Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
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 Correct angle (HdR) series worm gearbox is due to how we dual up the bearings on the input shaft. HdR series reducers can be found 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-loaded with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to solution for right-angle power transmitting for generations. Touted because of their low-cost and robust construction, worm reducers can be
found in nearly every industrial establishing requiring this kind of transmission. Sadly, 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 can be an alternative to worm gear models: the hypoid gear. Typically found in automotive applications, gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the problems that arise with worm reducers. Obtainable in smaller overall sizes and higher reduction potential, hypoid gearmotors possess a broader range of feasible uses than their worm counterparts. This not only allows heavier torque loads to become transferred at higher efficiencies, but it opens options for applications where space is a limiting factor. They are able to sometimes be costlier, but the cost savings in efficiency and maintenance are well worth it.
The following 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 usually a screw-like gear, that rotates perpendicular to its corresponding worm gear (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will total five revolutions as the output worm equipment is only going to complete one. With an increased ratio, for instance 60:1, the worm will comprehensive 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 component to the tooth contact (Determine 2).
Sliding Friction
In high reduction applications, such as 60:1, you will see a big amount of sliding friction due to the high number of input revolutions necessary to spin the output gear once. Low input velocity applications suffer from the same friction issue, but for a different cause. Since there exists a lot of tooth contact, the original energy to start rotation is greater than that of a comparable hypoid reducer. When powered 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 FAR MORE AFFORDABLE Right-Angle Reducer
However, hypoid gear sets contain the input hypoid gear, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm equipment technologies. They encounter friction losses due to the meshing of the gear teeth, with reduced sliding included. These losses are minimized using the hypoid tooth pattern that allows torque to be transferred easily and evenly over the interfacing surfaces. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary problems posed by worm gear sets is their lack of efficiency, chiefly in high reductions and low speeds. Typical 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
“Break-In” Period
Regarding worm gear sets, they do not operate at peak efficiency until a certain “break-in” period has occurred. Worms are typically made of metal, with the worm gear being made of bronze. Since bronze is certainly a softer metallic it is good at absorbing large shock loads but will not operate effectively until it’s been work-hardened. The warmth generated from the friction of regular working conditions helps to harden the top of worm gear.
With hypoid gear models, there is no “break-in” period; they are usually made from steel which has already been carbonitride high temperature treated. This allows the drive to use at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is among the most important factors to consider whenever choosing a gearmotor. Since most employ a long service lifestyle, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for a long time to come. Additionally, a far more efficient reducer allows for better reduction ability 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 have a reduction potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to decrease ratios of 10:1, and the excess reduction is supplied by a different type of gearing, such as for example 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 create 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 rather than oil that may incur higher costs. This price difference is composed for over the duration of the gearmotor due to increased efficiency and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste much less energy and maximize the energy becoming 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, using a hypoid reducer eliminates the necessity for cooling fins on the motor casing, additional reducing maintenance costs that would be required to keep carefully the fins clean and dissipating high temperature properly. A evaluation 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 created 133 in-lb of torque while the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The engine surface area temperature of both systems began at 68°F, room temperature. After 100 minutes of operating time, the temperature of both products started to level off, concluding the test. The difference in temperature at this point was significant: the worm unit reached a surface temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A notable difference around 26.4°F. Despite getting driven by the same electric motor, the worm device not only produced much less torque, but also wasted more energy. Important thing, this can result in a much heftier electrical costs 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 pressure on the lubrication, bearings, seals, and gears. After long-term exposure to high heat, these parts can fail, and essential oil changes are imminent because of lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance necessary to keep them working at peak performance. Oil lubrication is not required: the cooling potential of grease will do to guarantee the reducer will operate effectively. This eliminates the necessity for breather holes and any mounting constraints posed by oil lubricated systems. Additionally it is not necessary to replace lubricant since the grease is meant to last the life time use of the gearmotor, eliminating 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. Occasionally, a 1 horsepower motor traveling a worm reducer can create the same output as a comparable 1/2 horsepower electric motor driving a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer were compared for make use of on an equivalent application. This research fixed the reduction ratio of both gearboxes to 60:1 and compared engine power and output torque as it related to power drawn. The analysis figured a 1/2 HP hypoid gearmotor can be utilized to provide similar overall performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result showing a comparison of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor size, comes the benefit 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 a lot smaller than that of a similar worm gearmotor. This also helps make working environments safer since smaller gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is that they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equivalent power, hypoid drives considerably outperform their worm counterparts. One important aspect to consider is certainly that hypoid reducers can move loads from a dead stop with more relieve than worm reducers (Figure 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 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 proven throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As tested 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 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 proven, the entire footprint and symmetric design of hypoid gearmotors produces a far more aesthetically pleasing design while enhancing workplace safety; with smaller, less cumbersome gearmotors there is a smaller potential for interference with workers or machinery. Clearly, hypoid gearmotors are the best choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family of gearmotors that increase operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency devices for long-term energy financial savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, reliable, and provide high torque at low velocity unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-tight, chemically resistant systems that withstand harsh circumstances. These gearmotors also have multiple regular specifications, options, and mounting 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 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 Gearbox Worm Drive Applied to Both Shaft Ends
Anti-Rust Primer Applied Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Versions for 56C and 145TC Motors
Ever-Power A/S offers a very wide variety of worm gearboxes. Because of the modular design the standard program comprises countless combinations when it comes to selection of gear 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 simple and well proven. We only use high quality components such as homes in cast iron, light weight aluminum and stainless, worms in the event hardened and polished metal and worm wheels in high-grade bronze of unique alloys ensuring the optimum wearability. The seals of the worm gearbox are provided with a dust 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 allow for reductions of up to 100:1 in one single step or 10.000:1 in a double decrease. An comparative gearing with the same gear ratios and the same transferred power can be bigger when compared to a worm gearing. Meanwhile, the worm gearbox is certainly in a far more simple design.
A double reduction could 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 one of the key words of the typical gearboxes of the EP-Series. Further optimisation can be achieved through the use of adapted gearboxes or special gearboxes.
Low noise
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. In connection with our precision gearboxes, we consider extra care of any sound that can be interpreted as a murmur from the gear. So the general noise degree of our gearbox is certainly reduced to an absolute 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 considerably simpler and smaller sized.The worm gearbox is an angle gear. This is often an edge for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is quite firmly embedded in the apparatus house and is well suited for immediate suspension for wheels, movable arms and other areas rather than needing to create a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking impact, which in lots of 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 an array of solutions.
