Gearbox Worm Drive

Ever-Power Worm Gear Reducer
High-efficiency, high-strength double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient on the gearing for high efficiency.
Powered by Gearbox Worm Drive 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 are available in speed ratios which range 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 springtime loaded breather connect and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid versus. Worm Gears: A FAR MORE Cost Effective Right-Angle Reducer
Introduction
Worm reducers have already been the go-to solution for right-angle power transmitting for generations. Touted because of their low-cost and robust building, worm reducers can be
found in nearly every industrial establishing requiring this kind of transmission. However, they are inefficient at slower speeds and higher reductions, produce a lot of heat, take up a whole lot of space, and need regular maintenance.
Fortunately, there can be an option to worm gear models: the hypoid gear. Typically found in automotive applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that arise with worm reducers. Obtainable in smaller general sizes and higher decrease potential, hypoid gearmotors possess a broader range of possible uses than their worm counterparts. This not only enables heavier torque loads to become transferred at higher efficiencies, nonetheless it opens possibilities for applications where space can be 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 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 established there are two components: the input worm, and the output worm gear. The worm is certainly 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 finish five revolutions while the output worm equipment will only complete one. With an increased ratio, for example 60:1, the worm will finish 60 revolutions per one output revolution. It really is this fundamental arrangement that triggers the inefficiencies in worm reducers.
Worm Gear Set
To rotate the worm gear, the worm only experiences sliding friction. There is no rolling component to the tooth contact (Number 2).
Sliding Friction
In high reduction applications, such as for example 60:1, there will be a large amount of sliding friction due to the lot of input revolutions necessary to spin the output gear once. Low input velocity applications have problems with the same friction issue, but for a different reason. Since there is a large amount 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 motion along the worm equipment, and lots of that energy is dropped to friction.
Hypoid versus. Worm Gears: A FAR MORE AFFORDABLE Right-Angle Reducer
On the other hand, hypoid gear sets contain the input hypoid gear, and the output hypoid bevel gear (Figure 3).
Hypoid Gear Set
The hypoid gear established is a hybrid of bevel and worm equipment technologies. They experience friction losses because of the meshing of the apparatus teeth, with minimal sliding involved. These losses are minimized using the hypoid tooth design that allows torque to become transferred efficiently and evenly across the interfacing surfaces. This is what provides hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the biggest complications posed by worm equipment sets is their lack of efficiency, chiefly in high reductions and low speeds. Usual efficiencies may differ 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 run at peak efficiency until a particular “break-in” period has occurred. Worms are typically made of metal, with the worm equipment being manufactured from bronze. Since bronze is usually a softer metallic it is proficient at absorbing heavy shock loads but will not operate effectively until it’s been work-hardened. The heat generated from the friction of regular working conditions really helps to harden the top of worm gear.
With hypoid gear sets, there is no “break-in” period; they are typically 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.
Why is Efficiency Important?
Efficiency is among the most important factors to consider when choosing a gearmotor. Since most have a very long service existence, choosing a high-efficiency reducer will minimize costs related to procedure and maintenance for years to come. Additionally, a more efficient reducer allows for better reduction capability and use of a motor that
consumes less electrical power. Solitary 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 only 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 may have an increased upfront cost than worm drives. This is often attributed to the additional processing techniques required to produce hypoid gearing such as machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives instead of 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.
An increased efficiency hypoid reducer will ultimately waste much less energy and maximize the energy becoming transferred from the electric motor to the driven shaft. Friction is usually wasted energy that requires the form of high 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 engine casing, additional reducing maintenance costs that would be required to keep the fins clean and dissipating heat properly. A evaluation 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 models began to level off, concluding the check. The difference in temperature at this stage was substantial: the worm device reached a surface temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A notable difference around 26.4°F. Despite becoming powered 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 expenses for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of the 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 oil changes are imminent because of lubrication degradation.
Since hypoid reducers run cooler, there is little to no maintenance necessary to keep them working at peak performance. Oil lubrication is not required: the cooling potential of grease will do to guarantee the reducer will operate effectively. This eliminates the necessity for breather holes and any mounting constraints posed by oil lubricated systems. Additionally it is not necessary to displace lubricant since the grease is intended to last the life time use of the gearmotor, eliminating downtime and increasing productivity.
More Power in a Smaller sized Package
Smaller motors can be used in hypoid gearmotors due to the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor generating a worm reducer can create 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 had been compared for use on an equivalent program. 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 study 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 cost. A final result displaying a comparison of torque and power intake was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine size, comes the advantage to use these drives in more applications where space is a constraint. Because of the method the axes of the gears intersect, worm gears consider up more space than hypoid gears (Figure 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the entire footprint of the hypoid gearmotor is much smaller than that of a comparable worm gearmotor. This also helps make working conditions safer since smaller sized gearmotors pose a lower risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is usually they are symmetrical along their centerline (Number 9). Worm gearmotors are asymmetrical and result in machines that are not as aesthetically satisfying and limit the quantity of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of the same power, hypoid drives much outperform their worm counterparts. One essential requirement to consider is certainly 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 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 research are obvious: hypoid reducers transfer power better.
The Hypoid Gear Advantage
As proven throughout, the benefits of hypoid reducers speak for themselves. Their design allows them to perform more efficiently, cooler, and provide higher reduction ratios when compared to worm reducers. As tested using the studies shown throughout, hypoid gearmotors can handle higher preliminary inertia loads and transfer more torque with a smaller sized motor than a comparable worm gearmotor.
This can lead to upfront savings by allowing an individual 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 design of hypoid gearmotors produces a more aesthetically pleasing design while improving workplace safety; with smaller sized, much less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Obviously, hypoid gearmotors are 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 requirements and downtime. They provide premium efficiency systems for long-term energy cost savings. Besides being highly efficient, its hypoid/helical gearmotors are small in size and sealed forever. They are light, reliable, and provide high torque at low speed unlike their worm counterparts. They are permanently sealed with an electrostatic coating for a high-quality finish that assures regularly tough, water-restricted, chemically resistant products that withstand harsh conditions. These gearmotors also have multiple standard 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 gear attaches to 6 mm or 4.7 mm D-shaft diameters.
Worm Gear Swiftness 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 Inside and Outside Gearbox
Shaft Sleeve Protects All Shafts
S45C Carbon Steel Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers a very wide variety of worm gearboxes. Due to the modular design the standard programme comprises countless combinations when it comes to selection of gear housings, mounting and connection options, flanges, shaft designs, kind of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is easy and well proven. We just use high quality components such as homes in cast iron, light weight aluminum and stainless steel, worms in the event hardened and polished steel and worm tires in high-quality bronze of unique alloys ensuring the ideal wearability. The seals of the worm gearbox are provided with a dust lip which efficiently resists dust and water. Furthermore, 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 decrease. An equivalent gearing with the same equipment ratios and the same transferred power can be bigger when compared to a worm gearing. Meanwhile, the worm gearbox is certainly in a far more simple design.
A double reduction could be composed of 2 standard 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 terms 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 due to the very smooth running of the worm equipment 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 advantage producing the incorporation of the gearbox significantly simpler and more compact.The worm gearbox can be an angle gear. This is often an edge 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 perfect for direct suspension for wheels, movable arms and other parts 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 many situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them ideal for an array of solutions.