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December 16, 2019

Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
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 Correct 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 plug and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have been the go-to solution for right-angle power transmitting for generations. Touted for his or her low-cost and robust construction, worm reducers could be
found in nearly every industrial setting requiring this type of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, produce a lot of heat, take up a lot of space, and need regular maintenance.
Fortunately, there is an alternative to worm gear pieces: the hypoid gear. Typically found in automotive applications, gearmotor businesses have started integrating hypoid gearing into right-angle gearmotors to solve the issues that arise with worm reducers. Obtainable in smaller overall sizes and higher reduction potential, hypoid gearmotors have a broader range of possible uses than their worm counterparts. This not only allows heavier torque loads to end up being transferred at higher efficiencies, but it opens options for applications where space can be a limiting factor. They are able to 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 is certainly 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 full five revolutions as the output worm gear 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 really is this fundamental arrangement that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only encounters sliding friction. There is no rolling component to the tooth contact (Physique 2).
Sliding Friction
In high reduction applications, such as 60:1, you will see a big amount of sliding friction because of the high number of input revolutions necessary to spin the output equipment once. Low input acceleration applications suffer from the same friction issue, but also 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 needs more energy to continue its motion along the worm gear, and a lot of that energy is lost to friction.
Hypoid vs. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets consist of the input hypoid equipment, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear set is a hybrid of bevel and worm gear technologies. They encounter friction losses due to the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth design that allows torque to be transferred smoothly and evenly across the interfacing surfaces. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary problems posed by worm gear sets is their insufficient efficiency, chiefly in high reductions and low speeds. Regular efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment sets are usually 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 steel, with the worm equipment being manufactured from bronze. Since bronze can be a softer metallic it is good at absorbing weighty shock loads but does not operate successfully until it’s been work-hardened. The temperature generated from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are usually made from metal which has already been carbonitride high temperature treated. This allows the drive to operate at peak efficiency as soon as it is installed.
Why is 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 reduce costs related to operation and maintenance for a long time to come. Additionally, a far more efficient reducer allows for better reduction capability and use 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 have a reduction potential of 5:1 up to 120:1. Typically, hypoid gears themselves just go up to decrease 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 can be attributed to the excess processing techniques required to produce hypoid gearing such as machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with severe pressure additives rather than oil that will incur higher costs. This cost difference is composed for over the lifetime of the gearmotor due to increased functionality and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste much less energy and maximize the energy being transferred from the electric motor to the driven shaft. Friction is certainly wasted energy that takes the form of high temperature. Since worm gears generate more friction they run much hotter. In many cases, utilizing a hypoid reducer eliminates the need for cooling fins on the engine casing, additional reducing maintenance costs that would be required to keep 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 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 due to the inefficiencies of the worm reducer. The electric motor surface temperature of both units began at 68°F, space temperature. After 100 minutes of operating time, the temperature of both devices began to level off, concluding the check. The difference in temperature at this stage was substantial: the worm unit reached a surface temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A notable 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. Important thing, 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 putting extra thermal stress 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. Oil lubrication is not needed: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the need for breather holes and any mounting constraints posed by oil lubricated systems. It is also not necessary to displace lubricant because the grease is meant to last the life time use of the gearmotor, removing downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller motors can be utilized in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower motor traveling a worm reducer can produce the same output as a comparable 1/2 horsepower motor traveling a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer were compared for make use of on an equivalent app. This research 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 displaying a assessment of torque and power usage 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 way 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 much smaller sized than that of a comparable 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 can be that they are symmetrical along their centerline (Body 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 Form Comparison
In motors of the same power, hypoid drives significantly outperform their worm counterparts. One essential requirement to consider is definitely that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Body 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably more torque than worm gearmotors over 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 clear: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to run more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As proven using the studies offered throughout, hypoid gearmotors are designed for higher initial 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 better option in space-constrained applications. As shown, the overall footprint and symmetric design of hypoid gearmotors produces a more aesthetically pleasing style while enhancing workplace safety; with smaller, less cumbersome gearmotors there exists a smaller potential for interference with employees or machinery. Obviously, hypoid gearmotors will be the most suitable choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family of gearmotors that boost operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency products for long-term energy financial savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in size and sealed for life. They are light, dependable, and provide high torque at low acceleration unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant systems that Gearbox Worm Drive withstand harsh conditions. These gearmotors likewise have multiple regular 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
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 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 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 an extremely wide range 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 options, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We only use top quality components such as homes in cast iron, aluminum and stainless steel, worms in the event hardened and polished steel and worm wheels in high-grade bronze of special alloys ensuring the maximum wearability. The seals of the worm gearbox are provided with a dust lip which effectively resists dust and water. Furthermore, the gearboxes are greased forever with synthetic oil.
Large reduction 100:1 in a single step
As default the worm gearboxes allow for reductions as high as 100:1 in one step or 10.000:1 in a double decrease. An equivalent gearing with the same gear ratios and the same transferred power is certainly bigger than a worm gearing. In the mean time, the worm gearbox is definitely in a more simple design.
A double reduction could be composed of 2 regular 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 among the key words of the standard gearboxes of the EP-Series. Further optimisation may be accomplished by using adapted gearboxes or unique gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is due to the very easy operating 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 gear. Therefore the general noise level of our gearbox is 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 be a decisive advantage producing the incorporation of the gearbox significantly simpler and more compact.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 gear house and is perfect for direct suspension for wheels, movable arms and other parts rather than needing to create a separate suspension.
Self locking
For larger equipment 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 a wide range of solutions.