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.
Gearbox Worm Drive Powered by long-enduring 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 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 spring loaded breather connect and come pre-stuffed with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have already been the go-to option for right-angle power transmission for generations. Touted for their low-cost and robust construction, worm reducers can be
found in almost every industrial establishing requiring this type of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a lot of space, and require regular maintenance.
Fortunately, there is an alternative to worm gear sets: the hypoid gear. Typically found in automotive applications, gearmotor businesses have started integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Available in smaller overall sizes and higher reduction potential, hypoid gearmotors possess a broader range of possible uses than their worm counterparts. This not only allows heavier torque loads to become transferred at higher efficiencies, nonetheless it opens opportunities for applications where space is definitely a limiting factor. They are able to 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 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 set there are two components: the input worm, and the output worm gear. The worm is definitely 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 finish five revolutions as the output worm equipment will only complete one. With a higher ratio, for instance 60:1, the worm will finish 60 revolutions per one result 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 absolutely no rolling element of the tooth contact (Figure 2).
Sliding Friction
In high reduction applications, such as 60:1, there will be a huge amount of sliding friction because of the lot of input revolutions necessary to spin the output equipment once. Low input velocity applications suffer from the same friction problem, but also for a different reason. Since there is a lot of tooth contact, the original energy to begin rotation is higher than that of a similar hypoid reducer. When driven at low speeds, the worm requires more energy to keep its movement along the worm gear, and lots 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 gear (Figure 3).
Hypoid Gear Set
The hypoid gear arranged is a hybrid of bevel and worm gear technologies. They experience friction losses because of the meshing of the gear teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth pattern that allows torque to become transferred efficiently and evenly across the interfacing areas. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the biggest problems posed by worm gear sets is their lack of efficiency, chiefly at high reductions and low speeds. Regular efficiencies can vary from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid gear sets are typically 95% to 99% efficient (Figure 4).
Worm vs Hypoid Efficiency
“Break-In” Period
In the case of worm gear sets, they do not operate at peak efficiency until a certain “break-in” period has occurred. Worms are usually made of steel, with the worm gear being made of bronze. Since bronze is a softer steel it is proficient at absorbing large shock loads but will not operate successfully until it’s been work-hardened. The warmth produced from the friction of regular operating conditions helps to harden the surface of the worm gear.
With hypoid gear pieces, there is absolutely no “break-in” period; they are usually made from metal which has already been carbonitride warmth treated. This allows the drive to operate at peak efficiency as soon as it is installed.
How come Efficiency Important?
Efficiency is one of 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 allows for better reduction capacity and utilization of a motor that
consumes less electrical energy. Solitary 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 just go up to reduction ratios of 10:1, and the additional reduction is provided by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This is often attributed to the excess processing techniques necessary to create hypoid gearing such as machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with extreme pressure additives rather than oil that will incur higher costs. This price difference is made up 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 being transferred from the electric motor to the driven shaft. Friction is certainly wasted energy that requires the form of temperature. Since worm gears generate more friction they operate much hotter. In many cases, using a hypoid reducer eliminates the need for cooling fins on the motor casing, additional reducing maintenance costs that might be required to keep carefully the fins clean and dissipating warmth properly. A comparison of motor surface 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 motor surface area temperature of both products began at 68°F, room temperature. After 100 moments of operating period, the temperature of both units started to level off, concluding the test. The difference in temperature at this time was significant: the worm unit reached a surface area temperature of 151.4°F, while the hypoid unit only reached 125.0°F. A difference of about 26.4°F. Despite becoming powered by the same engine, the worm device not only produced less torque, but also wasted more energy. Important thing, 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 these drives by placing extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term exposure to 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 running at peak performance. 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 oil lubricated systems. It is also not necessary to replace lubricant because the grease is meant to last the lifetime utilization of the gearmotor, eliminating downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller motors can be used in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower motor traveling a worm reducer can create the same output as a comparable 1/2 horsepower motor 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 software. This research 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 study concluded that a 1/2 HP hypoid gearmotor can be used to provide similar overall performance to a 1 HP worm gearmotor, at a fraction of the electrical cost. A final result displaying a assessment of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor size, comes the advantage to use these drives in more applications where space is a constraint. Due to the way the axes of the gears intersect, worm gears consider up more space than hypoid gears (Shape 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 similar worm gearmotor. This also makes working environments safer since smaller gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is definitely they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and lead to machines that are not as aesthetically pleasing and limit the amount of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of the same power, hypoid drives far outperform their worm counterparts. One important aspect to consider is definitely that hypoid reducers can move loads from a lifeless stop with more ease than worm reducers (Body 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors above a 30:1 ratio because of 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 research are obvious: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to perform more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As verified using the studies presented throughout, hypoid gearmotors can handle higher preliminary 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 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 demonstrated, the overall footprint and symmetric style of hypoid gearmotors produces a more aesthetically pleasing style while improving workplace safety; with smaller, less cumbersome gearmotors there is a smaller chance of interference with employees or machinery. Clearly, hypoid gearmotors are the best choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors provides a family of gearmotors that boost operational efficiencies and reduce maintenance needs and downtime. They offer premium efficiency models for long-term energy savings. Besides being extremely efficient, its hypoid/helical gearmotors are small in proportions and sealed forever. They are light, dependable, and provide high torque at low rate 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 devices that withstand harsh circumstances. These gearmotors likewise have multiple regular specifications, options, and installation positions to ensure compatibility.
Specifications
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
Note: 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 Speed 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 variety of worm gearboxes. Due to the modular design the typical programme comprises countless combinations when it comes to selection of equipment housings, installation and connection choices, flanges, shaft designs, kind of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We just use top quality components such as houses in cast iron, aluminum and stainless steel, worms in the event hardened and polished steel and worm wheels in high-grade bronze of unique alloys ensuring the the best possible wearability. The seals of the worm gearbox are given with a dust lip which effectively resists dust and water. Furthermore, the gearboxes are greased forever 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 comparative gearing with the same gear ratios and the same transferred power is certainly bigger than a worm gearing. Meanwhile, the worm gearbox is in a 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 advantages of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key phrases of the standard gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or special gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is because of the very simple operating of the worm gear combined with the usage 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. So the general noise degree of our gearbox can be reduced to an absolute minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This frequently proves to be a decisive benefit making the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox is an angle gear. This is an advantage for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the gear house and is perfect 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 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.