at low speeds, the worm needs more energy to keep its movement along the worm gear, and lots of that energy is lost to friction.
Hypoid vs. Worm Gears: A FAR MORE AFFORDABLE 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 set is a hybrid of bevel and worm equipment technologies. They encounter friction losses because of the meshing of the apparatus teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth design which allows torque to become transferred smoothly and evenly over the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Performance Actually Differ?
One of the primary problems posed by worm gear sets is their lack of efﬁciency, chieﬂy at high reductions and low speeds. Standard 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
Regarding worm gear sets, they don’t run at peak efﬁciency until a particular “break-in” period has occurred. Worms are usually made of steel, with the worm equipment being made of bronze. Since bronze is definitely a softer metal it is good at absorbing weighty shock loads but will not operate efficiently until it has been work-hardened. The heat generated from the friction of regular operating conditions helps to harden the top of worm gear.
With hypoid gear pieces, there is absolutely no “break-in” period; they are typically made from steel which has recently been carbonitride heat treated. This allows the drive to operate at peak efﬁciency from the moment it is installed.
Why is Efficiency Important?
Efﬁciency is one of the most important things to consider when choosing a gearmotor. Since most have a very long service existence, choosing a high-efﬁciency reducer will minimize costs related to operation 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 power. Solitary stage worm reducers are usually limited to 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 just go up to decrease ratios of 10:1, and the additional reduction is provided by another type of gearing, such as helical.
Hypoid drives can have a higher upfront cost than worm drives. This could be attributed to the additional processing techniques necessary to generate hypoid gearing such as for example machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with severe pressure additives instead of oil that will incur higher costs. This price difference is composed for over the duration of the gearmotor because of increased performance and reduced maintenance.
An increased efﬁciency hypoid reducer will eventually waste much less energy and maximize the energy becoming transferred from the motor to the driven shaft. Friction is definitely wasted energy that takes the form of warmth. Since worm gears create more friction they run much hotter. In many cases, using a hypoid reducer eliminates the necessity for cooling ﬁns on the motor casing, further reducing maintenance costs that would be required to keep the ﬁns clean and dissipating warmth properly. A comparison of motor surface area 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 produced 204 in-lb of torque. This difference in torque is because of the inefﬁciencies of the worm reducer. The motor surface temperature of both products began at 68°F, area temperature. After 100 minutes of operating time, the temperature of both models started to level off, concluding the check. The difference in temperature at this stage was significant: the worm unit reached a surface temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A difference around 26.4°F. Despite being run by the same engine, the worm device not only produced much less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical costs for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of the drives by placing extra thermal pressure on the lubrication, bearings, seals, and gears. After Gearbox Worm Drive long-term contact with high heat, these parts can fail, and oil changes are imminent because of lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance necessary to keep them working at peak performance. Oil lubrication is not required: the cooling potential of grease will do to guarantee the reducer will operate effectively. This eliminates the necessity for breather holes and any installation constraints posed by essential oil lubricated systems. It is also not necessary to replace lubricant since the grease is meant to last the lifetime utilization of the gearmotor, getting rid of downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller sized motors can be used in hypoid gearmotors due to the more efﬁcient transfer of energy through the gearbox. In some instances, a 1 horsepower electric motor traveling a worm reducer can create the same output as a comparable 1/2 horsepower engine generating a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer had been compared for make use of on an equivalent software. This study ﬁxed the decrease ratio of both gearboxes to 60:1 and compared electric motor power and output torque as it linked to power drawn. The study 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 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 advantage 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 (Figure 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 than that of a comparable worm gearmotor. This also makes working conditions safer since smaller gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors is certainly that they are symmetrical along their centerline (Physique 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equivalent power, hypoid drives significantly outperform their worm counterparts. One essential requirement to consider is certainly that hypoid reducers can move loads from a dead stop with more relieve 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 results in both research are clear: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As proven throughout, the benefits 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 proven using the studies provided throughout, hypoid gearmotors are designed for 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 purchase 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 entire footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing style while enhancing workplace safety; with smaller, 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 benefits and reliability compared to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that boost operational efﬁciencies and reduce maintenance needs 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, dependable, and offer high torque at low speed unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality ﬁnish that assures consistently tough, water-tight, chemically resistant systems that withstand harsh circumstances. These gearmotors likewise have multiple standard speciﬁcations, options, and mounting positions to make sure compatibility.
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
Note: 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 Speed 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 Steel Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers a very wide range 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 options, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We only use top quality components such as homes in cast iron, aluminium and stainless steel, worms in case hardened and polished steel and worm wheels in high-grade bronze of particular alloys ensuring the optimum wearability. The seals of the worm gearbox are given with a dirt lip which successfully resists dust and drinking water. Furthermore, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in a single step
As default the worm gearboxes enable reductions as high as 100:1 in one single step or 10.000:1 in a double decrease. An comparative gearing with the same equipment ratios and the same transferred power is usually bigger when compared to a worm gearing. In the meantime, the worm gearbox is certainly in a far more simple design.
A double reduction may be composed of 2 standard 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 among the key words of the standard gearboxes of the EP-Series. Further optimisation can be achieved through the use of adapted gearboxes or special gearboxes.
Our worm gearboxes and actuators are extremely quiet. This is due to the very clean operating 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 that can be interpreted as a murmur from the apparatus. So the general noise level of our gearbox can be reduced to a complete minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This often proves to be a decisive benefit producing the incorporation of the gearbox significantly simpler and smaller sized.The worm gearbox is an angle gear. This is often an advantage 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 direct suspension for wheels, movable arms and other parts rather than needing to create a separate suspension.
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking impact, which in lots of situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for an array of solutions.
Ever-Power Worm Gear Reducer