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-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 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are given a brass spring loaded breather connect and come pre-packed with Mobil SHC634 synthetic gear oil.
Gearbox Worm Drive hypoid versus. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to alternative for right-angle power tranny for generations. Touted because of their low-cost and robust structure, worm reducers could be
found in almost every industrial environment requiring this kind of transmission. However, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a lot of space, and require regular maintenance.
Fortunately, there can be an option 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 issues that occur with worm reducers. Obtainable in smaller general sizes and higher reduction potential, hypoid gearmotors have a broader selection of feasible 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 definitely a limiting factor. They are able to sometimes be costlier, but the savings in efficiency and maintenance are well 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.
Just 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 definitely a screw-like equipment, that rotates perpendicular to its corresponding worm equipment (Figure 1). For instance, in a worm gearbox with a 5:1 ratio, the worm will finish five revolutions while the output worm gear is only going to complete one. With a higher ratio, for instance 60:1, the worm will comprehensive 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 equipment, the worm only encounters sliding friction. There is absolutely no rolling component to the tooth contact (Shape 2).
Sliding Friction
In high reduction applications, such as for example 60:1, there will be a sizable amount of sliding friction due to the high number of input revolutions required to spin the output gear once. Low input swiftness applications have problems with the same friction problem, but for a different reason. Since there exists a lot of tooth contact, the original energy to start rotation is greater than that of a comparable hypoid reducer. When driven at low speeds, the worm needs more energy to continue its movement along the worm equipment, 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 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 that allows torque to end up being transferred smoothly and evenly over the interfacing areas. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Performance Actually Differ?
One of the primary complications posed by worm gear sets is their insufficient efficiency, chiefly at high reductions and low speeds. Normal 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
Regarding worm gear sets, they don’t run at peak efficiency until a specific “break-in” period has occurred. Worms are usually made of metal, with the worm gear being made of bronze. Since bronze is definitely a softer steel it is good at absorbing weighty shock loads but does not operate successfully until it’s been work-hardened. The heat 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 usually made from metal which has already been carbonitride temperature treated. This enables the drive to operate at peak efficiency from the moment it is installed.
Why is Efficiency Important?
Efficiency is one of the most important factors to consider when choosing a gearmotor. Since many employ a long service lifestyle, choosing a high-efficiency reducer will reduce costs related to procedure and maintenance for a long time to come. Additionally, a more efficient reducer allows for better reduction capability and utilization of a motor that
consumes less electrical energy. One stage worm reducers are typically limited to ratios of 5:1 to 60:1, while hypoid gears have a reduction potential of 5:1 up to 120:1. Typically, hypoid gears themselves only go up to reduction ratios of 10:1, and the additional reduction is supplied by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have an increased upfront cost than worm drives. This can be attributed to the excess processing techniques necessary to produce hypoid gearing such as for example machining, heat treatment, and special grinding methods. Additionally, hypoid gearboxes typically utilize grease with intense pressure additives rather than oil which will incur higher costs. This price difference is made up for over the lifetime of the gearmotor because of increased overall performance and reduced maintenance.
An increased efficiency hypoid reducer will eventually waste much less energy and maximize the energy getting transferred from the motor to the driven shaft. Friction is usually wasted energy that requires the form of temperature. Since worm gears generate more friction they run much hotter. In many cases, utilizing a hypoid reducer eliminates the necessity for cooling fins on the motor casing, additional reducing maintenance costs that might be required to keep carefully the fins clean and dissipating temperature 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 created 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 units began at 68°F, space temperature. After 100 moments of operating period, the temperature of both models started to level off, concluding the test. The difference in temperature at this point was significant: the worm unit reached a surface temperature of 151.4°F, as the hypoid unit only reached 125.0°F. A 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 lead to a much heftier electrical expenses for worm users.
As previously mentioned and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This decreases the service life of these drives by placing extra thermal stress on the lubrication, bearings, seals, and gears. After long-term contact with 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 necessary to keep them working at peak performance. Essential oil lubrication is not needed: the cooling potential of grease is enough to ensure 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 replace 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 Package
Smaller sized motors can be utilized in hypoid gearmotors because of the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower engine traveling 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 Company, both a worm and hypoid reducer had been compared for make use of on an equivalent software. This research fixed the reduction ratio of both gearboxes to 60:1 and compared motor power and output torque as it linked to power drawn. The study figured a 1/2 HP hypoid gearmotor can be utilized to provide similar overall performance to a 1 HP worm gearmotor, at a fraction of the electrical price. A final result displaying a assessment of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in engine 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 (Determine 7).
Worm vs Hypoid Axes
Coupled with the capability to use a smaller motor, the entire footprint of the hypoid gearmotor is a lot smaller sized than that of a similar worm gearmotor. This also helps make working conditions safer since smaller sized gearmotors pose a lower threat of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is that they are symmetrical along their centerline (Figure 9). Worm gearmotors are asymmetrical and result in machines that aren’t as aesthetically satisfying and limit the amount of possible mounting positions.
Worm vs Hypoid Shape Comparison
In motors of equal power, hypoid drives considerably outperform their worm counterparts. One important aspect to consider is certainly that hypoid reducers can move loads from a dead stop with more relieve than worm reducers (Figure 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer substantially more torque than worm gearmotors over a 30:1 ratio due to 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 outcomes in both research 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 tested using the studies provided 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 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 shown, the entire footprint and symmetric style of hypoid gearmotors makes for a more aesthetically pleasing style while enhancing workplace safety; with smaller sized, less cumbersome gearmotors there exists a smaller chance of interference with employees or machinery. Obviously, hypoid gearmotors will be the most suitable choice for long-term cost benefits and reliability compared to worm gearmotors.
Brother Gearmotors offers a family group of gearmotors that enhance operational efficiencies and reduce maintenance requirements and downtime. They offer premium efficiency units for long-term energy cost savings. Besides being extremely efficient, its hypoid/helical gearmotors are compact in proportions and sealed for life. They are light, dependable, 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 consistently tough, water-limited, chemically resistant systems that withstand harsh circumstances. These gearmotors also have multiple regular specifications, options, and installation 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
Notice: 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 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 Versions for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide selection of worm gearboxes. Because of the modular design the standard programme comprises countless combinations when it comes to selection of gear housings, installation and connection choices, flanges, shaft designs, kind of oil, surface treatments etc.
Sturdy and reliable
The design of the EP worm gearbox is simple and well proven. We only use high quality components such as houses in cast iron, aluminium and stainless, worms in the event hardened and polished steel and worm wheels in high-quality bronze of special alloys ensuring the the best possible wearability. The seals of the worm gearbox are given with a dust lip which successfully 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 allow for reductions of up to 100:1 in one single step or 10.000:1 in a double reduction. An equivalent gearing with the same equipment ratios and the same transferred power is usually bigger when compared to a worm gearing. In the mean time, the worm gearbox is definitely in a far more simple design.
A double reduction may 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 words of the standard gearboxes of the EP-Series. Further optimisation may be accomplished through the use of adapted gearboxes or special gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is because of the very even working of the worm gear combined with the utilization of cast iron and high precision on element manufacturing and assembly. In connection with our precision gearboxes, we consider extra care of any sound that can be interpreted as a murmur from the gear. 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 making the incorporation of the gearbox considerably simpler and smaller sized.The worm gearbox is an angle gear. This is often an edge for incorporation into constructions.
Strong bearings in solid housing
The output shaft of the EP worm gearbox is very firmly embedded in the apparatus house and is perfect for direct 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 provides a self-locking impact, which in lots of situations can be utilized as brake or as extra protection. Also spindle gearboxes with a trapezoidal spindle are self-locking, making them well suited for a wide range of solutions.