Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient upon the gearing for high efficiency.
Powered by long-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 Right angle (HdR) series worm gearbox is due to how we double 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 spring loaded breather connect and come pre-stuffed 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 remedy for right-angle power transmitting for generations. Touted for their low-cost and robust building, worm reducers could be
found in nearly every industrial environment requiring this kind of transmission. Sadly, they are inefficient at slower speeds and Gearbox Worm Drive higher reductions, produce a lot of temperature, take up a lot of space, and require regular maintenance.
Fortunately, there can be an option to worm gear pieces: the hypoid gear. Typically found in auto applications, gearmotor businesses have begun integrating hypoid gearing into right-position gearmotors to solve the issues that arise with worm reducers. Available in smaller overall sizes and higher reduction potential, hypoid gearmotors have a broader selection of possible uses than their worm counterparts. This not merely allows heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens opportunities for applications where space can be 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 range of 1/50 to 3 horsepower, and in applications where speed and torque are controlled.
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 equipment (Figure 1). For example, 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 a higher ratio, for instance 60:1, the worm will complete 60 revolutions per one output revolution. It really is this fundamental set up 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 (Figure 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will see a sizable amount of sliding friction due to the lot of input revolutions necessary to spin the output equipment once. Low input quickness applications suffer from the same friction issue, but for a different cause. Since there is 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 continue its motion along the worm gear, 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 contain the input hypoid equipment, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm gear technologies. They experience friction losses due to 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 efficiently and evenly over the interfacing areas. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary complications posed by worm equipment sets is their insufficient efficiency, chiefly at high reductions and low speeds. Regular 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
“Break-In” Period
Regarding worm gear sets, they don't run at peak efficiency until a certain “break-in” period has occurred. Worms are typically made of steel, with the worm gear being made of bronze. Since bronze is certainly a softer metal it is proficient at absorbing large shock loads but will not operate effectively until it has been work-hardened. The warmth generated from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear models, there is no “break-in” period; they are typically made from metal which has already been carbonitride heat treated. This enables the drive to use 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 many employ a long service life, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for years to come. Additionally, a far more efficient reducer allows for better reduction capability and use of a motor that
consumes less electrical energy. Solitary stage worm reducers are usually limited to ratios of 5:1 to 60:1, while hypoid gears possess a decrease 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 a different type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives may have a higher upfront cost than worm drives. This can be attributed to the excess processing techniques necessary to create 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 that may incur higher costs. This cost difference is composed for over the lifetime of the gearmotor due to increased overall performance and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste less energy and maximize the energy becoming transferred from the engine to the driven shaft. Friction can be wasted energy that takes the form of high temperature. Since worm gears produce more friction they run much hotter. Oftentimes, using a hypoid reducer eliminates the necessity for cooling fins on the electric motor casing, further reducing maintenance costs that might be required to keep carefully the fins clean and dissipating high temperature properly. A assessment 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 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 motor surface area temperature of both units began at 68°F, space temperature. After 100 a few minutes of operating time, the temperature of both products started to level off, concluding the check. The difference in temperature at this time was significant: the worm device 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 driven by the same electric motor, the worm unit not only produced much less torque, but also wasted more energy. Bottom line, this can result in a much heftier electric costs for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This reduces the service life of these drives by placing extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these parts can fail, and essential oil changes are imminent due to lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance necessary to keep them running at peak performance. Essential oil lubrication is not needed: the cooling potential of grease will do to guarantee the reducer will operate effectively. This eliminates the necessity for breather holes and any mounting constraints posed by essential oil lubricated systems. It is also not necessary to replace lubricant since the grease is intended to last the life time use of the gearmotor, removing 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 motor driving a worm reducer can create the same result as a comparable 1/2 horsepower engine generating a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer had been compared for make use of 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 study concluded that 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 displaying a comparison of torque and power consumption 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 take up more space than hypoid gears (Figure 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized motor, the overall footprint of the hypoid gearmotor is much smaller sized than that of a similar worm gearmotor. This also makes working environments safer since smaller sized gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is usually they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and lead to 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 much 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 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 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 perform more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As tested using the studies offered throughout, hypoid gearmotors can handle higher initial 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 much better option in space-constrained applications. As demonstrated, the entire footprint and symmetric style of hypoid gearmotors produces a more aesthetically pleasing style while enhancing workplace safety; with smaller sized, much less cumbersome gearmotors there exists a smaller chance of interference with employees 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 increase operational efficiencies and reduce maintenance needs and downtime. They offer premium efficiency units for long-term energy financial savings. Besides being highly efficient, its hypoid/helical gearmotors are small in proportions and sealed forever. They are light, reliable, and offer high torque at low rate unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant systems that withstand harsh circumstances. These gearmotors also have multiple standard 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
Take 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 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 an extremely wide range of worm gearboxes. Due to the modular design the standard program comprises countless combinations when it comes to selection of gear housings, mounting and connection choices, 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 just use top quality components such as homes in cast iron, aluminum and stainless steel, worms in the event hardened and polished metal and worm tires in high-grade bronze of special alloys ensuring the the best possible wearability. The seals 
of the worm gearbox are given with a dust lip which successfully resists dust and drinking water. In addition, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes enable reductions as high as 100:1 in one step or 10.000:1 in a double decrease. An equivalent gearing with the same gear ratios and the same transferred power is definitely bigger when compared to a worm gearing. Meanwhile, the worm gearbox is usually in a far more simple design.
A double reduction could be composed of 2 regular gearboxes or as a special 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 advantages 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 can be achieved through the use of adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is because of the very simple working of the worm gear combined with the use of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we consider extra treatment of any sound that can be interpreted as a murmur from the apparatus. So the general noise degree of our gearbox is 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 become a decisive benefit producing the incorporation of the gearbox substantially 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 very firmly embedded in the gear house and is well suited for immediate suspension for wheels, movable arms and other areas rather than having to create a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes will provide a self-locking effect, 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 perfect for an array of solutions.
