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 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 springtime loaded breather plug and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to solution for right-angle power transmission for generations. Touted for his or her low-cost and robust construction, worm reducers can be
found in almost every industrial environment requiring this kind of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a whole lot of space, and require regular maintenance.
Fortunately, there can be an alternative to worm gear sets: the hypoid gear. Typically used in automotive 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 possess a broader range of feasible uses than their worm counterparts. This not only allows heavier torque loads to become transferred at higher efficiencies, nonetheless it opens options for applications where space is a limiting factor. They can sometimes be costlier, but the 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.
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 gear (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will complete five revolutions as the output worm gear will only complete one. With an increased ratio, for example 60:1, the worm will total 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 no rolling component to the tooth contact (Body 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will see a huge amount of sliding friction because of the high number of input revolutions necessary to spin the output gear once. Low input swiftness applications suffer from the same friction problem, but for a different reason. Since there is a lot of tooth contact, the initial energy to begin rotation is higher than that of a similar hypoid reducer. When powered at low speeds, the worm needs more energy to keep its motion along the worm gear, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
However, hypoid gear sets contain the input hypoid gear, and the output hypoid bevel equipment (Figure 3).
Hypoid Gear Set
The hypoid gear established 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 pattern which allows torque to be transferred smoothly and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness 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 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
“Break-In” Period
Regarding worm gear sets, they do not operate at peak efficiency until a specific “break-in” period has occurred. Worms are typically made of steel, with the worm gear being manufactured from bronze. Since bronze is definitely a softer steel it is good at absorbing weighty shock loads but does not operate efficiently until it has been work-hardened. The heat produced from the friction of regular operating conditions helps to harden the surface of the worm gear.
With hypoid gear models, there is absolutely no “break-in” period; they are typically made from steel which has recently been carbonitride heat treated. This enables the drive to operate at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is among the most important things to consider when choosing a gearmotor. Since the majority of have a very long service lifestyle, 
choosing a high-efficiency reducer will minimize costs related to operation and maintenance for a long time to come. Additionally, a more efficient reducer permits better reduction ability and usage 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 decrease potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the additional reduction is supplied by a different 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 additional processing techniques necessary to create hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically use grease with severe pressure additives rather than oil that may incur higher costs. This cost difference is composed for over the lifetime of the gearmotor because of increased performance and reduced maintenance.
A higher efficiency hypoid reducer will eventually waste less energy and maximize the energy getting transferred from the engine to the driven shaft. Friction is definitely wasted energy that takes the form of temperature. Since worm gears generate more friction they operate much hotter. Oftentimes, utilizing a hypoid reducer eliminates the need for cooling fins on the electric motor casing, further reducing maintenance costs that would be required to keep the fins clean and dissipating warmth properly. A assessment 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 as the hypoid gearmotor created 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The motor surface area temperature of both units began at 68°F, room temperature. After 100 moments of operating time, the temperature of both systems began to level off, concluding the test. The difference in temperature at this point was substantial: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A notable difference around 26.4°F. Despite getting powered by the same motor, the worm device not only produced less torque, but also wasted more energy. Important thing, this can lead to 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 the drives by putting extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these components can fail, and essential oil changes are imminent because of lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance required to keep them operating at peak performance. Oil lubrication is not required: the cooling potential of grease is enough to guarantee the reducer will operate effectively. This eliminates the need for breather holes and any installation constraints posed by oil lubricated systems. Additionally it is not necessary to replace lubricant since the grease is meant to last the lifetime usage of the gearmotor, removing 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 generate the same output as a comparable 1/2 horsepower engine driving a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer had been compared for make use of on an equivalent application. This study fixed the reduction ratio of both gearboxes to 60:1 and compared motor power and output torque as it linked to power drawn. The study concluded that 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 showing a comparison of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in engine size, comes the advantage to use these drives in more applications where space is a constraint. Because of the method the axes of the gears intersect, worm gears take 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 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 (Shape 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equal power, hypoid drives far outperform their worm counterparts. One important aspect to consider is usually that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Number 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably 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 results in both research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As shown throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and provide higher reduction ratios in comparison with worm reducers. As tested using the studies presented 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 the user to purchase 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 entire footprint and symmetric design of hypoid gearmotors makes for a 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. Obviously, hypoid gearmotors are the most suitable choice for long-term cost benefits and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that boost Gearbox Worm Drive operational efficiencies and reduce maintenance needs 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 offer high torque at low velocity unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-limited, chemically resistant models that withstand harsh circumstances. These gearmotors likewise have multiple standard specifications, options, and mounting positions to make sure compatibility.
Specifications
Material: 7005 aluminum gear 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 equipment attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Quickness 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 Used on Both Shaft Ends
Anti-Rust Primer Applied Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Steel 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 programme comprises countless combinations with regards to selection of equipment housings, installation 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 just use high quality components such as houses in cast iron, aluminum and stainless, worms in the event hardened and polished metal and worm tires in high-grade bronze of unique alloys ensuring the ideal wearability. The seals of the worm gearbox are given with a dirt lip which efficiently 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 equipment ratios and the same transferred power is usually bigger than a worm gearing. In the mean time, the worm gearbox is usually in a far more simple design.
A double reduction may 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 terms of the typical gearboxes of the EP-Series. Further optimisation may be accomplished by using adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are extremely quiet. This is due to the very smooth running of the worm equipment 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 which can be interpreted as a murmur from the gear. So the general noise degree 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 become a decisive advantage making the incorporation of the gearbox considerably simpler and more compact.The worm gearbox can be an angle gear. This is 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 direct suspension for wheels, movable arms and other parts rather than needing to build a separate suspension.
Self locking
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 a wide selection of solutions.
