Gearbox Worm Drive Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Low friction coefficient upon 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 Correct 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 ranging from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather plug and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Worm reducers have 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 establishing requiring this type of transmission. Sadly, they are inefﬁcient at slower speeds and higher reductions, produce a lot of heat, take up a lot of space, and require regular maintenance.
Fortunately, there is an option to worm gear sets: 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 have a broader selection 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 options for applications where space can be a limiting factor. They can sometimes be costlier, however the cost 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 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 gear (Figure 1). For instance, 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 a higher ratio, for instance 60:1, the worm will finish 60 revolutions per one result revolution. It really is this fundamental arrangement that triggers the inefﬁciencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only experiences sliding friction. There is absolutely no rolling element of the tooth contact (Body 2).
In high reduction applications, such as for example 60:1, you will have a large amount of sliding friction because of the lot of input revolutions necessary to spin the output gear once. Low input speed applications have problems with the same friction issue, but for a different reason. Since there is a lot 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 gear, and lots of that energy is lost to friction.
Hypoid vs. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets consist of the input hypoid gear, 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 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 be transferred smoothly and evenly over the interfacing areas. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest complications 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 do not run at peak efﬁciency until a specific “break-in” period has occurred. Worms are typically made of metal, with the worm gear being manufactured from bronze. Since bronze is a softer metallic it is good at absorbing heavy shock loads but does not operate efficiently until it has been work-hardened. The temperature generated from the friction of regular operating conditions really helps to harden the top of worm gear.
With hypoid gear pieces, there is no “break-in” period; they are typically made from metal which has recently been carbonitride temperature treated. This allows the drive to operate at peak efﬁciency as soon as it is installed.
How come Efficiency Important?
Efﬁciency is one of the most important factors to consider whenever choosing a gearmotor. Since many employ a long service existence, 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 capability and utilization of a motor that
consumes less electrical power. Single 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 just go up to reduction ratios of 10:1, and the excess reduction is supplied by another type of gearing, such as helical.
Hypoid drives may have a higher upfront cost than worm drives. This can be attributed to the additional processing techniques necessary to create hypoid gearing such as machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with severe pressure additives rather than oil that may incur higher costs. This cost difference is composed for over the duration of the gearmotor due to increased efficiency and reduced maintenance.
A higher efﬁciency hypoid reducer will ultimately waste less energy and maximize the energy becoming transferred from the engine to the driven shaft. Friction is certainly wasted energy that requires the form of high temperature. Since worm gears generate more friction they operate 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 would be required to keep the ﬁns clean and dissipating heat properly. A evaluation 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 produced 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 engine surface area temperature of both devices 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 considerable: the worm device reached a surface area temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A notable difference of about 26.4°F. Despite getting driven by the same engine, the worm device not only produced much less torque, but also wasted more energy. Important thing, this can lead to a much heftier electrical expenses for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This reduces the service life of the drives by putting extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these components can fail, and essential oil changes are imminent due to lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance necessary to keep them operating at peak performance. Essential oil lubrication is not required: the cooling potential of grease will do to guarantee the reducer will run effectively. This eliminates the necessity for breather holes and any mounting constraints posed by oil lubricated systems. It is also not necessary to replace lubricant because the grease is intended to last the lifetime 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 transfer of energy through the gearbox. In some instances, a 1 horsepower engine driving a worm reducer can produce the same result as a comparable 1/2 horsepower electric motor 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 program. This study ﬁxed the decrease ratio of both gearboxes to 60:1 and compared engine 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 cost. A ﬁnal result showing a evaluation of torque and power intake 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. Due to the way the axes of the gears intersect, worm gears consider up more space than hypoid gears (Body 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the entire footprint of the hypoid gearmotor is much smaller than that of a similar worm gearmotor. This also makes working conditions safer since smaller sized gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors can be they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equal power, hypoid drives far outperform their worm counterparts. One important aspect to consider can be that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Determine 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 results in both research are clear: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As demonstrated throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to run more efﬁciently, cooler, and provide higher reduction ratios when compared to worm reducers. As confirmed 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 better option in space-constrained applications. As shown, the entire footprint and symmetric style of hypoid gearmotors produces a more aesthetically pleasing design while improving workplace safety; with smaller sized, 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 in comparison to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that increase operational efﬁciencies and reduce maintenance requirements and downtime. They offer premium efﬁciency products for long-term energy savings. Besides being extremely efﬁcient, its hypoid/helical gearmotors are compact in size and sealed for life. They are light, reliable, 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 consistently tough, water-limited, chemically resistant devices that withstand harsh circumstances. These gearmotors also have multiple standard speciﬁcations, options, and installation positions to make sure 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
Note: 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 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 Design 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 Metal 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 standard programme comprises countless combinations when it comes to selection of gear housings, installation and connection options, 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 top quality components such as houses in cast iron, light weight aluminum and stainless, worms in case hardened and polished steel and worm tires in high-grade bronze of special alloys ensuring the the best wearability. The seals of the worm gearbox are given with a dust lip which effectively 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 step or 10.000:1 in a double decrease. An comparative gearing with the same gear ratios and the same transferred power is definitely bigger than a worm gearing. At the same time, the worm gearbox is in a far more simple design.
A double reduction may be composed of 2 regular gearboxes or as a particular 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 advantages of worm gearboxes in the EP-Series:
Compact design is among the key phrases of the standard gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or particular gearboxes.
Our worm gearboxes and actuators are really quiet. This is due to the very clean running of the worm equipment combined with the use of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we take extra care of any sound that can be interpreted as a murmur from the apparatus. Therefore the general noise degree of our gearbox is definitely 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 making the incorporation of the gearbox considerably simpler and smaller sized.The worm gearbox can be 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 quite firmly embedded in the gear house and is well suited for immediate suspension for wheels, movable arms and other parts rather than needing to create a separate suspension.
For larger equipment ratios, Ever-Power worm gearboxes provides a self-locking impact, which in lots of situations can be utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for a wide variety of solutions.
Gearbox Worm Drive Ever-Power Worm Gear Reducer