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-enduring 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 Right angle (HdR) series worm gearbox is because of how we double up the bearings on the input shaft. HdR series reducers are available in speed ratios ranging from 5:1 to 60:1 with imperial center distances which range from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather connect and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to remedy for right-angle power transmission for generations. Touted for their low-cost and robust construction, worm reducers could be
found in almost every industrial establishing requiring this type of transmission. However, they are inefficient at slower speeds and higher reductions, create a lot of temperature, take up a whole lot of space, and require regular maintenance.
Fortunately, there is an option to worm gear models: the hypoid gear. Typically found in automotive applications, gearmotor companies have started integrating hypoid gearing into right-position gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller general sizes and higher decrease potential, hypoid gearmotors have a broader selection of feasible uses than their worm counterparts. This not merely enables heavier torque loads to be transferred at higher efficiencies, but it opens options for applications where space is certainly a limiting factor. They can sometimes be costlier, but the cost savings in efficiency and maintenance are really worth it.
The next 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.
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 a screw-like equipment, that rotates perpendicular to its corresponding worm gear (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will comprehensive five revolutions while the output worm gear is only going to complete one. With an increased ratio, for instance 60:1, the worm will finish 60 revolutions per one output revolution. It is this fundamental set up that triggers 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 60:1, you will have a big amount of sliding friction because of the high number of input revolutions necessary to spin the output gear once. Low input quickness applications have problems with the same friction issue, but also for a different cause. Since there is a lot of tooth contact, the original energy to begin rotation is greater than that of a comparable hypoid reducer. When powered at low speeds, the worm requires more energy to keep its motion along the worm equipment, and lots of that energy is lost to friction.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
However, hypoid gear sets contain the input hypoid equipment, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear arranged is a hybrid of bevel and worm equipment technologies. They encounter friction losses because of the meshing of the gear teeth, with minimal sliding included. These losses are minimized using the hypoid tooth design that allows torque to become transferred easily and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical benefit 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 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
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 certainly a softer steel it is proficient at absorbing weighty shock loads but will not operate successfully until it has been work-hardened. The high temperature generated from the friction of regular operating conditions helps to harden the surface of the worm gear.
With hypoid gear models, there is absolutely no “break-in” period; they are typically made from steel which has already been carbonitride high temperature treated. This allows the drive to operate at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is one of the most important factors to consider whenever choosing a gearmotor. Since the majority of have a very long service lifestyle, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for a long time to arrive. Additionally, a far more efficient reducer permits better reduction capability and usage of a motor that
consumes less electrical energy. One stage worm reducers are usually limited by 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 just go up to reduction ratios of 10:1, and the additional reduction is provided by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This can be attributed to the additional processing techniques necessary to generate hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically use grease with severe pressure additives instead of oil that may incur higher costs. This cost difference is composed for over the duration of the gearmotor due to increased performance and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste less energy and maximize the energy being transferred from the engine to the driven shaft. Friction is certainly wasted energy that takes the form of temperature. Since worm gears create more friction they operate much hotter. Oftentimes, using a hypoid reducer eliminates the need for cooling fins on the engine casing, additional reducing maintenance costs that might be required to keep carefully the fins clean and dissipating warmth properly. A assessment of motor surface 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 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 motor surface temperature of both models began at 68°F, room 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 point was substantial: the worm unit reached a surface temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A notable difference of about 26.4°F. Despite being powered by the same engine, the worm unit not only produced less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electric bill for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces 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 operate cooler, there is little to no maintenance required to keep them running at peak performance. Oil lubrication is not needed: the cooling potential of grease is enough to guarantee the reducer will run effectively. This eliminates the necessity for breather holes and any installation constraints posed by essential oil lubricated systems. Additionally it is not necessary to replace lubricant because the grease is intended to last the life time use of the gearmotor, eliminating downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller sized motors can be used in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor generating a worm reducer can create the same result as a comparable 1/2 horsepower engine traveling a hypoid reducer. In a single study by Nissei Corporation, both a worm and hypoid reducer were compared for use on an equivalent app. This study fixed the reduction ratio of both gearboxes to 60:1 and compared engine power and result torque as it linked to power drawn. The study figured a 1/2 HP hypoid gearmotor can be used to provide similar performance to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result showing a assessment of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine size, comes the benefit 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 (Figure 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is much smaller sized than that of a similar 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 is definitely that they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equivalent power, hypoid drives far outperform their worm counterparts. One important aspect to consider can be that hypoid reducers can move loads from a lifeless stop with more relieve 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 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 outcomes in both research are clear: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As shown throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As confirmed using the studies shown throughout, hypoid gearmotors are designed for higher preliminary inertia loads and transfer more torque with a smaller motor than a comparable worm gearmotor.
This can result in upfront savings by allowing an individual to buy 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 design of hypoid gearmotors makes for a far 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. Obviously, hypoid gearmotors are the best 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 financial savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in proportions and sealed forever. They are light, dependable, and offer 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-tight, chemically resistant devices that withstand harsh circumstances. These gearmotors likewise have multiple standard specifications, options, and mounting positions to ensure compatibility.
Specifications
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 gear attaches to 4.7 mm D-shaft diameter. The worm equipment 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 Design for OEM Replacement
Double Bearings Applied to Both Shaft Ends
Anti-Rust Primer Applied Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Steel Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide selection of worm gearboxes. Because of the modular design the typical program comprises countless combinations with regards to selection of gear housings, installation and connection choices, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The look of the EP worm gearbox is easy and well proven. We only use top quality components such as houses in cast iron, aluminum and stainless steel, worms in the event hardened and polished steel and worm wheels in high-quality bronze of special alloys ensuring the ideal wearability. The seals of the worm gearbox are given with a dirt lip which successfully Gearbox Worm Drive resists dust and water. Furthermore, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in a single 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 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 in a 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 phrases of the typical gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or unique gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is because of the very simple operating of the worm equipment combined with the usage of cast iron and high precision on component manufacturing and assembly. Regarding the our precision gearboxes, we consider extra care of any sound that can be interpreted as a murmur from the gear. So the general noise level of our gearbox is usually 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 considerably simpler and more compact.The worm gearbox is an angle gear. This is often an edge 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 ideal for direct suspension for wheels, movable arms and other areas rather than having to build a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking effect, which in many situations can be used as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for a wide selection of solutions.
