Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Low friction coefficient on the gearing for high efficiency.
Powered by 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 because of how we dual up the bearings on the input shaft. HdR series reducers are available in speed ratios which range 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 plug and come pre-filled with Mobil SHC634 synthetic gear oil.
Gearbox Worm Drive hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
Worm reducers have been the go-to option for right-angle power tranny for generations. Touted for his or her low-cost and robust structure, worm reducers could be
found in nearly every industrial setting requiring this type of transmission. Sadly, they are inefﬁcient at slower speeds and higher reductions, create a lot of high temperature, take up a lot of space, and need regular maintenance.
Fortunately, there can be an option to worm gear units: the hypoid gear. Typically found in auto applications, gearmotor companies have started integrating hypoid gearing into right-position gearmotors to solve the problems that arise with worm reducers. Available in smaller general sizes and higher reduction potential, hypoid gearmotors have 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 usually a limiting factor. They are able to sometimes be costlier, but 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.
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 is usually a screw-like equipment, that rotates perpendicular to its corresponding worm equipment (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will full ﬁve revolutions while the output worm equipment is only going to complete one. With an increased ratio, for instance 60:1, the worm will full 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 encounters sliding friction. There is no rolling component to the tooth contact (Shape 2).
In high reduction applications, such as for example 60:1, there will be a huge amount of sliding friction because of the high number of input revolutions required to spin the output gear once. Low input velocity applications have problems with the same friction issue, but for a different reason. Since there is a lot of tooth contact, the original energy to start rotation is greater than that of a similar hypoid reducer. When driven at low speeds, the worm requires more energy to keep its movement along the worm equipment, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
However, hypoid gear sets consist of 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 because of the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth design that allows torque to become transferred smoothly and evenly over the interfacing areas. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary complications posed by worm gear sets is their insufficient efﬁciency, chieﬂy at high reductions and low speeds. Common efﬁciencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid gear sets are usually 95% to 99% efﬁcient (Figure 4).
Worm vs Hypoid Efficiency
In the case of worm gear sets, they don’t run at peak efﬁciency until a particular “break-in” period has occurred. Worms are usually made of metal, 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 generated from the friction of regular operating conditions helps to harden the top of worm gear.
With hypoid gear models, there is no “break-in” period; they are typically made from metal which has already been carbonitride warmth treated. This allows the drive to operate at peak efﬁciency as soon as it is installed.
Why is Efficiency Important?
Efﬁciency is one of the most important factors to consider when choosing a gearmotor. Since the majority of employ a long service lifestyle, choosing a high-efﬁciency reducer will minimize costs related to procedure and maintenance for a long time to arrive. Additionally, a more efﬁcient reducer allows for better reduction capacity and utilization of a motor that
consumes less electrical energy. Solitary stage worm reducers are typically limited by 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.
Hypoid drives may have an increased upfront cost than worm drives. This can be attributed to the additional processing techniques necessary to produce hypoid gearing such as machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with intense pressure additives instead of oil which will incur higher costs. This cost difference is made up for over the lifetime of the gearmotor due to increased performance and reduced maintenance.
A higher efﬁciency hypoid reducer will ultimately waste 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 warmth. Since worm gears create more friction they run much hotter. Oftentimes, using a hypoid reducer eliminates the necessity for cooling ﬁns on the motor casing, further reducing maintenance costs that might be required to keep carefully the ﬁns clean and dissipating temperature properly. A comparison of motor surface temperature between worm and hypoid gearmotors can be found 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 as 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 temperature of both systems began at 68°F, room temperature. After 100 minutes of operating time, the temperature of both systems began to level off, concluding the test. The difference in temperature at this time was considerable: the worm unit 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 becoming powered by the same motor, the worm device not only produced much less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical expenses for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This decreases the service life of these 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 operate cooler, there is little to no maintenance required to keep them operating at peak performance. Essential oil lubrication is not needed: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the necessity for breather holes and any installation constraints posed by essential oil lubricated systems. It is also not necessary to displace lubricant since the grease is intended to last the lifetime utilization of the gearmotor, getting rid of downtime and increasing productivity.
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 engine driving a worm reducer can produce 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 use on an equivalent software. This research ﬁxed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and result torque as it linked to power drawn. The study 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 price. A ﬁnal result displaying a assessment of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction 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 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 sized 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 certainly that they are symmetrical along their centerline (Figure 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equal power, hypoid drives much 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 (Body 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially 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 research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the advantages of hypoid reducers speak for themselves. Their style allows them to run more efﬁciently, cooler, and provide higher reduction ratios when compared to worm reducers. As verified using the studies shown 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 lead to 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 much better option in space-constrained applications. As shown, the entire footprint and symmetric style of hypoid gearmotors produces a more aesthetically pleasing style while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there exists a smaller chance of interference with workers or machinery. Obviously, hypoid gearmotors are the most suitable choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that enhance operational efﬁciencies and reduce maintenance requirements and downtime. They offer premium efﬁciency systems 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 quickness unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality ﬁnish that assures consistently tough, water-tight, chemically resistant products that withstand harsh circumstances. These gearmotors also have multiple standard speciﬁcations, options, and installation positions to ensure 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
Note: The helical spur equipment attaches to 4.7 mm D-shaft diameter. The worm gear attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Speed 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 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 a very wide selection of worm gearboxes. Because of the modular design the typical programme comprises countless combinations when it comes to selection of equipment housings, mounting and connection choices, flanges, shaft designs, kind of oil, surface treatments etc.
Sturdy and reliable
The look 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 tires in high-quality bronze of special alloys ensuring the ideal wearability. The seals of the worm gearbox are given with a dust lip which efficiently 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 equivalent gearing with the same gear ratios and the same transferred power is bigger than a worm gearing. At the same time, the worm gearbox is usually in a far 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 benefits of worm gearboxes in the EP-Series:
Compact design is among 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.
Our worm gearboxes and actuators are extremely quiet. This is because of the very simple operating of the worm gear combined with the use of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we take extra treatment of any sound that can be interpreted as a murmur from the gear. So the general noise level of our gearbox is certainly reduced to an absolute minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This often proves to become a decisive advantage making the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox is 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 perfect for direct suspension for wheels, movable arms and other parts rather than needing to create a separate suspension.
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking impact, which in many situations can be utilized as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for a wide range of solutions.
Gearbox Worm Drive
Ever-Power Worm Gear Reducer