Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient on the gearing for high efficiency.
Powered by long-long lasting 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 due to how we double 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are given 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 already been the go-to answer for right-angle power transmission for generations. Touted because of their low-cost and robust construction, worm reducers can be
found in nearly every industrial setting requiring this kind of transmission. Unfortunately, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a whole lot of space, and need regular maintenance.
Fortunately, there can be an alternative to worm gear models: the hypoid gear. Typically used in auto applications, gearmotor companies have begun integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller overall sizes and higher reduction potential, hypoid gearmotors have a broader selection of feasible uses than their worm counterparts. This not only allows heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens options for applications where space is definitely a limiting factor. They can sometimes be costlier, however the financial 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 established there are two components: the input worm, and the output worm gear. The worm is certainly 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 complete five revolutions as the output worm equipment is only going to complete one. With a higher ratio, for example 60:1, the worm will total 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 equipment, the worm only encounters sliding friction. There is no rolling component to the tooth contact (Body 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will see a huge amount of sliding friction due to the high number of input revolutions necessary to spin the output gear once. Low input rate applications suffer from the same friction issue, but also for a different reason. Since there exists a large amount 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 requires more energy to continue its motion along the worm equipment, 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 gear, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear set is a hybrid of bevel and worm gear 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 pattern which allows torque to be transferred easily and evenly over the interfacing areas. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest problems posed by worm gear sets is their lack of efficiency, chiefly at high reductions and low speeds. Typical efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid gear sets are typically 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
In the case of worm gear sets, they do not run at peak efficiency until a certain “break-in” period has occurred. Worms are typically made of metal, with the worm gear being made of bronze. Since bronze is certainly a softer steel it is good at absorbing weighty shock loads but will not operate effectively until it’s been work-hardened. The heat produced from the friction of regular working conditions helps to harden the surface of the worm gear.
With hypoid gear sets, there is no “break-in” period; they are typically made from steel which has recently been carbonitride heat treated. This enables the drive to use at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is among the most important factors to consider whenever choosing a gearmotor. Since many employ a long service life, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for a long time to come. Additionally, a far more efficient reducer permits better reduction capacity and usage of a motor that
consumes less electrical power. Solitary stage worm reducers are typically 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 only go up to reduction ratios of 10:1, and the excess reduction is provided by another type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This can be attributed to the excess processing techniques required to generate hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically make use of grease with extreme pressure additives rather than oil that may incur higher costs. This cost difference is made up for over the duration of the gearmotor due to 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 generate more friction they run much hotter. In many cases, using a hypoid reducer eliminates the necessity for cooling fins on the engine 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 both gearmotors had equally sized motors and carried the same load; the worm gearmotor produced 133 in-lb of torque as the hypoid gearmotor created 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The motor surface area temperature of both systems began at 68°F, space temperature. After 100 a few minutes of operating time, the temperature of both units started to level off, concluding the check. The difference in temperature at this stage was significant: the worm device reached a surface area temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A notable difference of about 26.4°F. Despite becoming run by the same electric motor, the worm device not only produced much less torque, but also wasted more energy. Important thing, this can result in a much heftier electric bill for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This decreases 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 elements can fail, and essential oil changes are imminent because of lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance required to keep them working at peak performance. Oil lubrication is not required: the cooling potential of grease will do to ensure the reducer will operate effectively. This eliminates the need for breather holes and any installation constraints posed by oil lubricated systems. Additionally it is not necessary to displace lubricant since the grease is meant to last the life time usage of the gearmotor, getting rid of downtime and increasing productivity.
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. Occasionally, a 1 horsepower motor driving a worm reducer can produce the same result as a comparable 1/2 horsepower engine driving a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer had been compared for use on an equivalent program. This study fixed the decrease ratio of both gearboxes to 60:1 and compared electric motor power and result torque as it linked to power drawn. The analysis figured a 1/2 HP hypoid gearmotor can be utilized to provide similar functionality to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result displaying a evaluation of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor size, comes the benefit to use these drives in more applications where space is a constraint. Due to the method the axes of the gears intersect, worm gears take up more space than hypoid gears (Determine 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized motor, the overall footprint of the hypoid gearmotor is a lot smaller sized than that of a comparable worm gearmotor. This also helps make working conditions safer since smaller sized gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is that they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equal power, hypoid drives considerably outperform their worm counterparts. One essential requirement to consider can be that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Physique 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 outcomes 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 provide higher reduction ratios in comparison with worm reducers. As proven using the studies offered 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 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 proven, the entire footprint and symmetric style of hypoid gearmotors produces a more aesthetically pleasing style while improving workplace safety; with smaller, less cumbersome gearmotors there is a smaller chance of interference with workers or machinery. Obviously, hypoid gearmotors are the best 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 units for long-term energy financial savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, reliable, and provide high torque at low speed unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-limited, chemically resistant models that withstand harsh conditions. These gearmotors also have multiple standard specifications, options, and mounting positions to make sure 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 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 Quickness 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 Gearbox Worm Drive Shafts
S45C Carbon Metal Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide variety of worm gearboxes. Because of the modular design the standard program comprises countless combinations with regards to selection of equipment 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 easy and well proven. We only use high quality components such as houses in cast iron, light weight aluminum and stainless steel, worms in case hardened and polished steel and worm wheels in high-grade bronze of special alloys ensuring the maximum wearability. The seals of the worm gearbox are provided with a dirt lip which efficiently resists dust and water. In addition, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes allow for reductions as high as 100:1 in one step or 10.000:1 in a double reduction. An comparative gearing with the same gear ratios and the same transferred power is bigger when compared to a worm gearing. In the meantime, the worm gearbox is certainly in a more simple design.
A double reduction may be composed of 2 standard 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 benefits of worm gearboxes in the EP-Series:
Compact design
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 unique gearboxes.
Low noise
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. Regarding the our precision gearboxes, we take extra treatment of any sound which can be interpreted as a murmur from the gear. So the general noise degree of our gearbox is certainly reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This often proves to be a decisive benefit producing the incorporation of the gearbox significantly simpler and smaller sized.The worm gearbox can be an angle gear. This is an advantage for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the gear house and is perfect for direct suspension for wheels, movable arms and other areas rather than needing to create a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking effect, which in many situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for an array of solutions.