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-enduring worm gears.
Minimum 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 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 ranging from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass springtime loaded breather plug and come pre-filled with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Worm reducers have already been the go-to alternative for right-angle power transmission for generations. Touted because of their low-cost and robust construction, worm reducers could be
found in nearly every industrial environment requiring this type of transmission. Unfortunately, they are inefﬁcient at slower speeds and higher reductions, produce a lot of warmth, take up a lot of space, and need regular maintenance.
Fortunately, there is an option to worm gear pieces: the hypoid gear. Typically found in auto applications, gearmotor companies have begun integrating hypoid gearing into right-position gearmotors to solve the issues that occur with worm reducers. Available in smaller overall sizes and higher decrease potential, hypoid gearmotors possess a broader range of feasible uses than their worm counterparts. This not only enables heavier torque loads to end up being transferred at higher efﬁciencies, but it opens options for applications where space is definitely a limiting factor. They can sometimes be costlier, however the savings in efﬁciency and maintenance are well worth it.
The following 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 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 example, in a worm gearbox with a 5:1 ratio, the worm will comprehensive ﬁve revolutions while the output worm gear is only going to complete one. With a higher ratio, for instance 60:1, the worm will finish 60 revolutions per one output revolution. It is this fundamental set up that triggers the inefﬁciencies in worm reducers.
Worm Gear Set
To rotate the worm gear, 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 have a huge amount of sliding friction due to the high number of input revolutions required to spin the output gear once. Low input swiftness applications suffer from the same friction issue, but for a different cause. Since there exists a lot of tooth contact, the original energy to start rotation is greater than that of a similar hypoid reducer. When driven at low speeds, the worm requires more energy to keep its motion along the worm equipment, and a lot of that energy is lost 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 set is a hybrid of bevel and worm equipment technologies. They encounter friction losses because of the meshing of the apparatus teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth pattern that allows torque to be transferred efficiently and evenly across the interfacing areas. This is what provides hypoid reducer a mechanical benefit over worm reducers.
How Much Does Performance Actually Differ?
One of the biggest problems posed by worm gear sets is their lack of efﬁciency, chieﬂy in high reductions and low speeds. Regular efﬁciencies can vary from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment sets are usually 95% to 99% efﬁcient (Figure 4).
Worm vs Hypoid Efficiency
In the case of worm gear sets, they don’t operate 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 steel it is good at absorbing large shock loads but does not operate efficiently until it has been work-hardened. The temperature produced from the friction of regular working conditions helps to harden the top of worm gear.
With hypoid gear sets, there is absolutely no “break-in” period; they are typically made from steel which has already been carbonitride warmth treated. This enables the drive to use at peak efﬁciency from the moment it is installed.
Why is Efficiency Important?
Efﬁciency is one of the most important things to consider whenever choosing a gearmotor. Since most 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 far more efﬁcient reducer permits better reduction capacity and usage of a motor that
consumes less electrical energy. Solitary 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 just go up to reduction ratios of 10:1, and the excess reduction is supplied by a different type of gearing, such as helical.
Hypoid drives may have a higher upfront cost than worm drives. This is often attributed to the excess processing techniques necessary to produce hypoid gearing such as for example machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with severe pressure additives instead of oil that will incur higher costs. This cost difference is made up for over the lifetime of the gearmotor because of increased performance and reduced maintenance.
An increased efﬁciency hypoid reducer will ultimately waste much less energy and maximize the energy getting transferred from the motor to the driven shaft. Friction is certainly wasted energy that requires the form of high temperature. Since worm gears produce more friction they run much hotter. Oftentimes, using a hypoid reducer eliminates the need for cooling ﬁns on the engine casing, further reducing maintenance costs that might be required to keep carefully the ﬁns clean and dissipating heat properly. A assessment of motor surface temperature between worm and hypoid gearmotors are available in Figure 5.
In testing the two gearmotors had equally sized motors and carried the same load; the worm gearmotor Gearbox Worm Drive created 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 engine surface area temperature of both systems began at 68°F, space temperature. After 100 moments of operating time, the temperature of both units began to level off, concluding the test. The difference in temperature at this stage was significant: the worm device reached a surface area temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A difference of about 26.4°F. Despite being powered by the same engine, the worm unit not only produced much 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 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 elements can fail, and oil changes are imminent because of lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance required to keep them working at peak performance. Oil lubrication is not needed: the cooling potential of grease will do to ensure the reducer will run effectively. This eliminates the need for breather holes and any mounting constraints posed by oil lubricated systems. It is also not necessary to displace lubricant because the grease is intended to last the life time use of the gearmotor, getting rid of downtime and increasing productivity.
More Power in a Smaller Package
Smaller sized motors can be utilized 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 generate the same output as a comparable 1/2 horsepower engine driving a hypoid reducer. In a single study by Nissei Company, both a worm and hypoid reducer were compared for use on an equivalent program. This study ﬁxed the decrease ratio of both gearboxes to 60:1 and compared motor power and output torque as it related to power drawn. The analysis 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 reduction in motor size, comes the benefit 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 (Physique 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller sized motor, the entire footprint of the hypoid gearmotor is much smaller sized than that of a comparable worm gearmotor. This also helps make working conditions safer since smaller gearmotors pose a lesser threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another beneﬁt of hypoid gearmotors is that they are symmetrical along their centerline (Determine 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equivalent power, hypoid drives significantly outperform their worm counterparts. One important aspect to consider is definitely that hypoid reducers can move loads from a dead 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 above 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 outcomes in both studies are clear: 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 proven using the studies shown throughout, hypoid gearmotors are designed for higher preliminary inertia loads and transfer more torque with a smaller sized 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 better option in space-constrained applications. As demonstrated, the overall footprint and symmetric style of hypoid gearmotors produces a far more aesthetically pleasing style while improving workplace safety; with smaller, less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Clearly, hypoid gearmotors will be the most suitable choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors provides a family group of gearmotors that boost operational efﬁciencies and reduce maintenance needs and downtime. They provide premium efﬁciency units for long-term energy savings. Besides being extremely efﬁcient, its hypoid/helical gearmotors are compact in proportions and sealed for life. They are light, dependable, and offer high torque at low acceleration unlike their worm counterparts. They are completely 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 likewise have multiple standard speciﬁcations, options, and mounting positions to ensure compatibility.
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
Take note: 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 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 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 a very wide variety of worm gearboxes. Because of the modular design the standard program 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 top quality components such as houses in cast iron, light weight aluminum and stainless, worms in the event hardened and polished steel and worm tires in high-grade bronze of unique alloys ensuring the maximum 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 as high as 100:1 in one step or 10.000:1 in a double reduction. An equivalent gearing with the same equipment ratios and the same transferred power is bigger when compared to a worm gearing. Meanwhile, the worm gearbox is definitely in a far more simple design.
A double reduction may be composed of 2 regular 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 advantages of worm gearboxes in the EP-Series:
Compact design is one of the key words of the typical gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or unique gearboxes.
Our worm gearboxes and actuators are extremely quiet. This is because of the very even running of the worm gear combined with the use of cast iron and high precision on element manufacturing and assembly. In connection with our precision gearboxes, we consider extra care of any sound which can be interpreted as a murmur from the gear. So the general noise degree of our gearbox is certainly reduced to a complete minimum.
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This often proves to be a decisive advantage making the incorporation of the gearbox significantly simpler and smaller sized.The worm gearbox can be an angle gear. This is an advantage for incorporation into constructions.
Solid bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the gear house and is ideal for direct suspension for wheels, movable arms and other areas rather than having to create a separate suspension.
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 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