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-long lasting worm gears.
Minimum speed fluctuation with low noise and low vibration.
Lightweight and compact relative to 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 which range from 5:1 to 60:1 with imperial center distances ranging from 1.33 to 3.25 inches. Also, our gearboxes are given a brass springtime loaded breather connect and come pre-filled 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 transmission for generations. Touted for his or her low-cost and robust structure, worm reducers could be
found in almost every industrial setting requiring this type of transmission. However, they are inefﬁcient at slower speeds and higher reductions, create a lot of warmth, take up a lot of space, and need regular maintenance.
Fortunately, there is an alternative to worm gear models: the hypoid gear. Typically used in auto applications, gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the issues that occur with worm reducers. Obtainable in smaller general sizes and higher reduction potential, hypoid gearmotors possess a broader selection of possible uses than their worm counterparts. This not merely enables heavier torque loads to end up being transferred at higher efﬁciencies, but it opens opportunities for applications where space is definitely a limiting factor. They can sometimes be costlier, but the financial savings in efﬁciency and maintenance are well worth it.
The following 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.
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 certainly a screw-like equipment, that rotates perpendicular to its corresponding worm equipment (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will total ﬁve revolutions while the output worm equipment will only complete one. With an increased ratio, for instance 60:1, the worm will finish 60 revolutions per one result revolution. It is this fundamental set up that triggers the inefﬁciencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only experiences sliding friction. There is no rolling element of the tooth contact (Determine 2).
In high reduction applications, such as 60:1, you will see a big amount of sliding friction because of the high number of input revolutions required to spin the output gear once. Low input rate applications have problems with the same friction problem, but also for a different reason. Since there exists a lot of tooth contact, the initial energy to begin rotation is greater than that of a similar hypoid reducer. When driven at low speeds, the worm requires 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 FAR MORE Cost Effective Right-Angle Reducer
However, 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 experience friction losses because of the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth design which allows torque to be transferred efficiently and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest complications posed by worm equipment sets is their lack of efﬁciency, chieﬂy in high reductions and low speeds. Common efﬁciencies may differ 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
In the case of worm gear sets, they do not run at peak efﬁciency until a particular “break-in” period has occurred. Worms are typically made of metal, with the worm gear being manufactured from bronze. Since bronze is certainly a softer steel it is good at absorbing heavy shock loads but does not operate successfully until it’s been work-hardened. The high temperature generated from the friction of regular operating conditions really helps to harden the top of worm gear.
With hypoid gear units, there is absolutely no “break-in” period; they are typically made from metal which has recently been carbonitride warmth treated. This enables the drive to use at peak efﬁciency as soon as it is installed.
How come Efficiency Important?
Efﬁciency is one of the most important factors to consider when choosing a gearmotor. Since many have a very long service life, choosing a high-efﬁciency reducer will minimize costs related to procedure and maintenance for a long time to come. Additionally, a far more efﬁcient reducer allows for better reduction capability 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 have a decrease 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 provided by another type of gearing, such as for example helical.
Hypoid drives can have a higher upfront cost than worm drives. This is often attributed to the additional processing techniques necessary to produce hypoid gearing such as machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with intense pressure additives instead of oil that will incur higher costs. This price difference is composed for over the lifetime of the gearmotor because of increased functionality and reduced maintenance.
A higher efﬁciency hypoid reducer will ultimately waste much less energy and maximize the energy being transferred from the electric motor to the driven shaft. Friction is wasted energy that takes the form of warmth. Since worm gears generate more friction they operate much hotter. Oftentimes, using a hypoid reducer eliminates the need for cooling ﬁns on the motor casing, further reducing maintenance costs that might be required to keep carefully 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 created 133 in-lb of torque while the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is due to the inefﬁciencies of the worm reducer. The electric motor surface area temperature of both Gearbox Worm Drive systems began at 68°F, area temperature. After 100 minutes of operating period, the temperature of both models began to level off, concluding the check. The difference in temperature at this stage was substantial: the worm device reached a surface area temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A notable difference around 26.4°F. Despite becoming run by the same electric motor, the worm unit not only produced less torque, but also wasted more energy. Important thing, this can result in a much heftier electrical bill for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This decreases 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 components can fail, and essential oil changes are imminent due to lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance required to keep them operating at peak performance. Essential oil lubrication is not needed: the cooling potential of grease is enough to ensure the reducer will run effectively. This eliminates the necessity for breather holes and any installation constraints posed by oil lubricated systems. It is also not necessary to displace lubricant because the grease is meant to last the life time utilization of the gearmotor, getting rid of downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller sized motors can be utilized in hypoid gearmotors because of the more efﬁcient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor driving a worm reducer can generate the same result as a comparable 1/2 horsepower motor generating a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer were compared for make use of on an equivalent software. This study ﬁxed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and output torque as it related to power drawn. The analysis concluded that a 1/2 HP hypoid gearmotor can be used to provide similar functionality to a 1 HP worm gearmotor, at a fraction of the electrical price. A ﬁnal result displaying a evaluation of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine 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 consider up more space than hypoid gears (Body 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is a lot smaller than that of a comparable worm gearmotor. This also makes working environments safer since smaller gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors can be that they are symmetrical along their centerline (Figure 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equal power, hypoid drives significantly outperform their worm counterparts. One important aspect to consider is usually that hypoid reducers can move loads from a lifeless stop with more relieve than worm reducers (Shape 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially 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 studies are obvious: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As demonstrated throughout, the advantages of hypoid reducers speak for themselves. Their style allows them to run more efﬁciently, cooler, and provide higher reduction ratios when compared to worm reducers. As proven using the studies shown throughout, hypoid gearmotors can handle higher preliminary inertia loads and transfer more torque with a smaller 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 demonstrated, the entire footprint and symmetric design of hypoid gearmotors makes for a more aesthetically pleasing style while improving workplace safety; with smaller sized, much less cumbersome gearmotors there is a smaller potential for interference with workers or machinery. Obviously, hypoid gearmotors are the most suitable choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that boost operational efﬁciencies and reduce maintenance requirements and downtime. They offer premium efﬁciency products for long-term energy financial savings. Besides being extremely efﬁcient, its hypoid/helical gearmotors are compact in size and sealed for life. They are light, dependable, and provide high torque at low quickness 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 systems that withstand harsh conditions. These gearmotors likewise have multiple standard speciﬁcations, options, and installation positions to make sure compatibility.
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
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 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 Used on Both Shaft Ends
Anti-Rust Primer Applied Outside and inside 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 variety of worm gearboxes. Because of the modular design the standard program comprises countless combinations when it comes to selection of gear housings, installation and connection options, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We just use top quality components such as houses in cast iron, aluminium and stainless steel, worms in case hardened and polished metal and worm wheels in high-grade bronze of unique alloys ensuring the optimum wearability. The seals of the worm gearbox are given with a dust lip which efficiently 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 single step or 10.000:1 in a double decrease. An equivalent gearing with the same equipment ratios and the same transferred power is certainly bigger than a worm gearing. At the same time, the worm gearbox can be in a more simple design.
A double reduction could 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 phrases of the typical gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or special gearboxes.
Our worm gearboxes and actuators are extremely quiet. This is because of the very even 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 consider extra care of any sound that can be interpreted as a murmur from the gear. Therefore the general noise degree of our gearbox is certainly reduced to a complete 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 significantly simpler and more compact.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 apparatus house and is perfect for direct suspension for wheels, movable arms and other areas rather than having to build a separate suspension.
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking impact, which in many situations can be utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them perfect for a wide selection of solutions.
Ever-Power Worm Gear Reducer