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-enduring worm gears.
Minimum speed fluctuation with low noise and low vibration.
Lightweight and compact relative to its high load capacity.
The structural strength of our cast iron, Heavy-duty Correct angle (HdR) series worm gearbox is because of 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-loaded with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
Worm reducers have already been the go-to answer for right-angle power transmission for generations. Touted because of their low-cost and robust construction, worm reducers could be
found in nearly every industrial environment requiring this kind of transmission. However, they are inefﬁcient at slower speeds and higher reductions, produce a lot of temperature, take up a whole lot of space, and need 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-position gearmotors to solve the issues that arise with worm reducers. Available in smaller overall sizes and higher reduction potential, hypoid gearmotors have a broader range of possible uses than their worm counterparts. This not only enables heavier torque loads to end up being transferred at higher efﬁciencies, nonetheless it opens possibilities for applications where space is usually a limiting factor. They can sometimes be costlier, but the financial 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.
How do Worm Gears and Hypoid Gears Differ?
In a worm gear set 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 gear (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will finish ﬁve revolutions while the output worm gear will only complete one. With an increased ratio, for instance 60:1, the worm will comprehensive 60 revolutions per one result revolution. It is this fundamental arrangement that causes the inefﬁciencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only experiences sliding friction. There is absolutely no rolling component to the tooth contact (Physique 2).
In high reduction applications, such as 60:1, you will see a huge amount of sliding friction due to the high number of input revolutions necessary to spin the output equipment once. Low input swiftness applications have problems with the same friction problem, but also for a different cause. Since there exists a large amount of tooth contact, the initial energy to start rotation is greater than that of a similar hypoid reducer. When driven at low speeds, the worm needs more energy to keep its motion along the worm equipment, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets consist of the input hypoid gear, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear set is a hybrid of bevel and worm gear technologies. They encounter friction losses because of the meshing of the apparatus teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth pattern which allows torque to end up being transferred efficiently and evenly over the interfacing areas. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Performance Actually Differ?
One of the primary problems posed by worm equipment sets is their lack of efﬁciency, chieﬂy at high reductions and low speeds. Regular 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 steel, with the worm equipment being manufactured from 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 heat produced from the friction of regular working conditions really helps to harden the surface of the worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are usually made from steel which has already been carbonitride high temperature treated. This enables the drive to operate 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 many employ a long service existence, choosing a high-efﬁciency reducer will reduce costs related to procedure and maintenance for years to arrive. Additionally, a far more efﬁcient reducer permits better reduction capacity and usage of a motor that
consumes less electrical energy. Single stage worm reducers are usually limited to ratios of 5:1 to 60:1, while hypoid gears have a decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves just go up to reduction ratios of 10:1, and the excess reduction is supplied by a different type of gearing, such as helical.
Hypoid drives may have an increased upfront cost than worm drives. This is often attributed to the excess processing techniques required to produce hypoid gearing such as machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives instead of oil which will incur higher costs. This cost difference is composed for over the duration of the gearmotor due to increased functionality and reduced maintenance.
A higher efﬁciency hypoid reducer will ultimately waste less energy and maximize the energy becoming transferred from the motor to the driven shaft. Friction is definitely wasted energy that requires the form of high temperature. Since worm gears produce more friction they run much hotter. Oftentimes, utilizing a hypoid reducer eliminates the necessity for cooling ﬁns on the motor casing, further reducing maintenance costs that would be required to keep the ﬁns clean and dissipating temperature properly. A evaluation of motor surface area 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 while the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is because of the inefﬁciencies of the worm reducer. The electric motor surface area temperature of both devices began at 68°F, area temperature. After 100 mins of operating period, the temperature of both units began to level off, concluding the check. The difference in temperature at this time was significant: the worm device reached a surface temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A difference of about 26.4°F. Despite getting powered by the same engine, the worm unit not only produced less torque, but also wasted more energy. Important thing, this can lead to a much heftier electric 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 placing extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term exposure to 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 required to keep them working at peak performance. Oil lubrication is not needed: 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 essential oil lubricated systems. Additionally it is not necessary to Gearbox Worm Drive displace 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 sized motors can be utilized in hypoid gearmotors due to the more efﬁcient transfer of energy through the gearbox. In some instances, a 1 horsepower engine traveling a worm reducer can create the same output as a comparable 1/2 horsepower motor driving a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer had been compared for use on an equivalent software. This study ﬁxed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and output torque as it linked to power drawn. The analysis concluded that a 1/2 HP hypoid gearmotor can be used to provide similar efficiency to a 1 HP worm gearmotor, at a fraction of the electrical cost. A ﬁnal result showing a assessment of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine size, comes the advantage 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 (Body 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the overall footprint of the hypoid gearmotor is much smaller than that of a similar worm gearmotor. This also helps make working environments safer since smaller gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors is that they are symmetrical along their centerline (Body 9). Worm gearmotors are asymmetrical and lead to machines that aren’t as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equivalent power, hypoid drives significantly outperform their worm counterparts. One essential requirement to consider is usually that hypoid reducers can move loads from a dead stop with more relieve than worm reducers (Shape 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors over a 30:1 ratio because of 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 outcomes in both research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to run more efﬁciently, cooler, and provide higher reduction ratios when compared to worm reducers. As confirmed using the studies offered throughout, hypoid gearmotors are designed for higher preliminary inertia loads and transfer more torque with a smaller sized motor when compared to a comparable worm gearmotor.
This can lead to upfront savings by allowing the user to purchase 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 demonstrated, the entire footprint and symmetric style of hypoid gearmotors produces a far more aesthetically pleasing style while enhancing workplace safety; with smaller, much less cumbersome gearmotors there is a smaller chance of interference with employees 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 of gearmotors that enhance operational efﬁciencies and reduce maintenance needs and downtime. They provide premium efﬁciency devices for long-term energy financial savings. Besides being extremely 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 completely sealed with an electrostatic coating for a high-quality ﬁnish that assures regularly tough, water-restricted, chemically resistant units that withstand harsh conditions. These gearmotors likewise have multiple regular speciﬁcations, options, and mounting positions to ensure compatibility.
Material: 7005 aluminum equipment box, SAE 841 bronze worm gear, 303/304 stainless 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 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 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 an extremely wide selection of worm gearboxes. Due to the modular design the typical program comprises countless combinations with regards to selection of equipment housings, installation and connection choices, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We just use top quality components such as houses in cast iron, light weight aluminum and stainless, worms in the event hardened and polished steel and worm tires in high-quality bronze of unique alloys ensuring the the best wearability. The seals of the worm gearbox are provided with a dust lip which efficiently resists dust and water. In addition, the gearboxes are greased for life 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 decrease. An comparative gearing with the same gear ratios and the same transferred power is certainly bigger than a worm gearing. Meanwhile, the worm gearbox is usually in a more simple design.
A double reduction may be composed of 2 regular gearboxes or as a particular 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 advantages of worm gearboxes in the EP-Series:
Compact design is one of the key words of the typical gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or special gearboxes.
Our worm gearboxes and actuators are extremely quiet. This is due to the very easy operating of the worm equipment combined with the utilization of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we take extra care of any sound that can be interpreted as a murmur from the apparatus. Therefore the general noise degree of our gearbox is definitely reduced to a complete minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This frequently proves to be a decisive advantage producing the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox can be an angle gear. This is often an advantage for incorporation into constructions.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the gear house and is well suited for direct suspension for wheels, movable arms and other parts rather than having to build a separate suspension.
For larger equipment ratios, Ever-Power worm gearboxes provides 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 an array of solutions.
Ever-Power Worm Gear Reducer