Audible noise is evidence to investigate, but fault location depends on whether the sound tracks speed, torque or the machine structure.
Helical Gearbox Noise Diagnosis by Speed and Load
read more
EP-S57 Helical-Worm Gear Reducer
The EP-S57 is a 2 (1 helical + 1 worm) helical-worm gear reducer with right-angle output, delivering up to 450 N·m from 0.12–3.0 kW across gear ratios 8.74–196.11. Available in foot-mount (S), flange-mount (SF), hollow-bore (SA), flange+hollow (SAF), and torque-arm (SAT) configurations — quieter and more efficient than conventional worm reducers.
MOQ: flexible. Minimum order value USD 1,500; mixed orders and trial quantities welcome.
Product Overview — EP-S57 Helical-Worm Gear Reducer
The EP-S57 helical-worm gear reducer occupies the mid-range of the S-series, targeting the continuous-duty production drives common in food, dairy, packaging, and agricultural machinery. With 0.12–3.0 kW motor power input, up to 450 N·m output torque, and ratios spanning 8.74–196.11, it provides the combination of compact right-angle form and high available ratio that makes helical-worm drives the dominant choice for moderate-torque process machinery.
The helical pre-stage is ground to DIN 7 quality, operating with contact ratios above 1.8 for smooth, progressive load transfer. The worm gear set uses a phosphor-bronze wheel on a hardened and ground steel worm, providing the tribological compatibility that ensures stable efficiency over thousands of operating hours. Oil bath lubrication sustains both gear sets without oil pumps or active lubrication systems, keeping the unit self-contained and maintenance-simple.
The EP-S57's hollow-bore SA and SAF variants are particularly valued in screw-conveyor and agitator drive applications where shaft-mounting eliminates the coupling and alignment procedure that foot-mounted units require. Learn more about the S-series and our other product families on the Ever Power about page.
Technical Specifications — EP-S57
| Parameter | Specification |
|---|---|
| Gear Type | Helical pre-stage + worm gear set (right-angle output) |
| Number of Stages | 2 (1 helical + 1 worm) |
| Motor Power Range | 0.12–3.0 kW |
| Max Output Torque | 450 N·m |
| Gear Ratio Range | 8.74–196.11 |
| Output Speed Range | 7–161 rpm |
| Approximate Unit Weight | 14–22 kg |
| Max Output Radial Load | 5,500 N |
| Overall Efficiency | 75–82% (vs 55–65% for equivalent single-stage worm) |
| Lubrication | Oil bath; ISO VG 220 synthetic-blend worm gear oil (factory fill) |
| Housing Material | Close-grained cast iron (HT250) |
| Worm Shaft Material | 20CrMnTi alloy steel, case-hardened HRC 58–62, profile ground Ra ≤ 0.4 µm |
| Worm Wheel Material | Centrifugally cast phosphor-bronze (ZCuSn10P1) |
| Helical Stage Material | 20CrMnTi alloy steel, case-hardened, precision ground DIN 6 |
| Protection Rating | IP55 standard; IP65 optional |
| Ambient Temperature | −25 °C to +40 °C (standard lubricant) |
| Noise Level | ≤ 68 dB(A) at rated load (1 m, free-field) |
| Standards Compliance | ISO 14521 worm gear rating; ISO 281 bearing life; CE Machinery Directive |
Structural Types & Mounting Configurations — S57 Series
The S57 series is produced in five structural types plus an input-shaft-only SA-SZ variant. All share the same internal helical-worm gear train and achieve identical output torque and efficiency ratings. The structural type determines the mounting method and driven-machine interface.
| Type Code | Description |
|---|---|
| S57 | foot-mounted, solid output shaft |
| SF57 | B5 flange-mounted, solid output shaft |
| SA57 | shaft-mounted, hollow output bore |
| SAF57 | B5 flange + hollow output bore |
| SAT57 | torque-arm, hollow output bore |
SF and SAF Mounting Positions
Flange-mounted SF57 and SAF57 variants support all six standard mounting positions. Oil fill level and breather plug position must be adjusted per mounting position — refer to the position-specific lubrication table in the installation manual.
SA and SAT Torque-Arm Mounting Positions
The SA57 shaft-mounted and SAT57 torque-arm variants mount directly onto the driven shaft, reacting torque through the torque arm rather than a baseplate. This eliminates shaft-to-shaft coupling alignment and is particularly suited to conveyor head drives and drum agitators.
Key Advantages of the EP-S57 Helical-Worm Reducer
Superior Efficiency vs. Worm-Only Drives
The helical input stage of the EP-S57 achieves ≥98% per-stage efficiency, contributing directly to the 75–82% overall efficiency of the complete unit — 15–25 percentage points above conventional single-stage worm reducers. In continuous-duty applications this margin translates to measurable energy cost reduction and lower operating heat, reducing cooling requirements and extending lubricant life.
Right-Angle Compact Form Factor
The S-series right-angle configuration delivers 450 N·m from a housing sized for 0.12–3.0 kW — a torque density comparable to much larger parallel-shaft units. The perpendicular input-to-output layout is inherently suited to machine geometries where the motor and driven shaft cannot share the same axis, eliminating additional bevel stages or chain-and-sprocket drives that add cost and maintenance.
Significantly Quieter Operation
By pre-reducing speed in the helical stage before it reaches the worm mesh, the EP-S57 reduces worm sliding velocity at any given overall ratio. Lower sliding velocity directly reduces worm-mesh friction noise, yielding typical noise levels 6–10 dB(A) below equivalent single-stage worm reducers — an advantage valued in food production halls, pharmaceutical facilities, and any environment with operator occupancy near the drive.
Wide High-Reduction Ratio Range
Ratios from 8.74 to 196.11 in a single housing are achievable with the EP-S57, covering applications from moderately fast conveyor drives at the lower end to very slow-rotation stirring and positioning drives at the upper end. This breadth eliminates the need to cascade multiple reducers in most applications, simplifying the drivetrain and reducing total installation length.
Multiple Structural Types
Five structural types — S, SF, SA, SAF, SAT — plus the SA-SZ input shaft variant address every practical machine interface without custom engineering. SA and SAF hollow-bore types allow direct shaft mounting, eliminating flexible couplings and their associated alignment requirements. The SAT torque-arm type simplifies drum and conveyor installations further by reacting torque through a single rubber-buffered arm rather than a rigid baseplate.
Long-Life Worm Gear Materials
The EP-S57 worm wheel is manufactured from centrifugally cast phosphor-bronze (ZCuSn10P1), chosen for its combination of high load capacity, low friction against hardened steel, and resistance to adhesive wear under boundary-lubrication conditions during start-up. The hardened and profile-ground worm shaft (Ra ≤ 0.4 µm) maintains an elastohydrodynamic oil film across the full operating speed range, extending tooth-surface life to typically 25,000–40,000 hours.
Structural Type Diagrams — S57 Series
Use the diagrams below to confirm the external geometry, mounting interface, and connection dimensions of each S57 structural type before finalising your machine design. Certified dimensional drawings in DXF and PDF are available on request.
S57 Foot-Mount, Solid Output Shaft
SF57 B5 Flange, Solid Output Shaft
SA57 Shaft-Mounted, Hollow Bore
SAF57 B5 Flange + Hollow Bore
SAT57 Torque-Arm, Hollow Bore
SA57-SZ Input Shaft Only
Industry Applications — Where the EP-S57 Excels
| Industry Sector | Typical Application |
|---|---|
| Bakery & Confectionery | Dough portioners, enrobing chain drives, and chocolate moulding carousel index drives. |
| Dairy Processing | Cream separator drives, cheese-vat agitators, and pasteuriser conveyor flights in hygienic environments. |
| Carton & Tray Forming | Carton-erecting head units, glue-fold press drives, and tray-former magazine feeds. |
| Agriculture | Seeder metering wheels, fertiliser spreader discs, and irrigation-reel auto-rewind units. |
Application Case Study: Chocolate Enrobing Belt
A confectionery manufacturer upgraded the drive on a 3-metre enrobing conveyor with an EP-S57 and stainless-fastener washdown pack. The unit ran continuously through three daily CIP wash cycles using 65 °C water and maintained oil-seal integrity after 22 months. Speed consistency improved from ±2.1% to ±0.4%, reducing chocolate overcoat weight variation and saving 1.8% of raw chocolate per annum.
Model Designation Guide — How to Order an EP-S57
Every element of the S-series order code defines a specific product attribute. The example below shows a 1.5 kW, torque-arm, hollow-bore unit in mounting position M1:
EP - S57 - SAT - Y - 2 - 1.5 - 4P - M1
| Code Element | Meaning |
|---|---|
| EP | Brand identifier — Ever Power |
| S57 | Series and frame size — S-series helical-worm |
| SAT | Structural type: torque-arm, hollow-bore output |
| Y | Motor type: Y-series IEC standard induction motor |
| 2 | Number of gear stages (helical + worm) |
| 1.5 | Motor rated power in kW |
| 4P | Motor pole count (1,450 rpm at 50 Hz) |
| M1 | Mounting position (1 of 6 standard positions) |
Frequently Asked Questions — EP-S57
EP-S57 — Where Hygiene and Performance Meet
Food, dairy, and pharmaceutical production lines demand drives that perform reliably in washdown environments without contamination risk. The EP-S57 with food-grade lubricant and stainless fasteners is used by leading European and North American food equipment OEMs. Contact our team to discuss your washdown-rating requirement, frame-agreement pricing, or OEM supply programme.
Blogs Updated
Coupling Alignment for Inline Helical Gearbox Installations
Flexible couplings accommodate limited relative movement, but poor shaft alignment still affects bearings and seals.
Helical Gearbox Oil Leak Diagnosis and Seal Protection
Oil observed on a housing may have traveled from a vent, joint or shaft seal; finding the first wet point is essential.