As efficiency continues to become a priority, a new type of gear is gaining traction in right-angle gearheads, replacing the commonly used worm gears. Historically, worm gears have been the go-to choice for right-angle gearheads due to their affordability and durability, making them suitable for general applications. However, they struggle at lower speeds (higher reduction ratios), generating excessive heat, consuming more power, and requiring regular maintenance. With the growing emphasis on global efficiency standards, another gear technology is being embraced.
Typically utilized in automotive applications, hypoid gears are now being incorporated into right-angle gear motors to address the shortcomings of worm gears and enhance overall gear motor performance. While hypoid gear motors might have a higher initial cost compared to worm gear motors due to advanced machining, heat treatment, and specialized grinding processes, the long-term benefits often justify the investment for numerous applications.
Differences:
In a worm gear set, there are two primary components: the input worm and the corresponding output worm gear. The input worm, resembling a screw, rotates perpendicularly to its paired output worm gear. For example, in a worm gearhead with a 5:1 ratio, the input worm completes five rotations while the output worm gear accomplishes just one. However, torque multiplication isn't proportional to the ratio since much torque is lost due to sliding friction.
On the other hand, a hypoid gear set consists of an input hypoid gear and an output hypoid bevel gear. Combining elements of both bevel and worm gear technologies, hypoid gears exhibit significantly higher efficiency, even at high reduction ratios. This is achieved through a unique tooth pattern that minimizes sliding friction between the gears, allowing for more efficient torque transfer from the motor shaft to the load shaft.
To learn more about the distinctions between hypoid and worm gears, please refer to our white paper titled "Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer."
This article will summarize the key performance differences between hypoid and worm gears, as outlined in the white paper.
- Superior gear efficiency
- Reduced heat generation
- Smaller footprint
- Lower power consumption
Superior Gear Efficiency:
One of the main drawbacks of worm gears is their poor efficiency in transferring torque. Worm gear efficiency typically ranges from 40% to 85%, depending on the ratio, which spans from 60:1 to 10:1. They also require a "break-in" period to reach peak efficiency. Hypoid gears, however, boast efficiencies of 95% to 99% and do not necessitate a break-in period.
With the increasing focus on reducing power consumption (such as meeting IE3 or NEMA Premium Efficiency standards), efficiency has become one of the most critical factors when selecting a gear motor. Since motors already have a long lifespan, choosing an efficient gearhead complements the motor, reducing maintenance costs over time.
Less Heat Generation:
A more efficient gearhead generates less wasted energy. Friction, a form of wasted energy, manifests as heat. Given that worm gears generate more sliding friction than hypoid gears, they tend to run hotter, which accelerates wear and tear on the lubrication, bearings, seals, and gears.
Hypoid gears, due to reduced sliding friction, operate cooler, maintaining peak performance with minimal intervention. The grease used in hypoid gear motors is designed to last the entire lifespan of the gear motor, eliminating the need for frequent lubricant replacements. This helps minimize downtime and boosts productivity. Additionally, features like cooling fins, breather holes, and other auxiliary cooling systems are unnecessary, contributing to lower operational costs.
Upon comparing a hypoid gearbox and a worm gearbox using the same motor, we observed a significant 26.4°F difference in temperature once equilibrium was reached.
Smaller Footprint:
The intersection of the gears' axes in a hypoid gear set allows it to occupy a smaller footprint than a worm gear set. This advantage is particularly beneficial in applications where space is limited.
Another benefit of hypoid gear motors is their axial symmetry from the motor shaft to the load shaft. Worm gear motors lack this symmetry, resulting in machinery that is less visually appealing and offering fewer mounting options.
Less Power Consumption:
In certain scenarios, a smaller motor can provide equivalent torque for the same application. Comparing a hypoid gear motor with a worm gear motor of similar output reveals that the hypoid gear motor uses a 1/2 HP motor, whereas the worm gear motor employs a 1 HP motor. Coupled with reduced energy loss from sliding friction, the smaller motor results in even lower power consumption costs.
Conclusion:
The superior efficiency and design of hypoid gears offer numerous advantages over worm gears, including higher torque transfer, lower operating temperatures, smaller footprints, increased reliability, extended lifespans, and reduced power consumption. These factors lead to lower operational expenses in the long term and enable the creation of smaller machines. Although the upfront costs of hypoid gears may be higher, their benefits should be considered when selecting motors for future machinery projects.
To learn more about the differences between hypoid and worm gears, please read our white paper, "Hypoid vs. Worm Gears: A More Cost Effective Right-Angle Reducer."
Oriental Motor provides right-angle hypoid gearhead options for the Brother Mid H2 Series, Brother Mid F3 Series, BMU Series, BLE2 Series, and K2S Series (coming soon).
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