Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Low friction coefficient upon the gearing for high efficiency.
Powered by long-long lasting 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 Right angle (HdR) series worm gearbox is due to how we double up the bearings on the input shaft. HdR series reducers can be found 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 supplied with a brass spring loaded breather connect and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Worm reducers have been the go-to solution for right-angle power tranny for generations. Touted for his or her low-cost and robust building, worm reducers can be
found in nearly every industrial setting requiring this type of transmission. Regrettably, they are inefﬁcient at slower speeds and higher reductions, create a lot of warmth, 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-position gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller overall sizes and higher decrease potential, hypoid gearmotors possess a broader selection of feasible uses than their worm counterparts. This not only allows heavier torque loads to become transferred at higher efﬁciencies, but it opens possibilities for applications where space is definitely a limiting factor. They can sometimes be costlier, however the savings in efﬁciency and maintenance are well 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 arranged 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 complete ﬁve revolutions while the output worm gear will only complete one. With a higher ratio, for example 60:1, the worm will complete 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 equipment, the worm only experiences sliding friction. There is absolutely no rolling element of the tooth contact (Physique 2).
In high reduction applications, such as 60:1, there will be a huge amount of sliding friction because of the lot of input revolutions necessary to spin the output equipment once. Low input acceleration applications suffer from the same friction issue, but for a different reason. Since there is a large amount of tooth contact, the original energy to begin rotation is greater than that of a comparable hypoid reducer. When driven at low speeds, the worm requires more energy to continue its movement along the worm equipment, and a lot of that energy is dropped to friction.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
However, hypoid gear sets contain the input hypoid equipment, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm gear technologies. They experience friction losses because of the meshing of the apparatus teeth, with reduced sliding included. These losses are minimized using the hypoid tooth design which allows torque to become transferred easily and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest problems posed by worm gear sets is their lack of efﬁciency, chieﬂy in high reductions and low speeds. Usual efﬁciencies can vary 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
Regarding worm gear sets, they don’t run at peak efﬁciency until a certain “break-in” period has occurred. Worms are usually made of steel, with the worm gear being manufactured from bronze. Since bronze is usually a softer steel it is good at absorbing heavy shock loads but does not operate effectively until it’s been work-hardened. The high temperature 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 steel which has recently been carbonitride high temperature treated. This enables the drive to operate 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 the majority of have a very long service lifestyle, choosing a high-efﬁciency reducer will minimize 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 power. Solitary stage worm reducers are usually limited to 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 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 could be attributed to the additional processing techniques required to create hypoid gearing such as machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives instead of oil which will incur higher costs. This price difference is composed for over the duration of the gearmotor because of increased overall performance and reduced maintenance.
A higher efﬁciency hypoid reducer will ultimately waste less energy and maximize the energy being transferred from the electric motor to the driven shaft. Friction is wasted energy that takes the form of temperature. Since worm gears produce more friction they run much hotter. In many cases, using a hypoid reducer eliminates the need for cooling ﬁns on the motor casing, additional reducing maintenance costs that would be required to keep carefully the ﬁns clean and dissipating temperature properly. A comparison of motor surface 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 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 motor surface temperature of both units began at 68°F, space temperature. After 100 mins of operating period, the temperature of both devices started to level off, concluding the test. The difference in temperature at this stage was substantial: the worm device reached a surface temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A difference of about 26.4°F. Despite getting run by the same electric motor, the worm device not only produced much less torque, but also wasted more energy. Bottom line, this can result in a much heftier electric costs for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces 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 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. Essential oil lubrication is not required: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the need for breather holes and any installation constraints posed by oil lubricated systems. It is also not necessary to replace lubricant since the grease is intended to last the lifetime use of the gearmotor, removing 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 engine generating a worm reducer can generate 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 were compared for use on an equivalent program. This study ﬁxed the decrease ratio of both gearboxes to 60:1 and compared motor power and output torque as it linked to power drawn. The analysis figured 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 consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in motor size, comes the advantage to use these drives in more applications where space is a constraint. Due to the method the axes of the gears intersect, worm gears take 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 a lot smaller than that of a similar worm gearmotor. This also makes working environments safer since smaller gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors is certainly they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and lead to machines that aren’t as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same 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 relieve 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 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 obvious: 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 perform more efﬁciently, cooler, and offer higher reduction ratios when compared to worm reducers. As tested using the studies offered throughout, hypoid gearmotors can handle 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 an individual 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 proven, the entire footprint and symmetric design of hypoid gearmotors makes for a more aesthetically pleasing style while improving workplace safety; with smaller, less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Clearly, hypoid gearmotors are the best choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that enhance operational efﬁciencies and reduce maintenance needs and downtime. They offer premium efﬁciency devices for long-term energy cost savings. Besides being extremely efﬁcient, its hypoid/helical gearmotors are compact in size and sealed for life. They are light, reliable, and provide high torque at low swiftness 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 products that withstand harsh conditions. These gearmotors also have multiple standard speciﬁcations, options, and mounting positions to make sure compatibility.
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 a very wide selection of worm gearboxes. Because of the modular design the standard programme comprises countless combinations with regards to selection of gear housings, installation and connection options, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We only 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 particular alloys ensuring the optimum wearability. The seals of the worm gearbox are provided with a dust lip which efficiently resists dust and drinking water. In addition, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in a single step
As default the worm gearboxes enable reductions of up to 100:1 in one single 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 than a worm gearing. Gearbox Worm Drive Meanwhile, 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 standard gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or special gearboxes.
Our worm gearboxes and actuators are really quiet. This is due to the very simple working of the worm gear combined with the usage of cast iron and high precision on element manufacturing and assembly. In connection with our precision gearboxes, we take extra care of any sound which can be interpreted as a murmur from the gear. So the general noise level of our gearbox is reduced to a complete minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This frequently proves to be a decisive benefit making the incorporation of the gearbox significantly simpler and more compact.The worm gearbox can be an angle gear. This is often an advantage for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the gear house and is well suited for immediate suspension for wheels, movable arms and other areas rather than needing to create a separate suspension.
For larger gear ratios, Ever-Power worm gearboxes will provide a self-locking effect, which in lots of situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them perfect for an array of solutions.
Ever-Power Worm Gear Reducer