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Compact worm gears are widely used but have poor efficiency.Bevel gear units in monoblock housings perform better.A comparison.
Due to increasingly scarce energy resources, energy costs are constantly increasing these days.This global problem forces countries to find new energy resources or to use existing energy resources efficiently.Against this background, many products – from lamps to cars – are being redeveloped.There is still a lot of potential in the industrial environment, including gearboxes.
Inexpensive worm gears with a compact design are widely used on the gear market.The disadvantage of this gearbox is that the friction between the worm shaft and the worm wheel causes a large part of the losses.This leads to poor transmission efficiency.Since increasing gear reduction increases the friction in worm gears, the efficiency also decreases further.The result: Half of the power of the driving electric motor is converted in the form of heat in applications with high gear ratios.In addition, machines that continuously run at high engine power consume a lot of energy.
In 2013, Yılmaz Redüktör company started series production of its highly efficient, cost-effective and compact K0 series bevel gearboxes.They have the advantages of worm gears while eliminating their significant disadvantages.
A worm gear consists of a worm shaft and a worm wheel, the axes of which are not parallel but generally at right angles to one another.So there is a constant sliding of the flanks.This results in a high sliding speed between the worm wheel and worm shaft.A bevel gear consists of a bevel gear and a bevel pinion, the axes of which are also arranged at right angles to each other.However, the sliding speed, which is caused by the relative movements of the contact surfaces of the bevel gear and bevel pinion, is relatively low compared to worm gears.For this reason, gearboxes in the K0 series have better efficiency than worm gearboxes.Replacing them is easy: The K0 series gearboxes can replace worm wheel gearboxes because the dimensions of the Holl shaft diameter, the output flange and the torque arm are the same.
Yilmaz Redüktör produces the K0 series with high reduction ratios in a monoblock housing.While the reduction ratios in a worm gearbox range from 7.5 to 100 in one stage, the K0 series gearboxes, in contrast, are designed for reductions from 6 to 140 with two or three stages.The use of profile grinding machines for high-precision machining of gears, including bevel gears, reduces running noise and increases efficiency even with high gear ratios.
The use of profile grinding machines for high-precision machining of gears, including bevel gears, reduces running noise and increases efficiency even with high gear ratios.(Image: Image: Yilmaz Redüctör)
The K0 series gearboxes are supplied with self-made electric motors in efficiency class IE2 for outputs from 0.25 kW.On request, these can also be supplied with electric motors in efficiency class IE3 for outputs from 0.25 kW.
Comparison between the K0 series and the worm gear transmission using an example of performance.(Image: Image: Yilmaz Redüctör)
As can be seen from the table, when selecting the geared motor, the decision is made in favor of the K0 series with a geared motor power of 0.75 kW, as the worm gearbox requires a larger geared motor power of 1.1 kW for the same purpose due to its poor efficiency.Compared to worm gear drives, the K0 series consumes less energy under the same operating conditions (4000 operating hours per year).This saves 262 euros a year.This means that the acquisition costs for a gearbox from the K0 series are amortized in a short time.When operating for over 4000 hours per year, the profit increases proportionally to the electricity saving rate of 30%.
In addition to the high efficiency, other advantages of the K0 series compared to the worm gear drive are a high nominal torque and a long service life with the same reduction ratio.
The bevel gearboxes achieve a high power density because the housing is designed as a monoblock.This allows precise tolerances between the center distances to be achieved.(Image: Image: Yilmaz Redüktör)
Yılmaz Redüktör's gearboxes are optimized for power density, which means the best possible load capacity with the smallest possible volume.This high power density was achieved because the developers designed the gearbox housing as a monoblock.The monoblocks are cast in one piece and machined with a single device using CNC-controlled machines.In this way, very rigid housings with precise tolerances between the center distances can be achieved.
In addition, the positioning of the bearings and gears in the monoblock housing reduces running noise.In addition, due to this design, there are no screw connections on the case.The risk of an oil leak is also reduced.(ud)
What exactly is a worm gear?
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