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-enduring 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 ranging from 1.33 to 3.25 inches. Also, our gearboxes are given a brass spring loaded breather connect and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to answer 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. Unfortunately, they are inefficient at slower speeds and higher reductions, create a lot of temperature, take up a whole lot of space, and require regular maintenance.
Fortunately, there is an option to worm gear units: the hypoid gear. Typically found in automotive applications, gearmotor businesses have started integrating hypoid gearing into right-angle gearmotors to solve the problems that arise with worm reducers. Obtainable in smaller general sizes and higher decrease potential, hypoid gearmotors possess a broader selection of feasible uses than their worm counterparts. This not only enables heavier torque loads to be transferred at higher efficiencies, nonetheless it opens options for applications where space can be a limiting factor. They are able to sometimes be costlier, however the cost savings in efficiency and maintenance are well 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 established there are two components: the input worm, and the output worm gear. The worm can be a screw-like gear, that rotates perpendicular to its corresponding worm equipment (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will comprehensive five revolutions while 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 really is this fundamental set up 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 (Shape 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will see a large amount of sliding friction because of the high number of input revolutions necessary to spin the output gear once. Low input rate applications suffer from the same friction issue, but also for a different cause. Since there is a lot 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 needs 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 More Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets contain the input hypoid equipment, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear arranged is a hybrid of bevel and worm equipment technologies. They encounter friction losses because of the meshing of the gear teeth, with minimal sliding included. These losses are minimized using the hypoid tooth pattern that allows torque to become transferred smoothly and evenly over the interfacing areas. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest problems posed by worm equipment sets is their lack of efficiency, chiefly in high reductions and low speeds. Normal efficiencies can vary 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
In the case of worm gear sets, they don’t run at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of steel, with the worm equipment being made of bronze. Since bronze is certainly a softer metallic it is good at absorbing large shock loads but does not operate efficiently until it has been work-hardened. The warmth produced from the friction of regular working conditions helps to harden the top of worm gear.
With hypoid gear units, there is absolutely no “break-in” period; they are typically made from metal which has already been carbonitride temperature treated. This allows the drive to use at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is among the most important factors to consider when choosing a gearmotor. Since the majority of have a very long service existence, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for years to arrive. Additionally, a more efficient reducer permits better reduction capability and utilization of a motor that
consumes less electrical power. Single stage worm reducers are usually limited to ratios of 5:1 to 60:1, while hypoid gears possess a decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the excess reduction is provided by another type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives may have a higher upfront cost than worm drives. This is often attributed to the excess processing techniques necessary to create hypoid gearing such as for example machining, heat therapy, and special grinding techniques. 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 efficiency and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste less energy and maximize the energy becoming transferred from the electric motor to the driven shaft. Friction can be wasted energy that requires the form of heat. Since worm gears create more friction they operate much hotter. Oftentimes, utilizing a hypoid reducer eliminates the need for cooling fins on the motor casing, additional reducing maintenance costs that might be required to keep the fins clean and dissipating temperature properly. A evaluation of motor surface temperature between worm and hypoid gearmotors are available in Figure 5.
In testing both gearmotors had equally sized motors and carried the same load; the worm gearmotor produced 133 in-lb of torque while the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is because of the inefficiencies of the worm reducer. The motor surface temperature of both devices began at 68°F, area temperature. After 100 moments of operating time, the temperature of both products began to level off, concluding the test. The difference in temperature at this point was significant: the worm unit reached a surface area temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A difference around 26.4°F. Despite becoming run by the same engine, 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 run much hotter than equivalently rated hypoid reducers. This decreases 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 elements can fail, and essential 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 installation constraints posed by essential oil lubricated systems. Additionally it is not necessary to replace lubricant because the grease is intended to last the lifetime use of the gearmotor, eliminating downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor generating a worm reducer can generate the same result as a comparable 1/2 horsepower engine traveling a hypoid reducer. In a single study by Nissei Corporation, both a worm and hypoid reducer had been compared for use on an equivalent program. This research fixed the decrease ratio of both gearboxes to 60:1 and compared engine power and output torque as it linked to power drawn. The study figured a 1/2 HP hypoid gearmotor can be utilized to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result displaying a evaluation of torque and power intake 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 consider up more space than hypoid gears (Determine 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized 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 sized gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is certainly that they are symmetrical along their centerline (Shape 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 Form Comparison
In motors of equivalent power, hypoid drives much outperform their worm counterparts. One important aspect to consider is definitely 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 over 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 shown throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to perform more efficiently, cooler, and offer higher reduction ratios in comparison with worm reducers. As confirmed 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 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 much better option in space-constrained applications. As shown, the entire footprint and symmetric style of hypoid gearmotors makes for a far more aesthetically pleasing design while improving workplace safety; with smaller, much less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Clearly, hypoid gearmotors will be 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 needs and downtime. They provide premium efficiency units for long-term energy financial savings. Besides being highly efficient, its hypoid/helical gearmotors are compact in proportions 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 regularly tough, water-tight, chemically resistant products that withstand harsh conditions. These gearmotors likewise 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 equipment attaches to 4.7 mm D-shaft diameter. The worm equipment attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Acceleration 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 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 an Gearbox Worm Drive extremely wide range of worm gearboxes. Due to the modular design the typical programme comprises countless combinations with regards to selection of gear housings, mounting and connection options, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We just use high quality components such as houses in cast iron, light weight aluminum and stainless steel, worms in case hardened and polished metal and worm tires in high-grade bronze of unique alloys ensuring the maximum wearability. The seals of the worm gearbox are given with a dust lip which efficiently resists dust and drinking water. In addition, 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 can be bigger than a worm gearing. In the meantime, the worm gearbox is definitely in a far more simple design.
A double reduction could 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 benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key phrases of the typical gearboxes of the EP-Series. Further optimisation may be accomplished by using adapted gearboxes or special gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is because of the very clean operating of the worm equipment combined with the usage of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we take extra care of any sound that can be interpreted as a murmur from the apparatus. So the general noise level of our gearbox is definitely reduced to a complete 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 advantage making the incorporation of the gearbox considerably simpler and smaller sized.The worm gearbox is an angle gear. This is an edge for incorporation into constructions.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the apparatus house and is perfect for direct suspension for wheels, movable arms and other areas rather than needing to create a separate suspension.
Self locking
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 security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for a wide range of solutions.