Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
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 relative to its high load capacity.
The structural strength of our cast iron, Heavy-duty Right 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 ranging from 5:1 to 60:1 with imperial center distances ranging from 1.33 to 3.25 inches. Also, our gearboxes are given a brass spring loaded breather connect and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
Worm reducers have been the go-to solution for right-angle power tranny for generations. Touted because of their low-cost and robust structure, worm reducers can be
found in almost every industrial setting requiring this kind of transmission. Unfortunately, they are inefﬁcient at slower speeds and higher reductions, produce a lot of warmth, take up a whole lot of space, and require regular maintenance.
Fortunately, there is an alternative to worm gear pieces: the hypoid gear. Typically used in auto applications, gearmotor businesses have begun integrating hypoid gearing into right-position gearmotors to solve the problems that occur with worm reducers. Available in smaller general sizes and higher reduction potential, hypoid gearmotors have a broader range of possible uses than their worm counterparts. This not only enables heavier torque loads to be Gearbox Worm Drive transferred at higher efﬁciencies, nonetheless it opens options for applications where space is definitely a limiting factor. They are able to 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 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 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 instance, in a worm gearbox with a 5:1 ratio, the worm will comprehensive ﬁve revolutions as the output worm equipment will only complete one. With an increased ratio, for example 60:1, the worm will full 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 experiences sliding friction. There is no rolling component to the tooth contact (Number 2).
In high reduction applications, such as for example 60:1, you will see a sizable amount of sliding friction due to the high number of input revolutions necessary to spin the output gear once. Low input rate applications have problems with the same friction problem, but for a different cause. Since there exists a lot of tooth contact, the original energy to start rotation is higher than that of a similar hypoid reducer. When powered at low speeds, the worm requires more energy to keep its movement along the worm equipment, and a lot 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 gear, 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 be transferred efficiently and evenly across the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest problems posed by worm gear sets is their insufficient efﬁciency, chieﬂy in high reductions and low speeds. Normal efﬁciencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment sets are typically 95% to 99% efﬁcient (Figure 4).
Worm vs Hypoid Efficiency
Regarding worm gear sets, they don’t operate at peak efﬁciency until a particular “break-in” period has occurred. Worms are typically made of metal, with the worm equipment being manufactured from bronze. Since bronze is definitely a softer steel it is proficient at absorbing heavy shock loads but does not operate successfully until it’s been work-hardened. The high temperature produced from the friction of regular working conditions really 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 recently been carbonitride heat treated. This allows the drive to use at peak efﬁciency from the moment it is installed.
How come Efficiency Important?
Efﬁciency is one of the most important things to consider whenever choosing a gearmotor. Since many employ a long service existence, choosing a high-efﬁciency reducer will reduce costs related to procedure and maintenance for years to arrive. Additionally, a more efﬁcient reducer allows for better reduction capability and utilization of a motor that
consumes less electrical energy. One stage worm reducers are typically limited to ratios of 5:1 to 60:1, while hypoid gears have a decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the additional reduction is supplied by another type of gearing, such as helical.
Hypoid drives may have a higher upfront cost than worm drives. This can be attributed to the excess processing techniques necessary to generate hypoid gearing such as for example machining, heat therapy, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with extreme pressure additives instead of oil that may incur higher costs. This cost difference is composed for over the duration of the gearmotor because of increased overall performance and reduced maintenance.
An increased efﬁciency hypoid reducer will ultimately waste less energy and maximize the energy being transferred from the electric motor to the driven shaft. Friction is usually wasted energy that takes the form of high temperature. Since worm gears produce more friction they run much hotter. Oftentimes, utilizing a hypoid reducer eliminates the necessity for cooling ﬁns on the engine casing, additional reducing maintenance costs that would be required to keep carefully the ﬁns clean and dissipating high temperature properly. A assessment of motor surface area 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 as the hypoid gearmotor created 204 in-lb of torque. This difference in torque is because of the inefﬁciencies of the worm reducer. The motor surface temperature of both devices began at 68°F, area temperature. After 100 moments of operating period, the temperature of both devices started to level off, concluding the check. The difference in temperature at this point was considerable: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A difference around 26.4°F. Despite being run by the same electric motor, the worm device not only produced less torque, but also wasted more energy. Bottom line, this can result in a much heftier electric bill for worm users.
As previously stated and proven, worm reducers run 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 components 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 working at peak performance. Essential oil lubrication is not required: 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 oil lubricated systems. Additionally it is not necessary to replace lubricant because the grease is meant to last the life time usage of the gearmotor, getting rid of downtime and increasing efficiency.
More Power in a Smaller Package
Smaller sized 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 produce the same output as a comparable 1/2 horsepower engine traveling a hypoid reducer. In a single study by Nissei Corporation, both a worm and hypoid reducer had been compared for make use of on an equivalent program. This research ﬁxed the reduction ratio of both gearboxes to 60:1 and compared engine power and result torque as it linked to power drawn. The analysis concluded that a 1/2 HP hypoid gearmotor can be used to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical price. A ﬁnal result showing a evaluation of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor size, comes the advantage to use these drives in more applications where space is a constraint. Because of the method the axes of the gears intersect, worm gears consider up more space than hypoid gears (Number 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 than that of a comparable worm gearmotor. This also helps make working conditions safer since smaller sized gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors is usually that they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equivalent power, hypoid drives significantly outperform their worm counterparts. One important aspect to consider can be that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Number 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 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 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 verified using the studies provided 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 demonstrated, the overall footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing style while improving workplace safety; with smaller, less cumbersome gearmotors there exists a smaller potential for interference with employees or machinery. Obviously, hypoid gearmotors will be the best choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors provides a family of gearmotors that boost 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 small in size and sealed for life. 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 regularly tough, water-restricted, chemically resistant units that withstand harsh circumstances. These gearmotors likewise have multiple standard speciﬁcations, options, and mounting positions to make sure compatibility.
Material: 7005 aluminum gear 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
Take 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 Applied to Both Shaft Ends
Anti-Rust Primer Applied Outside and inside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide selection of worm gearboxes. Due to the modular design the typical programme comprises countless combinations when it comes to selection of gear housings, mounting and connection choices, flanges, shaft designs, kind of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We just use high 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 special alloys ensuring the maximum wearability. The seals of the worm gearbox are given with a dirt lip which successfully resists dust and drinking water. Furthermore, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in one 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 equipment ratios and the same transferred power is usually bigger when compared to a worm gearing. At the same time, the worm gearbox is in a more simple design.
A double reduction could be composed of 2 standard gearboxes or as a special gearbox.
Maximum output torque
5:1 – 90:1
5:1 – 75:1
7:1 – 60:1
7:1 – 100:1
7:1 – 60:1
7:1 – 100:1
Other product advantages of worm gearboxes in the EP-Series:
Compact design is one of the key words of the typical gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or unique gearboxes.
Our worm gearboxes and actuators are really quiet. This is due to the very soft working of the worm equipment combined with the use of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we take extra treatment of any sound which can be interpreted as a murmur from the apparatus. So the general noise level of our gearbox is definitely reduced to a complete minimum.
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 considerably simpler and more compact.The worm gearbox can be 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 very firmly embedded in the apparatus house and is ideal for direct suspension for wheels, movable arms and other areas rather than needing to build a separate suspension.
For larger gear ratios, Ever-Power worm gearboxes will provide a self-locking effect, which in many situations can be used as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for an array of solutions.
Gearbox Worm Drive
Ever-Power Worm Gear Reducer