Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Low friction coefficient on the gearing for high efficiency.
Powered by long-long lasting 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 Worm Drive 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 supplied with a brass springtime loaded breather plug and come pre-packed with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Worm reducers have already been the go-to alternative for right-angle power tranny for generations. Touted for his or her low-cost and robust building, worm reducers can be
found in nearly every industrial setting requiring this type of transmission. Sadly, they are inefﬁcient at slower speeds and higher reductions, produce a lot of temperature, take up a lot of space, and require regular maintenance.
Fortunately, there can be an alternative to worm gear models: the hypoid gear. Typically found in auto applications, gearmotor businesses have begun integrating hypoid gearing into right-position gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller overall sizes and higher reduction potential, hypoid gearmotors possess a broader range of feasible uses than their worm counterparts. This not only enables heavier torque loads to become transferred at higher efﬁciencies, but it opens possibilities for applications where space can be 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 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 established there are two components: the input worm, and the output worm gear. The worm is certainly 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 total ﬁve revolutions as the output worm equipment is only going to complete one. With an increased ratio, for example 60:1, the worm will finish 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 equipment, the worm only encounters sliding friction. There is no rolling element of the tooth contact (Body 2).
In high reduction applications, such as 60:1, there will be a huge amount of sliding friction because of the high number of input revolutions required to spin the output equipment once. Low input speed applications suffer from the same friction issue, but for a different cause. Since there is a large amount of tooth contact, the initial energy to begin rotation is greater than that of a similar 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 lost to friction.
Hypoid vs. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
On the other hand, hypoid gear sets consist of 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 experience friction losses because of the meshing of the gear teeth, with minimal sliding included. These losses are minimized using the hypoid tooth pattern which allows torque to end up being transferred easily and evenly over the interfacing surfaces. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest complications posed by worm equipment sets is their lack of efﬁciency, chieﬂy in high reductions and low speeds. Usual 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 do not run at peak efﬁciency until a specific “break-in” period has occurred. Worms are typically made of steel, with the worm equipment being made of bronze. Since bronze is usually a softer metal it is good at absorbing large shock loads but will not operate effectively until it has been work-hardened. The temperature generated from the friction of regular working conditions helps to harden the top of worm gear.
With hypoid gear sets, there is no “break-in” period; they are typically made from metal which has recently been carbonitride heat treated. This allows the drive to use 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 most have a very long service existence, choosing a high-efﬁciency reducer will reduce costs related to procedure and maintenance for years to arrive. Additionally, a more efﬁcient reducer permits better reduction capability and utilization of a motor that
consumes less electrical energy. One 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 only go up to reduction ratios of 10:1, and the additional reduction is supplied by another type of gearing, such as for example helical.
Hypoid drives can have an increased upfront cost than worm drives. This can be attributed to the additional processing techniques required to produce hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically use grease with intense pressure additives rather than oil that may incur higher costs. This price difference is made up for over the lifetime of the gearmotor because of increased overall performance and reduced maintenance.
A higher efﬁciency hypoid reducer will ultimately waste much less energy and maximize the energy becoming transferred from the electric motor to the driven shaft. Friction is wasted energy that takes the form of high temperature. Since worm gears produce more friction they run much hotter. In many cases, utilizing a hypoid reducer eliminates the need for cooling ﬁns on the motor casing, further reducing maintenance costs that might be required to keep the ﬁns clean and dissipating high temperature properly. A assessment of motor surface area 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 electric motor surface temperature of both models began at 68°F, room temperature. After 100 mins of operating time, the temperature of both models started 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 notable difference of about 26.4°F. Despite being run by the same electric motor, the worm unit not only produced less torque, but also wasted more energy. Important thing, 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 reduces 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 parts can fail, and essential oil changes are imminent because of lubrication degradation.
Since hypoid reducers operate 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 will do to ensure the reducer will run effectively. This eliminates the necessity for breather holes and any mounting constraints posed by essential oil lubricated systems. It is also not necessary to replace lubricant since the grease is meant to last the life time utilization of the gearmotor, getting rid of downtime and increasing efficiency.
More Power in a Smaller Package
Smaller sized motors can be used in hypoid gearmotors because of the more efﬁcient transfer of energy through the gearbox. Occasionally, a 1 horsepower motor traveling a worm reducer can generate the same output as a comparable 1/2 horsepower electric motor driving a hypoid reducer. In a single study by Nissei Corporation, both a worm and hypoid reducer were compared for use on an equivalent program. 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 analysis figured a 1/2 HP hypoid gearmotor can be utilized to provide similar functionality to a 1 HP worm gearmotor, at a fraction of the electrical cost. A ﬁnal result displaying a evaluation of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in engine size, comes the benefit to use these drives in more applications where space is a constraint. Because of the method 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 motor, the overall footprint of the hypoid gearmotor is a lot smaller sized than that of a comparable worm gearmotor. This also makes working conditions safer since smaller 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 (Physique 9). Worm gearmotors are asymmetrical and lead to machines that are not as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equivalent power, hypoid drives much outperform their worm counterparts. One essential requirement to consider is usually that hypoid reducers can move loads from a lifeless 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 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 clear: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As proven throughout, the advantages of hypoid reducers speak for themselves. Their design allows them to run more efﬁciently, cooler, and provide higher reduction ratios in comparison with worm reducers. As tested using the studies offered throughout, hypoid gearmotors can handle 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 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 proven, the entire footprint and symmetric design of hypoid gearmotors produces a far more aesthetically pleasing design while improving workplace safety; with smaller sized, 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 savings and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that increase operational efﬁciencies and reduce maintenance needs and downtime. They provide premium efﬁciency units for long-term energy cost savings. Besides being highly efﬁcient, its hypoid/helical gearmotors are compact in proportions and sealed forever. They are light, reliable, and offer high torque at low swiftness unlike their worm counterparts. They are permanently 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 also have multiple standard speciﬁcations, options, and installation positions to make sure 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
Notice: 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 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 Style 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 Steel 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 programme comprises countless combinations with regards to selection of gear housings, mounting and connection choices, 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 high quality components such as houses in cast iron, aluminum and stainless, worms in case hardened and polished metal and worm wheels in high-quality bronze of special alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dust lip which efficiently resists dust and water. Furthermore, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes allow for reductions as high as 100:1 in one single step or 10.000:1 in a double reduction. An equivalent gearing with the same equipment ratios and the same transferred power is usually bigger than a worm gearing. Meanwhile, the worm gearbox is certainly in a 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 advantages of worm gearboxes in the EP-Series:
Compact design is one of the key words of the standard gearboxes of the EP-Series. Further optimisation may be accomplished by using adapted gearboxes or special gearboxes.
Our worm gearboxes and actuators are extremely quiet. This is because of the very clean working of the worm gear combined with the use 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. Therefore the general noise level of our gearbox is usually reduced to an absolute minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This often proves to be a decisive benefit 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 quite firmly embedded in the gear house and is ideal for direct suspension for wheels, movable arms and other areas rather than having to build a separate suspension.
For larger equipment 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 ideal for a wide selection of solutions.
Ever-Power Worm Gear Reducer