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-long lasting worm gears.
Minimal speed fluctuation with low noise and low vibration.
Lightweight and compact in accordance with its high load capacity.
The structural strength of our cast iron, Heavy-duty Right angle (HdR) series worm gearbox is because of how we dual 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 supplied with a brass spring loaded breather plug and come pre-packed with Mobil SHC634 synthetic gear oil.
Gearbox Worm Drive hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer
Worm reducers have already been the go-to solution for right-angle power transmission for generations. Touted for their low-cost and robust building, worm reducers can be
found in almost every industrial establishing requiring this type of transmission. However, they are inefﬁcient at slower speeds and higher reductions, create a lot of warmth, take up a lot of space, and need regular maintenance.
Fortunately, there is an alternative to worm gear models: the hypoid gear. Typically found in automotive applications, gearmotor companies 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 have a broader range of possible uses than their worm counterparts. This not merely allows heavier torque loads to become transferred at higher efﬁciencies, but it opens opportunities for applications where space can be a limiting factor. They can sometimes be costlier, but the financial savings in efﬁciency and maintenance are really 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 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 equipment (Figure 1). For example, 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 complete 60 revolutions per one result revolution. It really is this fundamental set up that triggers the inefﬁciencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only encounters sliding friction. There is no rolling component to the tooth contact (Number 2).
In high reduction applications, such as 60:1, you will see a big amount of sliding friction because of the lot of input revolutions necessary to spin the output equipment once. Low input speed applications suffer from the same friction problem, but also for a different cause. Since there exists a lot of tooth contact, the original energy to begin rotation is greater than that of a similar hypoid reducer. When powered at low speeds, the worm needs more energy to continue its motion along the worm equipment, and lots of that energy is lost to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
On the other hand, 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 equipment technologies. They encounter friction losses because of the meshing of the gear teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth pattern which allows torque to be transferred efficiently and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the primary problems posed by worm gear sets is their insufficient efﬁciency, chieﬂy in high reductions and low speeds. Common 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
Regarding worm gear sets, they don’t operate at peak efﬁciency until a specific “break-in” period has occurred. Worms are usually made of metal, with the worm equipment being made of bronze. Since bronze can be a softer metallic it is proficient at absorbing large shock loads but will not operate efficiently until it has been work-hardened. The temperature generated from the friction of regular operating conditions really helps to harden the top of worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are usually made from metal which has already been carbonitride high temperature treated. This enables the drive to use at peak efﬁciency as soon as it is installed.
Why is Efficiency Important?
Efﬁciency is one of the most important things to consider when choosing a gearmotor. Since the majority of have a very long service existence, choosing a high-efﬁciency reducer will reduce costs related to operation and maintenance for a long time to arrive. Additionally, a far more efﬁcient reducer allows for better reduction capacity and utilization 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 just 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 necessary to generate hypoid gearing such as for example machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with extreme pressure additives rather than oil that will incur higher costs. This cost difference is composed for over the lifetime of the gearmotor because of increased efficiency and reduced maintenance.
A higher efﬁciency hypoid reducer will ultimately waste less energy and maximize the energy getting transferred from the engine to the driven shaft. Friction is wasted energy that requires the form of warmth. Since worm gears produce more friction they run much hotter. In many cases, using a hypoid reducer eliminates the need for cooling ﬁns on the motor casing, further reducing maintenance costs that would be required to keep the ﬁns clean and dissipating high temperature properly. A assessment of motor surface 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 as 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 units began at 68°F, room temperature. After 100 minutes of operating time, the temperature of both models started to level off, concluding the test. The difference in temperature at this time was significant: 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 electric motor, the worm device not only produced much less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical costs for worm users.
As previously mentioned and proven, worm reducers run much hotter than equivalently rated hypoid reducers. This reduces the service life of these drives by putting extra thermal stress 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 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 necessity for breather holes and any installation constraints posed by oil lubricated systems. It is also not necessary to displace lubricant because the grease is meant to last the life time use of the gearmotor, eliminating downtime and increasing productivity.
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 engine driving a worm reducer can create the same output as a comparable 1/2 horsepower motor generating a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer were compared for make use of on an equivalent program. This study ﬁxed the reduction ratio of both gearboxes to 60:1 and compared electric motor power and result torque as it linked to power drawn. The analysis concluded that 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 price. A ﬁnal result displaying a assessment of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in electric motor 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 take up more space than hypoid gears (Body 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is a lot smaller sized than that of a comparable worm gearmotor. This also helps make working conditions safer since smaller gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors can be they are symmetrical along their centerline (Shape 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 significantly outperform their worm counterparts. One important aspect to consider is definitely that hypoid reducers can move loads from a lifeless stop with more relieve than worm reducers (Body 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably more torque than worm gearmotors over a 30:1 ratio due to 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 clear: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As shown throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to perform more efﬁciently, cooler, and provide higher reduction ratios in comparison with worm reducers. As tested using the studies shown throughout, hypoid gearmotors are designed for 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 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 demonstrated, the entire footprint and symmetric design of hypoid gearmotors makes for a more aesthetically pleasing style while enhancing workplace safety; with smaller, less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Clearly, hypoid gearmotors are the most suitable choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that boost operational efﬁciencies and reduce maintenance requirements and downtime. They provide premium efﬁciency units for long-term energy financial savings. Besides being extremely efﬁcient, its hypoid/helical gearmotors are small in proportions and sealed forever. They are light, dependable, 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 consistently tough, water-restricted, chemically resistant products that withstand harsh conditions. These gearmotors likewise have multiple regular speciﬁcations, options, and installation 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
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 Velocity 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 an extremely wide range of worm gearboxes. Because of the modular design the typical program comprises countless combinations when it comes to selection of equipment housings, mounting 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 top quality components such as houses in cast iron, aluminium 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 given with a dirt 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 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 can be bigger than a worm gearing. Meanwhile, 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.
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 benefits 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 can be achieved by using adapted gearboxes or special gearboxes.
Our worm gearboxes and actuators are extremely quiet. This is due to the very smooth working of the worm equipment combined with the use of cast iron and high precision on element manufacturing and assembly. Regarding the our precision gearboxes, we take extra treatment of any sound that can be interpreted as a murmur from the apparatus. Therefore the general noise level of our gearbox is reduced to an absolute minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This often proves to be a decisive benefit making the incorporation of the gearbox substantially simpler and smaller sized.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 areas rather than needing to create a separate suspension.
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking impact, 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 perfect for a wide variety of solutions.
Ever-Power Worm Gear Reducer