Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient upon the gearing for high efficiency.
Powered by long-enduring worm gears.
Minimal 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 dual 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 given a brass springtime loaded breather plug and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
Introduction
Worm reducers have been the go-to answer for right-angle power tranny for generations. Touted for his or her low-cost and robust construction, worm reducers can be
found in almost every industrial setting requiring this type of transmission. Unfortunately, they are inefficient at slower speeds and Gearbox Worm Drive higher reductions, create a lot of heat, take up a whole lot of space, and need regular maintenance.
Fortunately, there is an alternative to worm gear models: the hypoid gear. Typically used in automotive applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that arise with worm reducers. Available in smaller general sizes and higher decrease potential, hypoid gearmotors have a broader selection of feasible uses than their worm counterparts. This not merely allows heavier torque loads to become transferred at higher efficiencies, nonetheless it opens options for applications where space is usually a limiting factor. They can sometimes be costlier, however the cost 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 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 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 arrangement that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only encounters sliding friction. There is absolutely no rolling element of the tooth contact (Shape 2).
Sliding Friction
In high reduction applications, such as 60:1, there will be a big amount of sliding friction because of the high number of input revolutions required to spin the output equipment once. Low input acceleration applications have problems with the same friction problem, but also for a different cause. Since there is a large amount of tooth contact, the original energy to begin rotation is greater than that of a similar hypoid reducer. When powered at low speeds, the worm needs more energy to continue its movement along the worm equipment, and a lot of that energy is lost to friction.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
However, hypoid gear sets consist of the input hypoid equipment, and the output hypoid bevel gear (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 apparatus teeth, with reduced sliding included. These losses are minimized using the hypoid tooth pattern that allows torque to be transferred smoothly and evenly across the interfacing surfaces. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest problems posed by worm equipment sets is their lack of efficiency, chiefly at high reductions and low speeds. Standard 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 operate 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 definitely a softer steel it is good at absorbing weighty shock loads but will not operate successfully until it’s been work-hardened. The high temperature produced from the friction of regular operating conditions really helps to harden the surface of the worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are usually made from steel which has recently been carbonitride high temperature treated. This allows the drive to operate at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is among the most important factors to consider when 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 more efficient reducer permits better reduction capacity and usage of a motor that
consumes less electrical power. Single stage worm reducers are usually limited by 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 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 an increased upfront cost than worm drives. This could be attributed to the additional processing techniques required to produce hypoid gearing such as machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically use grease with extreme pressure additives rather than oil which will incur higher costs. This price difference is made up for over the duration of the gearmotor because of increased performance and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste much less energy and maximize the energy being transferred from the motor to the driven shaft. Friction is usually wasted energy that takes the form of temperature. Since worm gears generate more friction they operate much hotter. In many cases, using a hypoid reducer eliminates the need for cooling fins on the engine casing, further reducing maintenance costs that would be required to keep the fins clean and dissipating warmth properly. A comparison of motor surface temperature between worm and hypoid gearmotors are available 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 while the hypoid gearmotor created 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The engine surface temperature of both products began at 68°F, room temperature. After 100 mins of operating time, the temperature of both models began to level off, concluding the check. The difference in temperature at this point was considerable: the worm unit reached a surface area temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A notable difference of about 26.4°F. Despite becoming run by the same engine, the worm device not only produced less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical bill for worm users.
As previously stated 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 components can fail, and 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. Oil lubrication is not required: the cooling potential of grease is enough to ensure the reducer will run 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 because the grease is meant to last the life time utilization of the gearmotor, eliminating downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower engine generating a worm reducer can produce the same result as a comparable 1/2 horsepower electric motor traveling a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer had been compared for use on an equivalent software. This study fixed the decrease ratio of both gearboxes to 60:1 and compared engine 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 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 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 (Shape 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the overall footprint of the hypoid gearmotor is a lot smaller sized than that of a similar worm gearmotor. This also makes working conditions safer since smaller gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is certainly that they are symmetrical along their centerline (Determine 9). Worm gearmotors are asymmetrical and lead to machines that aren’t as aesthetically 
satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of the same power, hypoid drives far outperform their worm counterparts. One essential requirement to consider can be 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 considerably more torque than worm gearmotors over a 30:1 ratio due to their higher efficiency (Figure 11).
Worm vs Hypoid Result 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 studies are clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As shown throughout, the advantages of hypoid reducers speak for themselves. Their style allows them to run more efficiently, cooler, and offer higher reduction ratios when compared to worm reducers. As confirmed using the studies provided throughout, hypoid gearmotors are designed for higher preliminary inertia loads and transfer more torque with a smaller sized motor when compared to a comparable worm gearmotor.
This can result in 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 better option in space-constrained applications. As shown, the overall footprint and symmetric design of hypoid gearmotors makes for a far more aesthetically pleasing design while improving workplace safety; with smaller, much 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 provides a family group of gearmotors that enhance operational efficiencies and reduce maintenance requirements and downtime. They provide premium efficiency products for long-term energy cost savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, dependable, and provide high torque at low quickness unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-limited, chemically resistant devices that withstand harsh conditions. These gearmotors likewise have multiple regular specifications, options, and mounting positions to make sure 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 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 Swiftness 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 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 programme comprises countless combinations with regards to selection of equipment housings, installation and connection options, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The look of the EP worm gearbox is simple 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-quality bronze of particular alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dust lip which efficiently resists dust and drinking water. Furthermore, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes allow for reductions of up to 100:1 in one single step or 10.000:1 in a double reduction. An comparative gearing with the same equipment 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 advantages of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key phrases of the standard 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 extremely quiet. This is due to the very clean operating of the worm gear combined with the use of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we take extra care of any sound which can be interpreted as a murmur from the gear. Therefore the general noise level of our gearbox can be 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 be a decisive advantage producing the incorporation of the gearbox considerably simpler and smaller sized.The worm gearbox is an angle gear. This is 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 perfect for immediate suspension for wheels, movable arms and other areas rather than needing to build a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking impact, 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 well suited for a wide selection of solutions.