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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.
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 Correct angle (HdR) series worm gearbox is due to 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 supplied with a brass spring loaded breather connect and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More Cost Effective Right-Angle Reducer
Introduction
Worm reducers have already been the go-to answer for right-angle power tranny for generations. Touted for his or her low-cost and robust structure, worm reducers could be
found in almost every industrial environment requiring this type of transmission. However, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a lot of space, and need regular maintenance.
Fortunately, there is an option to worm gear sets: the hypoid gear. Typically used in automotive applications, gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the problems that arise with worm reducers. Available in smaller overall sizes and higher decrease potential, hypoid gearmotors possess 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 possibilities for applications where space is definitely a limiting factor. They can sometimes be costlier, however the financial savings in efficiency and maintenance are really worth it.
The next 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 arranged there are two components: the input worm, and the output worm gear. The worm is a screw-like equipment, that rotates perpendicular to its corresponding worm equipment (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will finish five revolutions as the output worm gear is only going to complete one. With an increased ratio, for example 60:1, the worm will total 60 revolutions per one output revolution. It really 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 component to the tooth contact (Number 2).
Sliding Friction
In high reduction applications, such as 60:1, you will see a sizable amount of sliding friction because of the high number of input revolutions necessary to spin the output gear once. Low input quickness applications suffer from the same friction problem, but for a different reason. Since there exists a large amount of tooth contact, the initial energy to start rotation is higher than that of a similar hypoid reducer. When powered at low speeds, the worm requires more energy to continue its movement along the worm gear, and a lot of that energy is dropped to friction.
Hypoid vs. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
However, hypoid gear sets contain the input hypoid equipment, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm equipment technologies. They experience friction losses because of the meshing of the apparatus teeth, with minimal sliding included. These losses are minimized using the hypoid tooth design that allows torque to be transferred easily 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 complications posed by worm gear sets is their lack of efficiency, chiefly in high reductions and low speeds. Usual 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
“Break-In” Period
In the case of worm gear sets, they don’t run at peak efficiency until a particular “break-in” period has occurred. Worms are typically made of metal, with the worm equipment being made of bronze. Since bronze is certainly a softer steel it is proficient at absorbing heavy shock loads but does not operate efficiently until it has been work-hardened. The warmth produced from the friction of regular operating conditions really helps to harden the surface of the worm gear.
With hypoid gear sets, there is no “break-in” period; they are typically made from metal which has already been carbonitride high temperature treated. This allows the drive to use at peak efficiency from the moment it is installed.
Why is Efficiency Important?
Efficiency is among the most important things to consider whenever choosing a gearmotor. Since most have a very long service life, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for a long time to arrive. Additionally, a far more efficient reducer permits better reduction capability and usage of a motor that
consumes less electrical power. Single stage worm reducers are typically 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 just go up to reduction ratios of 10:1, and the additional reduction is provided by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This is often attributed to the additional processing techniques required to produce hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically make use of 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 less energy and maximize the energy getting transferred from the motor to the driven shaft. Friction can be wasted energy that requires the form of high temperature. Since worm gears produce more friction they run much hotter. In many cases, utilizing a hypoid reducer eliminates the necessity for cooling fins on the electric motor casing, further reducing maintenance costs that would be required to keep carefully the fins clean and dissipating high temperature properly. A comparison 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 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 engine surface area temperature of both models began at 68°F, room temperature. After 100 moments of operating period, the temperature of both units began to level off, concluding the test. The difference in temperature at this time was considerable: the worm unit reached a surface area temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A notable difference of about 26.4°F. Despite becoming driven by the same engine, the worm unit not only produced much less torque, but also wasted more energy. Important thing, this can result in a much heftier electrical expenses for worm users.
As previously stated and proven, worm reducers operate much Gearbox Worm Drive hotter than equivalently rated hypoid reducers. This reduces the service life of these drives by placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these components can fail, and oil changes are imminent because of 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 needed: the cooling potential of grease is enough to guarantee the reducer will run effectively. This eliminates the necessity for breather holes and any installation constraints posed by oil lubricated systems. It is also not necessary to displace lubricant because the grease is intended to last the lifetime utilization of the gearmotor, removing downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller sized motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower motor traveling a worm reducer can generate the same result as a comparable 1/2 horsepower electric motor generating 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 electric motor power and result torque as it linked to power drawn. The study concluded that a 1/2 HP hypoid gearmotor can be used to provide similar performance to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a comparison of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in motor size, comes the benefit to use these drives in more applications where space is a constraint. Because of the method the axes of the gears intersect, worm gears take up more space than hypoid gears (Physique 7).
Worm vs Hypoid Axes
Coupled with the capability 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 helps make working conditions safer since smaller gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors can be that they are symmetrical along their centerline (Shape 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same power, hypoid drives significantly outperform their worm counterparts. One essential requirement to consider is that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Shape 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably 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 results in both studies are obvious: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As tested using the studies provided throughout, hypoid gearmotors can handle higher preliminary inertia loads and transfer more torque with a smaller sized 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 proven, the overall footprint and symmetric design of hypoid gearmotors makes for a far more aesthetically pleasing design while improving workplace safety; with smaller sized, less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Obviously, hypoid gearmotors will be the best choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that increase operational efficiencies and reduce maintenance requirements and downtime. They provide premium efficiency models for long-term energy financial savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in size and sealed for life. They are light, dependable, and offer high torque at low rate unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-restricted, chemically resistant units that withstand harsh conditions. These gearmotors also have multiple standard specifications, options, and installation positions to ensure 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
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 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 Style for OEM Replacement
Double Bearings Applied to Both Shaft Ends
Anti-Rust Primer Applied Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Steel Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers a very wide range of worm gearboxes. Because of the modular design the typical program comprises countless combinations with regards to selection of gear housings, installation and connection options, flanges, shaft designs, type of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We only use top quality components such as houses in cast iron, aluminum and stainless steel, worms in the event hardened and polished steel and worm wheels in high-grade bronze of unique alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dust lip which successfully resists dust and water. Furthermore, the gearboxes are greased forever 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. At the same time, the worm gearbox is definitely in a far more simple design.
A double reduction may be composed of 2 regular 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 advantages of worm gearboxes in the EP-Series:
Compact design
Compact design is one of the key words of the standard gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very soft working of the worm gear combined with the use of cast iron and high precision on component manufacturing and assembly. Regarding the 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 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 advantage making the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox is an angle gear. This is an advantage for incorporation into constructions.
Strong 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 parts rather than having to create a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide 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 ideal for a wide range of solutions.