Gearbox Worm Drive

Ever-Power Worm Gear Reducer
High-efficiency, high-power double-enveloping worm reducer
Overview
Technical Info
Low friction coefficient upon the gearing for high efficiency.
Powered by long-lasting worm gears.
Minimal 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 because of how we dual 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 which range from 1.33 to 3.25 inches. Also, our gearboxes are supplied with a brass spring loaded breather plug and come pre-loaded with Mobil SHC634 synthetic gear oil.
Hypoid vs. Worm Gears: A More AFFORDABLE Right-Angle Reducer
Introduction
Worm reducers have been the go-to answer for right-angle power transmitting 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. Unfortunately, they are inefficient at slower speeds and higher reductions, create a lot of heat, take up a whole lot of space, and require regular maintenance.
Fortunately, there is an alternative to worm gear pieces: the hypoid gear. Typically found in automotive applications, gearmotor companies have started integrating hypoid gearing into right-angle gearmotors to solve the problems that occur with worm reducers. Obtainable in smaller general sizes and higher reduction potential, hypoid gearmotors have a broader range of feasible uses than their worm counterparts. This not merely allows heavier torque loads to end up being transferred at higher efficiencies, but it opens options for applications where space is usually a limiting factor. They can sometimes be costlier, however the financial savings in efficiency and maintenance are Gearbox Worm Drive really worth it.
The following 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 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 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 a higher ratio, for instance 60:1, the worm will complete 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 gear, the worm only experiences sliding friction. There is absolutely no rolling component to the tooth contact (Determine 2).
Sliding Friction
In high reduction applications, such as 60:1, you will see a big amount of sliding friction due to the high number of input revolutions necessary to spin the output gear once. Low input swiftness applications have problems with the same friction problem, but also for a different reason. Since there exists a lot of tooth contact, the original energy to start rotation is higher than that of a comparable hypoid reducer. When powered at low speeds, the worm requires more energy to keep its motion along the worm equipment, and lots of that energy is dropped to friction.
Hypoid vs. Worm Gears: A More Cost Effective 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 due to the meshing of the apparatus teeth, with minimal sliding included. These losses are minimized using the hypoid tooth design which allows torque to become transferred efficiently and evenly over the interfacing areas. This is what gives the hypoid reducer a mechanical advantage over worm reducers.
How Much Does Effectiveness Actually Differ?
One of the primary problems posed by worm gear sets is their lack of efficiency, chiefly in high reductions and low speeds. Normal efficiencies can vary 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 don't run at peak efficiency until a particular “break-in” period has occurred. Worms are usually made of steel, with the worm gear being manufactured from bronze. Since bronze is certainly a softer metallic it is proficient at absorbing weighty shock loads but does not operate efficiently until it has been work-hardened. The heat produced from the friction of regular operating conditions really helps to harden the surface of the worm gear.
With hypoid gear units, there is absolutely no “break-in” period; they are typically made from metal which has already been carbonitride high temperature treated. This enables the drive to operate at peak efficiency as soon as it is installed.
Why is Efficiency Important?
Efficiency is among the most important things to consider when choosing a gearmotor. Since the majority of employ a long service life, choosing a high-efficiency reducer will reduce costs related to operation and maintenance for a long time to come. Additionally, a far more efficient reducer allows for better reduction ability and use of a motor that
consumes less electrical power. Single 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 additional reduction is supplied by a different type of gearing, such as helical.
Minimizing Costs
Hypoid drives can have a higher upfront cost than worm drives. This could be attributed to the excess processing techniques necessary to generate hypoid gearing such as machining, heat therapy, and special grinding techniques. Additionally, hypoid gearboxes typically utilize grease with severe pressure additives instead of oil which will incur higher costs. This cost difference is composed for over the lifetime of the gearmotor due to increased efficiency and reduced maintenance.
An increased efficiency hypoid reducer will ultimately waste 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 warmth. Since worm gears generate more friction they run much hotter. Oftentimes, using a hypoid reducer eliminates the necessity for cooling fins on the electric motor casing, additional reducing maintenance costs that would be required to keep carefully the fins clean and dissipating warmth 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 as the hypoid gearmotor produced 204 in-lb of torque. This difference in torque is due to the inefficiencies of the worm reducer. The motor surface temperature of both systems began at 68°F, area temperature. After 100 moments of operating time, the temperature of both systems began to level off, concluding the test. The difference in temperature at this time was considerable: the worm unit reached a surface area temperature of 151.4°F, as the hypoid unit just reached 125.0°F. A notable difference around 26.4°F. Despite getting driven by the same motor, the worm device not only produced much less torque, but also wasted more energy. Bottom line, this can lead to a much heftier electrical costs for worm users.
As previously stated and proven, worm reducers operate much hotter than equivalently rated hypoid reducers. This reduces the service life of these drives by putting extra thermal pressure on the lubrication, bearings, seals, and gears. After long-term exposure to high heat, these components can fail, and essential oil changes are imminent due to lubrication degradation.
Since hypoid reducers run 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 need for breather holes and any installation constraints posed by oil lubricated systems. Additionally it is not necessary to replace lubricant because the grease is meant 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 because of the more efficient transfer of energy through the gearbox. Occasionally, a 1 horsepower electric motor driving a worm reducer can produce the same output as a comparable 1/2 horsepower engine generating a hypoid reducer. In one study by Nissei Company, both a worm and hypoid reducer were compared for make use of on an equivalent software. This study fixed the decrease ratio of both gearboxes to 60:1 and compared electric motor power and result torque as it related to power drawn. The study 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 comparison of torque and power usage was prepared (Figure 6).
Worm vs Hypoid Power Consumption
With this reduction in electric motor size, comes the advantage to use these drives in more applications where space is a constraint. Due to 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 ability to use a smaller sized motor, the overall footprint of the hypoid gearmotor is much smaller than that of a similar worm gearmotor. This also helps make working environments safer since smaller gearmotors pose a lesser risk of interference (Figure 8).
Worm vs Hypoid Footprint Compairson
Another benefit of hypoid gearmotors is usually that they are symmetrical along their centerline (Shape 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 Form Comparison
In motors of equal power, hypoid drives considerably outperform their worm counterparts. One important aspect to consider is definitely that hypoid reducers can move loads from a dead stop with more ease than worm reducers (Figure 10).
Worm vs Hypoid Allowable Inertia
Additionally, hypoid gearmotors can transfer considerably 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 research are obvious: hypoid reducers transfer power more effectively.
The Hypoid Gear Advantage
As shown throughout, the advantages 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 initial inertia loads and transfer more torque with a smaller sized motor than a comparable worm gearmotor.
This can result in upfront savings by allowing an individual to purchase 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 style of hypoid gearmotors makes for a more aesthetically pleasing design while enhancing workplace safety; with smaller, less cumbersome gearmotors there is a smaller potential for interference with employees or machinery. Clearly, hypoid gearmotors will be the best 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 needs and downtime. They offer premium efficiency products for long-term energy financial savings. Besides being highly efficient, its hypoid/helical gearmotors are small in size and sealed for life. They are light, dependable, and offer high torque at low speed unlike their worm counterparts. They are completely sealed with an electrostatic coating for a high-quality finish that assures consistently tough, water-limited, chemically resistant models that withstand harsh conditions. These gearmotors likewise have multiple standard 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
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 Quickness 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 Metal Shafts
Flange Mount Models for 56C and 145TC Motors
Ever-Power A/S offers an extremely wide range of worm gearboxes. Because of the modular design the standard program comprises countless combinations when it comes to selection of equipment housings, mounting and connection options, flanges, shaft designs, type 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, worms in the event hardened and polished steel and worm wheels in high-grade bronze of particular alloys ensuring the maximum wearability. The seals of the worm gearbox are given with a dirt lip which effectively 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 of up to 100:1 in one step or 10.000:1 in a double decrease. An equivalent gearing with the same gear ratios and the same transferred power can be bigger when compared to a worm gearing. At the same 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 benefits of worm gearboxes in the EP-Series:
Compact design
Compact design is among the key terms of the typical gearboxes of the EP-Series. Further optimisation can be achieved through the use of adapted gearboxes or particular gearboxes.
Low noise
Our worm gearboxes and actuators are really quiet. This is due to the very simple running of the worm equipment combined with the use of cast iron and high precision on component manufacturing and assembly. In connection with our precision gearboxes, we take extra treatment of any sound that can be interpreted as a murmur from the gear. So 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 more compact.The worm gearbox is 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 quite firmly embedded in the apparatus house and is well suited for immediate suspension for wheels, movable arms and other parts rather than needing to create a separate suspension.
Self locking
For larger gear ratios, Ever-Power worm gearboxes provides a self-locking impact, which in lots of 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.