Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient upon the gearing for high efficiency.
Powered by long-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 Right 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather plug and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
Introduction
Worm reducers have been the go-to option for right-angle power transmission for generations. Touted because of their low-cost and robust building, worm reducers can be
found in almost every industrial environment requiring this type of transmission. Unfortunately, they are inefficient at slower speeds and higher reductions, create a lot of temperature, take up a 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 companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that arise with worm reducers. Obtainable in smaller overall sizes and higher reduction potential, hypoid gearmotors have a broader selection of feasible uses than their worm counterparts. This not merely allows heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens opportunities for applications where space is a limiting factor. They can sometimes be costlier, but the financial savings in efficiency and maintenance are really worth it.
The following 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 established there are two components: the input worm, and the output worm gear. The worm is a screw-like gear, that rotates perpendicular to its corresponding worm equipment (Figure 1). For example, in a worm gearbox with a 5:1 ratio, the worm will complete five revolutions as the output worm gear 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 is this fundamental arrangement that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only experiences sliding friction. There is absolutely no rolling element of the tooth contact (Number 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will have a big amount of sliding friction due to the lot of input revolutions required to spin the output equipment once. Low input quickness applications suffer from the same friction issue, but also for a different reason. Since there is a large amount of tooth contact, the initial energy to start 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 FAR 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 set is a hybrid of bevel and worm gear technologies. They encounter friction losses due to the meshing of the gear teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth design which allows torque to become transferred efficiently and evenly across the interfacing surfaces. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest problems posed by worm equipment sets is their insufficient efficiency, chiefly in high reductions and low speeds. Usual efficiencies can vary 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 particular “break-in” period has occurred. Worms are usually made of metal, with the worm equipment being manufactured from bronze. Since bronze is usually a softer metallic it is good at absorbing heavy shock loads but will not operate successfully until it has been work-hardened. The high temperature 
produced from the friction of regular operating conditions helps to harden the top of worm gear.
With hypoid gear sets, there is no “break-in” period; they are typically made from steel which has already been carbonitride warmth treated. This enables 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 many employ a long service life, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for years to come. Additionally, a more efficient reducer allows for better reduction ability and usage of a motor that
consumes less electrical power. Single stage worm reducers are typically 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 additional reduction is provided by a different type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This could be attributed to the additional processing techniques necessary to produce hypoid gearing such as for example machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically use grease with severe pressure additives instead of oil which will incur higher costs. This cost difference is made up for over the duration of the gearmotor due to increased functionality and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste less energy and maximize the energy getting transferred from the motor to the driven shaft. Friction is wasted energy that requires the form of heat. Since worm gears create more friction they run much hotter. In many cases, utilizing a hypoid reducer eliminates the necessity for cooling fins on the engine casing, further reducing maintenance costs that might be required to keep the fins clean and dissipating temperature properly. A comparison 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 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 models began at 68°F, space temperature. After 100 mins of operating period, the temperature of both products began to level off, concluding the test. The difference in temperature at this time was considerable: the worm device 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 driven by the same electric motor, the worm device not only produced less torque, but also wasted more energy. Bottom line, this can result in a much heftier electric expenses for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of the drives by putting 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 due to lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance required to keep them working at peak performance. Essential oil lubrication is not required: the cooling potential of grease is enough to guarantee the reducer will run effectively. This eliminates the need for breather holes and any installation constraints posed by essential oil lubricated systems. It is also not necessary to replace lubricant because the grease is intended to last the lifetime use of the gearmotor, eliminating downtime and increasing productivity.
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 engine traveling a worm reducer can produce the same result as a comparable 1/2 horsepower engine generating 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 electric motor power and result torque as it related to power drawn. The study concluded that a 1/2 HP hypoid gearmotor can be utilized to provide similar performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result displaying a comparison 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 (Physique 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller motor, the entire footprint of the hypoid gearmotor is much smaller than that of a similar worm gearmotor. This also makes 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 they are symmetrical along their centerline (Physique 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 equal power, hypoid drives much outperform their worm counterparts. One essential requirement to consider is definitely that hypoid reducers can move loads from a dead stop with more relieve than worm reducers (Figure 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 demonstrated 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 proven using the studies presented throughout, hypoid gearmotors are designed for higher initial inertia loads and transfer more torque with a smaller motor when compared to a comparable worm gearmotor.
This can lead to upfront savings by allowing an individual 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 overall footprint and symmetric design of hypoid gearmotors produces a more aesthetically pleasing design while improving workplace safety; with smaller, much less cumbersome gearmotors there exists a smaller potential for interference with employees or machinery. Clearly, 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 enhance operational efficiencies and reduce maintenance requirements and downtime. They provide premium efficiency systems for long-term energy savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in size and sealed forever. They are light, dependable, and offer high torque at low swiftness unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-tight, chemically resistant products that withstand harsh conditions. These gearmotors also have multiple standard specifications, options, and mounting positions to ensure 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
Notice: 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 Outside and inside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Metal Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide range of worm gearboxes. Due to the modular design the standard programme comprises countless combinations when it comes to selection of gear housings, installation and connection options, flanges, shaft designs, type of oil, surface treatments 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, aluminum and stainless steel, worms in the event hardened and polished metal and worm wheels in high-grade bronze of particular alloys ensuring the optimum wearability. The seals of the worm gearbox are given with a dust lip which successfully resists dust and drinking water. In addition, the gearboxes are greased for life with synthetic oil.
Large reduction 100:1 in a single 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 comparative gearing with the same gear ratios and the same transferred power is certainly bigger when compared to a worm gearing. At the same time, the worm gearbox is in a far more simple design.
A double reduction may be composed of 2 standard 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 one of the key words of the standard gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or unique gearboxes.
Low noise
Our worm gearboxes and Gearbox Worm Drive actuators are extremely quiet. This is because of the very easy operating of the worm gear combined with the use of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we take extra care of any sound which can be interpreted as a murmur from the gear. So the general noise degree of our gearbox is usually reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to one another. This frequently proves to become a decisive advantage making the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox can be 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 immediate suspension for wheels, movable arms and other areas rather than needing to build a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes will provide a self-locking effect, which in many situations can be used as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for an array of solutions.