Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low Gearbox Worm Drive 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 because of 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are given a brass springtime loaded breather plug and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have been the go-to remedy for right-angle power tranny for generations. Touted for his or her low-cost and robust building, worm reducers could be
found in almost every industrial setting requiring this kind of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, produce a lot of high temperature, take up a lot of space, and require regular maintenance.
Fortunately, there can be an option to worm gear units: the hypoid gear. Typically found in automotive applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Available in smaller general 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 possibilities for applications where space can be a limiting factor. They can 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 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 established there are two components: the input worm, and the output worm gear. The worm is a screw-like gear, that rotates perpendicular to its corresponding worm gear (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will comprehensive five revolutions as the output worm gear will only complete one. With a higher ratio, for instance 60:1, the worm will finish 60 revolutions per one result revolution. It really 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 component to the tooth contact (Physique 2).
Sliding Friction
In high reduction applications, such as 60:1, you will have a sizable amount of sliding friction because of the lot of input revolutions required to spin the output equipment 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 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 keep its motion along the worm gear, and lots of that energy is lost to friction.
Hypoid versus. 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 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 pattern that allows torque to end up being transferred smoothly and evenly across the interfacing surfaces. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest complications posed by worm gear sets is their lack of efficiency, chiefly in high reductions and low speeds. Standard efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment sets are usually 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
Regarding worm gear sets, they don’t operate at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of steel, with the worm equipment being manufactured from bronze. Since bronze is a softer steel it is proficient at absorbing large shock loads but does not operate successfully until it has been work-hardened. The warmth generated from the friction of regular working conditions helps to harden the surface of the worm gear.
With hypoid gear pieces, there is no “break-in” period; they are typically made from metal which has recently been carbonitride temperature treated. This enables the drive to operate at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is one of the most important things to consider when choosing a gearmotor. Since the majority of 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 more efficient reducer permits better reduction capability and utilization 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 have a reduction potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to decrease ratios of 10:1, and the additional reduction is supplied by another type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This could be attributed to the excess processing techniques necessary to produce hypoid gearing such as machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with extreme pressure additives instead of oil which will incur higher costs. This cost difference is made up for over the duration of the gearmotor due to increased performance 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 definitely wasted energy that takes the form of heat. Since worm gears create more friction they run much hotter. In many cases, using a hypoid reducer eliminates the necessity for cooling fins on the motor casing, further reducing maintenance costs that would be required to keep carefully the fins clean and dissipating warmth 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 produced 204 in-lb of torque. This difference in torque is because of the inefficiencies of the worm reducer. The motor surface temperature of both units began at 68°F, space temperature. After 100 moments of operating period, the temperature of both models started to level off, concluding the check. The difference in temperature at this stage 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 run by the same electric motor, the worm unit not only produced much less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical expenses for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This decreases the service life of the drives by putting extra thermal stress on the lubrication, bearings, seals, and gears. After long-term exposure to high heat, these elements can fail, and oil changes are imminent due to lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance necessary to keep them operating at peak performance. Oil lubrication is not needed: the cooling potential of grease is enough to ensure the reducer will operate effectively. This eliminates the need 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 lifetime utilization of the gearmotor, removing downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller motors can be used in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine driving a worm reducer can create the same result as a comparable 1/2 horsepower engine traveling 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 output torque as it related to power drawn. The analysis concluded that a 1/2 HP hypoid gearmotor can be utilized to provide similar performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result showing a evaluation of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in motor size, comes the advantage to use these drives in more applications where space is a constraint. Due to 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 capability 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 helps make working environments safer since smaller gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is certainly they are symmetrical along their centerline (Determine 9). Worm gearmotors are asymmetrical and lead to 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 significantly outperform their worm counterparts. One essential requirement to consider is that hypoid reducers can move loads from a lifeless stop with more relieve than worm reducers (Body 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially 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 results in both research are clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As shown 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 proven using the studies provided 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 the user to buy 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 shown, the overall footprint and symmetric design of hypoid gearmotors produces a far more aesthetically pleasing design while improving workplace safety; with smaller sized, less cumbersome gearmotors there is a smaller potential for interference with workers or machinery. Obviously, hypoid gearmotors will be the most suitable choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that enhance operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency products for long-term energy savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in proportions and sealed for life. They are light, dependable, 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-tight, chemically resistant units that withstand harsh circumstances. These gearmotors also have multiple standard specifications, options, and installation positions to make sure compatibility.
Specifications
Material: 7005 aluminum equipment 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
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 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 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 selection of worm gearboxes. Because of the modular design the standard programme comprises countless combinations with regards to selection of gear housings, mounting and connection choices, 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 only use high quality components such as homes in cast iron, aluminum and stainless, worms in case hardened and polished metal and worm wheels in high-grade bronze of particular alloys ensuring the maximum wearability. The seals of the worm gearbox are given with a dust lip which effectively resists dust and water. In addition, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes enable reductions of up to 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 usually bigger than a worm gearing. Meanwhile, the worm gearbox is definitely in a more simple design.
A double reduction could 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 special gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very simple running 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 that can be interpreted as a murmur from the apparatus. So the general noise level of our gearbox is reduced to an absolute minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This frequently proves to be a decisive benefit producing the incorporation of the gearbox significantly 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 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 provides a self-locking impact, 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 perfect for a wide variety of solutions.