Gearbox Worm Drive

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-enduring 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 is due to how we double up the bearings on the input shaft. HdR series reducers can be found 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 spring loaded breather connect and come pre-stuffed with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A FAR MORE AFFORDABLE 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 structure, worm reducers can be
found in almost every industrial setting requiring this kind of transmission. Regrettably, they are inefficient at slower speeds and higher reductions, produce a lot of temperature, take up a lot of space, and need regular maintenance.
Fortunately, there can be an option to worm gear pieces: the hypoid gear. Typically found in automotive applications, gearmotor businesses have started integrating hypoid gearing into right-position gearmotors to solve the issues that occur with worm reducers. Available in smaller general 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 be transferred at higher efficiencies, but it opens possibilities for applications where space is usually a limiting factor. They can sometimes be costlier, however the 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 set there are two components: the input worm, and the output worm gear. The worm is usually 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 comprehensive five revolutions as the output worm gear will only complete one. With an increased ratio, for instance 60:1, the worm will total 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 gear, the worm only encounters sliding friction. There is no rolling element of the tooth contact (Shape 2).
Sliding Friction
In high reduction applications, such as 60:1, you will have a big amount of sliding friction due to the high number of input revolutions necessary to spin the output gear once. Low input rate applications suffer from the same friction issue, but also for a different cause. Since there is a large amount of tooth contact, the original energy to begin rotation is greater than that of a comparable hypoid reducer. When driven at low speeds, the worm needs more energy to keep its movement along the worm gear, and a lot of that energy is dropped to friction.
Hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
However, hypoid gear sets consist of the input hypoid equipment, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear arranged is a hybrid of bevel and worm equipment technologies. They encounter friction losses because of the meshing of the gear teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth pattern which allows torque to be transferred efficiently and evenly over the interfacing areas. 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 gear sets is their insufficient efficiency, chiefly in high reductions and low speeds. Standard efficiencies may differ 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
“Break-In” Period
In the case of worm gear sets, they don’t run at peak efficiency until a certain “break-in” period has occurred. Worms are usually made of metal, with the worm gear being manufactured from bronze. Since bronze is a softer metallic it is good at absorbing weighty shock loads but will not operate efficiently until it’s been work-hardened. The temperature produced from the friction of regular working conditions helps to harden the top of worm gear.
With hypoid gear pieces, there is no “break-in” period; they are usually made from steel which has already been carbonitride high temperature treated. This enables the drive to use at peak efficiency from the moment it is installed.
How come Efficiency Important?
Efficiency is one of the most important factors to consider when choosing a gearmotor. Since many employ a long service life, choosing a high-efficiency reducer will minimize costs related to operation and maintenance for a long time to arrive. Additionally, a far more efficient reducer permits better reduction capacity and utilization of a motor that
consumes less electrical energy. One stage worm reducers are typically limited by 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 decrease ratios of 10:1, and the excess reduction is provided by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This is often attributed to the excess processing techniques necessary to create hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically make use of grease with intense pressure additives instead of oil which 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 eventually waste much less energy and maximize the energy getting transferred from the electric motor to the driven shaft. Friction is definitely wasted energy that requires the form of high temperature. 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 engine casing, additional reducing maintenance costs that might be required to keep the fins clean and dissipating warmth properly. A assessment of motor surface area 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 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 units began at 68°F, room temperature. After 100 minutes of operating period, the temperature of both units started to level off, concluding the check. The difference in temperature at this stage was considerable: the worm device reached a surface area temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A difference around 26.4°F. Despite becoming driven by the same engine, the worm unit not only produced less torque, but also wasted more energy. Important thing, this can result in a much heftier electric costs for worm users.
As previously stated and proven, worm reducers run 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 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 ensure the reducer will operate effectively. This eliminates the need for breather holes and any mounting constraints posed by essential oil lubricated systems. It is also not necessary to displace lubricant since the grease is intended to last the life time use of the gearmotor, eliminating downtime and increasing efficiency.
More Power in a Smaller sized Package
Smaller sized motors can be Gearbox Worm Drive utilized in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower electric motor driving a worm reducer can create the same result as a comparable 1/2 horsepower electric motor traveling a hypoid reducer. In one study by Nissei Corporation, both a worm and hypoid reducer were compared for use on an equivalent software. This study fixed the decrease ratio of both gearboxes to 60:1 and compared motor power and result torque as it linked 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 evaluation of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in motor size, comes the advantage to use these drives in more applications where space is a constraint. Because of the way the axes of the gears intersect, worm gears take up more space than hypoid gears (Number 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the overall footprint of the hypoid gearmotor is much smaller sized than that of a comparable worm gearmotor. This also makes working conditions safer since smaller gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is that they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically pleasing and limit the quantity of possible mounting positions.
Worm vs Hypoid Form Comparison
In motors of equivalent power, hypoid drives much outperform their worm counterparts. One essential requirement to consider can be that hypoid reducers can move loads from a lifeless stop with more relieve than worm reducers (Determine 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors over 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 studies are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As demonstrated throughout, the benefits of hypoid reducers speak for themselves. Their style allows them to run more efficiently, cooler, and offer higher reduction ratios when compared to worm reducers. As verified using the studies shown throughout, hypoid gearmotors are designed for higher preliminary inertia loads and transfer more torque with a smaller motor than 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 style of hypoid gearmotors produces a far more aesthetically pleasing design while improving workplace safety; with smaller sized, less cumbersome gearmotors there exists a smaller potential for interference with workers or machinery. Obviously, hypoid gearmotors will be the most suitable choice for long-term cost savings and reliability compared to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that enhance operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency products for long-term energy savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in size and sealed forever. They are light, reliable, and provide 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 circumstances. These gearmotors also have multiple regular specifications, options, and mounting positions to ensure compatibility.
Specifications
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
Take note: The helical spur gear attaches to 4.7 mm D-shaft diameter. The worm equipment attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Rate 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 Used on 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 a very wide range of worm gearboxes. Because of the modular design the typical program comprises countless combinations with regards to selection of equipment housings, mounting and connection choices, flanges, shaft designs, kind of oil, surface treatments etc.
Sturdy and reliable
The look of the EP worm gearbox is easy and well proven. We just use top quality components such as homes in cast iron, aluminium and stainless steel, worms in the event hardened and polished steel and worm wheels in high-quality bronze of unique alloys ensuring the maximum wearability. The seals of the worm gearbox are given with a dirt lip which successfully resists dust and water. Furthermore, the gearboxes are greased forever 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 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. In the meantime, the worm gearbox is certainly in a far 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 one of the key words of the standard gearboxes of the EP-Series. Further optimisation can be achieved by using adapted gearboxes or unique gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is because of the very easy 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 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 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 producing the incorporation of the gearbox significantly simpler and more compact.The worm gearbox can be 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 very firmly embedded in the apparatus house and is perfect for immediate suspension for wheels, movable arms and other areas rather than having to build a separate suspension.
Self locking
For larger equipment ratios, Ever-Power worm gearboxes will provide a self-locking effect, which in lots of situations can be used as brake or as extra security. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for an array of solutions.

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