Gearbox Worm Drive

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.
Powered by long-lasting 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 Right angle (HdR) series worm gearbox is because of 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 given a brass spring loaded breather connect and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to remedy for right-angle power transmitting for generations. Touted because of their low-cost and robust structure, worm reducers can be
found in almost every industrial establishing requiring this kind of transmission. Sadly, they are inefficient at slower speeds and higher reductions, create a lot of heat, 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 auto applications, gearmotor companies have begun integrating hypoid gearing into right-position gearmotors to solve the problems that arise with worm reducers. Available in smaller general sizes and higher decrease potential, hypoid gearmotors possess a broader selection of possible uses than their worm counterparts. This not only allows heavier torque loads to end up being transferred at higher efficiencies, nonetheless it opens options for applications where space is a limiting factor. They are able to sometimes be costlier, however 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 set 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 gear (Figure 1). For instance, 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 a higher ratio, for example 60:1, the worm will finish 60 revolutions per one result revolution. It is this fundamental set up that causes the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm equipment, the worm only experiences sliding friction. There is no rolling component to the tooth contact (Determine 2).
Sliding Friction
In high reduction applications, such as for example 60:1, you will have a large amount of sliding friction due to the high number of input revolutions necessary to spin the output equipment once. Low input velocity applications suffer from the same friction issue, but also for a different reason. Since there is 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 keep its movement along the worm gear, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR 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 set is a hybrid of bevel and worm equipment technologies. They encounter friction losses due to the meshing of the apparatus teeth, with reduced sliding involved. These losses are minimized using the hypoid tooth pattern that allows torque to end up being transferred efficiently and evenly over the interfacing surfaces. This is what gives the hypoid reducer a mechanical benefit over worm reducers.
How Much Does Efficiency Actually Differ?
One of the biggest problems posed by worm equipment sets is their insufficient efficiency, chiefly at high reductions and low speeds. Usual efficiencies may differ from 40% to 85% for ratios of 60:1 to 10:1 respectively. Conversely, hypoid equipment 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 run at peak efficiency until a particular “break-in” period has occurred. Worms are typically made of steel, with the worm equipment being manufactured from bronze. Since bronze is certainly a softer metallic it is good at absorbing weighty shock loads but does 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 models, there is no “break-in” period; they are typically made from steel which has already been carbonitride heat 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 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 more efficient reducer allows for better reduction ability and use of a motor that
consumes less electrical power. Single stage worm reducers are usually limited to 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 another type of gearing, such as for example helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This could be attributed to the additional processing techniques required to produce hypoid gearing such as machining, heat treatment, and special grinding techniques. Additionally, hypoid gearboxes typically make use of grease with extreme pressure additives instead of oil that will incur higher costs. This cost difference is composed for over the duration of the gearmotor due to increased efficiency and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste less energy and maximize the energy getting transferred from the engine to the driven shaft. Friction is certainly wasted energy that takes the form of temperature. Since worm gears generate more friction they operate 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 the fins clean and dissipating heat 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 produced 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The electric motor surface temperature of both systems began at 68°F, space temperature. After 100 moments of operating time, the temperature of both products began to level off, concluding the test. The difference in temperature at this time was significant: the worm unit reached a surface temperature of 151.4°F, while the hypoid unit just reached 125.0°F. A notable difference around 26.4°F. Despite getting run by the same motor, the worm unit not only produced less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electric expenses for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This decreases the service life of these drives by placing extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term contact with high heat, these elements can fail, and essential oil changes are imminent due to lubrication degradation.
Since hypoid reducers operate cooler, there is little to no maintenance necessary 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 operate 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 since 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 used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. In some instances, a 1 horsepower electric motor generating a worm reducer can generate the same result as a comparable 1/2 horsepower motor traveling 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 research fixed the decrease 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 used to provide similar functionality to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result showing a evaluation of torque and power consumption was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this decrease in motor size, comes the benefit to use these drives in more applications where space is a constraint. Due to the method the axes of the gears intersect, worm gears consider up more space than hypoid gears (Number 7).
Worm vs Hypoid Axes
Coupled with the ability to use a smaller sized motor, the overall footprint of the hypoid gearmotor is a lot smaller than that of a comparable worm gearmotor. This also helps make working environments safer since smaller sized 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 (Shape 9). Worm gearmotors are asymmetrical and lead to machines that are not 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 important aspect to consider is certainly that hypoid reducers can move loads from a lifeless stop with more relieve than worm reducers (Shape 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably 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 research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As proven 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 confirmed using the studies provided throughout, hypoid gearmotors are designed for higher initial 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 much better option in space-constrained applications. As demonstrated, the entire footprint and symmetric design of hypoid gearmotors makes for a far more aesthetically pleasing design while improving workplace safety; with smaller, much less cumbersome gearmotors there exists a smaller chance of interference with employees or machinery. Obviously, hypoid gearmotors will be the best choice for long-term cost savings and reliability in comparison to worm gearmotors.
Brother Gearmotors offers a family of gearmotors that boost operational efficiencies and reduce maintenance needs and downtime. They provide premium efficiency systems for long-term energy financial savings. Besides being highly 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 permanently sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-limited, chemically resistant systems that withstand harsh circumstances. 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
Take note: 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 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 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 a very wide range of worm gearboxes. Because of the modular design the standard programme comprises countless combinations when it comes to selection of gear housings, mounting and connection options, flanges, shaft designs, type of oil, surface remedies etc.
Sturdy and reliable
The design of the EP worm gearbox is simple 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 particular alloys ensuring the the best wearability. The seals of the worm gearbox are provided with a dust lip which effectively resists dust and water. In addition, the gearboxes are Gearbox Worm Drive greased forever with synthetic oil.
Large reduction 100:1 in one step
As default the worm gearboxes enable reductions as high as 100:1 in one step or 10.000:1 in a double decrease. An comparative gearing with the same gear ratios and the same transferred power can be bigger when compared to a worm gearing. In the meantime, the worm gearbox is in a far more simple design.
A double reduction could be composed of 2 regular gearboxes or as a special 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 typical 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 extremely quiet. This is because of the very easy running 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 that can be interpreted as a murmur from the gear. Therefore the general noise level of our gearbox is certainly reduced to a complete minimum.
Angle gearboxes
On the worm gearbox the input shaft and output shaft are perpendicular to each other. This often proves to become a decisive advantage making the incorporation of the gearbox substantially simpler and smaller sized.The worm gearbox is an angle gear. This is often an advantage for incorporation into constructions.
Solid 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 parts rather than having to build a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides 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 perfect for an array of solutions.

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