Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient on the gearing for high efficiency.
Powered by long-enduring 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 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 spring loaded breather plug and come pre-stuffed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
Introduction
Worm reducers have been the go-to remedy for right-angle power transmitting for generations. Touted for their low-cost and robust building, worm reducers can be
found in almost every industrial establishing 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 alternative to worm 
gear sets: the hypoid gear. Typically used in automotive applications, gearmotor companies have begun integrating hypoid gearing into right-position gearmotors to solve the issues that occur with worm reducers. Obtainable in smaller general sizes and higher decrease potential, hypoid gearmotors have a broader range of possible uses than their worm counterparts. This not only enables heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens options for applications where space is a limiting factor. They can sometimes be costlier, however the savings in efficiency and maintenance are well worth it.
The following 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.
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 can be 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 finish five revolutions while the output worm equipment will only complete one. With an increased ratio, for instance 60:1, the worm will full 60 revolutions per one output revolution. It is this fundamental arrangement that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only encounters sliding friction. There is no rolling component to the tooth contact (Number 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will have a large amount of sliding friction due to the high number of input revolutions necessary to spin the output equipment once. Low input speed applications suffer from the same friction issue, but also for a different reason. Since there is a large amount of tooth contact, the original energy to begin 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 gear, and a lot of that energy is dropped to friction.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets consist of 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 equipment technologies. They encounter friction losses due to the meshing of the gear teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth pattern which allows torque to become transferred smoothly and evenly across the interfacing surfaces. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest complications posed by worm equipment sets is their insufficient 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 typically 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
In the case of worm gear sets, they don’t run at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of metal, with the worm equipment being manufactured from bronze. Since bronze is a softer metallic it is good at absorbing large shock loads but will not operate effectively until it has been work-hardened. The heat produced from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear sets, there is no “break-in” period; they are typically made from metal which has recently been carbonitride temperature treated. This enables the drive to use at peak efficiency from the moment it is installed.
Why is Efficiency Important?
Efficiency is one of the most important things to consider when choosing a gearmotor. Since most have a very long service existence, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for a long time to come. Additionally, a more efficient reducer permits better reduction capacity and utilization 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 decrease 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 supplied by another type of gearing, such as helical.
Minimizing Costs
Hypoid drives may have a higher upfront cost than worm drives. This is often attributed to the additional processing techniques required to generate hypoid gearing such as for example machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically make use of grease with severe pressure additives rather than oil that may incur higher costs. This price difference is made up for over the lifetime of the gearmotor due to increased overall performance and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste less energy and maximize the energy becoming transferred from the engine to the driven shaft. Friction is definitely wasted energy that requires the form of warmth. Since worm gears create more friction they run much hotter. In many cases, using a hypoid reducer eliminates the need for cooling fins on the electric motor casing, additional 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 are available in Figure 5.
In testing the two gearmotors had equally sized motors and carried the same load; the worm gearmotor Gearbox Worm Drive created 133 in-lb of torque while the hypoid gearmotor created 204 in-lb of torque. This difference in torque is because of the inefficiencies of the worm reducer. The electric motor surface area temperature of both models began at 68°F, space temperature. After 100 moments of operating time, the temperature of both products started to level off, concluding the test. The difference in temperature at this stage was significant: 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 getting run by the same engine, the worm device not only produced much less torque, but also wasted more energy. Important thing, this can lead to a much heftier electrical 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 putting extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these parts 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 running at peak performance. Oil lubrication is not required: the cooling potential of grease is enough to guarantee 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 meant to last the lifetime usage of the gearmotor, eliminating downtime and increasing productivity.
More Power in a Smaller 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 generating a worm reducer can produce the same output as a comparable 1/2 horsepower motor driving a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer had been compared for use on an equivalent application. This study fixed the decrease ratio of both gearboxes to 60:1 and compared motor power and output torque as it related to power drawn. The study 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 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 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 (Figure 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the overall footprint of the hypoid gearmotor is much smaller sized than that of a comparable worm gearmotor. This also helps make working conditions safer since smaller sized gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is usually that they are symmetrical along their centerline (Number 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 much outperform their worm counterparts. One essential requirement to consider is certainly that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Determine 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 shown throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to run more efficiently, cooler, and provide higher reduction ratios in comparison with worm reducers. As proven using the studies provided throughout, hypoid gearmotors are designed for higher initial inertia loads and transfer more torque with a smaller motor when compared to 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 much better option in space-constrained applications. As shown, the overall footprint and symmetric design of hypoid gearmotors makes for a far more aesthetically pleasing style while improving workplace safety; with smaller sized, much less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Obviously, hypoid gearmotors are the best choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that boost operational efficiencies and reduce maintenance requirements and downtime. They provide premium efficiency systems for long-term energy savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, reliable, and offer 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 products that withstand harsh conditions. 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
Notice: The helical spur gear attaches to 4.7 mm D-shaft diameter. The worm gear attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Rate 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 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 variety of worm gearboxes. Because of the modular design the standard programme comprises countless combinations with regards to selection of equipment housings, mounting 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 just use top quality components such as houses in cast iron, aluminum and stainless, worms in case hardened and polished steel and worm tires in high-grade bronze of unique alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dirt lip which efficiently resists dust and drinking water. In addition, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in a single step
As default the worm gearboxes allow for reductions as high as 100:1 in one single step or 10.000:1 in a double reduction. An equivalent gearing with the same gear ratios and the same transferred power is definitely bigger when compared to a worm gearing. Meanwhile, the worm gearbox is in a more simple design.
A double reduction could be composed of 2 standard gearboxes or as a particular 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 by using adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is because of the very even working of the worm equipment combined with the use of cast iron and high precision on element manufacturing and assembly. In connection with our precision gearboxes, we consider extra care of any sound which can be interpreted as a murmur from the apparatus. Therefore the general noise degree of our gearbox is usually reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This often proves to become a decisive benefit making the incorporation of the gearbox significantly simpler and smaller sized.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 well suited for direct suspension for wheels, movable arms and other parts rather than needing to create a separate suspension.
Self locking
For larger equipment 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 well suited for an array of solutions.
