Online magazine for design and development

Here you will find everything that the designer needs for his design and the development engineer for his new development, from the draft to quality assurance in production, such as new products, their applications, new technologies or research results. Company reports as well as topics on technological and megatrends in all industrial sectors complete our range of industry news. Let's start with the news.

Company News

Jumo's new Sensilo plant construction is progressing
Jumo is building a factory in the technology park for the production of temperature and pressure sensors with a production area of ​​around 13 m². At around 000 million euros, the new building is the largest investment in the company's history.
3DExperience Word 2024 in Dallas
At 3DExperience World 2024 in February in Dallas, Texas, Dassault Systèmes celebrated the event's 25th anniversary. The annual user meeting supports the global community in the development of future-proof products and processes.
Michael Koch GmbH moves into a new workshop
There is now more space available in Michael Koch's “Factory” for the assembly of customer- and machine-specific safe braking resistors. The new, modern hall was recently “taken by storm” by the employees.
Elon Musk is suing OpenAI for profit-making
Elon Musk files a lawsuit against OpenAI and CEO Sam Altman, accusing them of breach of contract because the company, which was originally designed as a nonprofit, is now operating for profit.
Murat Simsir strengthens strategic corporate management at Montech
Murat Simsir took over the position of CSO at Montech on January 1, 2024. The former head of sales and project management is now strengthening the company's strategic management as part of the management team.
AREAS OF EXPERTISE

Industry news for your design and development from the specialist areas

switch cabinet

switch cabinet

On to the intelligent drive train for predictive maintenance

The Roba-brake-checker module or the torque-measuring shaft coupling from Mayr ensure intelligent safety in smart production.

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plastics

plastics

The first 100 Igus bikes hit the streets

The first 100 Igus Urban Bikes hit the streets and an in-house production facility with a capacity of 10.000 bicycles is set up in Cologne.

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Couplings

Couplings

Torque measuring shaft coupling

The smart steel multi-plate coupling Roba-drive-checker from Mayr can do more than just transmit torque and compensate for shaft misalignment.

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Robotic

Robotic

Programming robots for cable handling

As an exhibitor in the Application Park at the Hannover Messe, Artiminds Robotics is presenting a cable handling application for precise cable harness assembly.

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INDUSTRY SPECIALS

Industry news for your design and development from the branches

food technology

food technology

Lubrication and sealing-optimized linear guide

Schaeffler presents linear guides for food technology with optimized seals, wipers and long-term lubrication units.

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Mobile Machinery

Mobile Machinery

Flexible, customizable gateway for agricultural technology

IFM Electronic is presenting the Isobus Gateway at the Hannover Messe, which is designed for agricultural equipment and can be specifically adapted.

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Energy Technology

Energy Technology

All Electric Society – vision of the future of connectivity

At the Hannover Messe Preview, Harting gives an outlook on the Hannover Messe and draws the future picture of an “All Electric Society”.

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Inverter

Inverter

Certified servo controller with Profisafe interface

At Logimat, Wittenstein is presenting a safety-certified servo controller with a Profisafe interface and integrated safety card for AGVs.

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EXHIBITION SPECIALS

Industry fair news

Hannover Messe promotes energy for sustainable industry
As a networked industrial ecosystem, the exhibitors demonstrate how climate neutrality can be achieved through the use of electrification, digitalization and automation under the guiding theme of Energizing a sustainable Industry.
Control Fair 2024 | The industry is already looking forward to Stuttgart
Control 2024, the important international trade fair for quality assurance, will take place from April 23rd to 26th in Stuttgart. The trade fair places a particular focus on automation and digitalization.
SPS Nuremberg: Now in 16 halls!
The SPS – Smart Production Solutions from November 14th to 16.11th. 2023 will see significant growth in the trade fair compared to the previous year and is on the way to pre-Corona levels.

An worm gear is characterized by its ability to achieve high torque transmission in a compact design. It finds Application in elevators, conveyor systems or in automation technology where low-noise operation and self-locking are required. Modern worm gears are efficient, durable and optimized for precise control tasks. In this article you will discover some of these gearboxes from various manufacturers.

Groschopp worm gear

Contents

  • Two-stage worm spur gearbox with high ratios
  • Investigation of the load capacity limits on the worm wheel
  • Maintenance-free universal worm and bevel gears
  • Servo worm gears with high speed Reserve
  • Small angle and worm gears now in the webshop
  • Precise combination of worm gear and encoder
  • Powerful worm gear with backlash from 3,3 arcmin
  • Worm gearbox with high efficiency
  • Frequently asked questions

 

Two-stage worm spur gearbox with high ratios

Groschopp worm gear solid shaftFebruary 15.02.2023, XNUMX | The worm-helical gearboxes of the ZK series from Groschopp has grown: The ZK30 combination of worm and spur gear stages allows high gear ratios and offers good efficiency. Made of aluminum, the gearboxes are particularly efficient and economical in combination with induction or servo motors. They are also robust, highly resilient and run quietly. Integrated mounting surfaces make the gearboxes versatile.

The ZK series is suitable for applications that require an angled outlet or a compact size. The nominal torque of the ZK30 is 30 Nm, further versions for 50 Nm are being planned. With ratios from 34,5:1 to 690:1, the combination gearbox achieves significantly better efficiency than two-stage worm gearboxes. Worm stage and helical gearing in the spur gear stage enable quiet operation of the easily mountable gearbox.

For applications in harsh environments such as food technology, pharmaceutical or chemical industries as well as in offshore use, there is an easy-to-clean one Version in stainless steel. Other features include ball bearings and the 14 mm solid shaft or 15 mm hollow shaft in the output. The load capacity of the output shaft is 300 N radially and 140 N axially.

Investigation of the load capacity limits on the worm wheel

FVA worm gear15.03.2021/XNUMX/XNUMX | the Drive Technology Research Association e. V. (FVA) makes a recommendation for examining the load capacity limits of worm gears. In a worm gear, the worm wheel is usually subject to comparatively high levels of wear. Sometimes this is desired, whenever it is used to run in or adjust the flank of the worm wheel to that of the worm, which increases the load capacity. However, after running in, wear and tear can mean a limit to the load-bearing capacity. Because increasing wear can lead to tooth failure.

In addition to the continuously progressive wear and tear, dimples in the shape of a Fatigue damage arise. Dimples are caused by cracks on or just below the surface. They get into the material and can then come back to the surface. Then pieces of material break off and leave gaps in the active flank surface. Those are the dimples.

Dimples increase wear

If the resulting dimples cause parts of the tooth flank break away, this in turn leads to increased wear because the flank is not completely available for load transfer and the remaining flank areas are therefore subject to higher loads. The interaction between wear and pitting distorts the results of pure wear tests due to the appearance of pitting. If no pits form, the wear intensity for the material-lubricant pairing can be determined in comparatively simple tests. This can be used to determine the service life of the gearing.

For efficient and reliable determination of the Wear intensity of worm gears, the operating conditions of experimental tests should be chosen so that no dimples occur. The operating conditions under which dimples occur would have to be determined in order to recommend action for resource-optimized and, if necessary, to develop a concise implementation of experiments.

The goal should be the Trial duration to be reduced to 10 to 15%. Example, i=50, n1=500 rpm against wear, 3.000.000 load changes (after the contact pattern has been developed) means 10 rpm 600 revolutions/h for the wheel and thus a test time of 5000 h to realize 3 million load changes. An acceptable test time would be e.g. B. 500 to 750 hours.

Maintenance-free universal worm and bevel gears

Norelem worm gearMay 29.05.2018, XNUMX | The new worm gears from are particularly compact and powerful at the same time Norelem. The angular gears are maintenance-free thanks to a special, encapsulated aluminum housing: This reliably prevents grease from escaping or the effects of dust, which also has a positive effect on the service life. The directions of rotation are arbitrary for both types of gears.

The universally applicable worm gears are available in one size with a center distance of 20 mm and with 7 different ratios 13: 1 to 65: 1. The left-handed worm wheel is made of special brass, the worm itself is made of case-hardened steel. This combination of materials ensures smooth power transmission and high efficiency. The maximum axial and radial loads are between 200 and 500 N. There are
Output torques of up to 15 Nm can be achieved, with the drive speed up to 1000 min-1 may be.

In the Bevel driven Customers can choose between seven different sizes with leg lengths from 32 to 60 mm. With a ratio of 1:1, they cover a wide range of applications with torques of up to 10 Nm. They are equipped with surface-hardened steel bevel gears and ball-bearing shafts. The bevel gearboxes can be mounted in all installation situations using a simple screw fastening.

Servo worm gears with high speed Reserve

Wittenstein alpha worm gear22.09.2016 | Wittenstein Alpha presents the expanded portfolio of servo worm gears from the “V-Drive” product family. The newly developed V-Drive Basic is initially available in two sizes with basic output type hollow shaft and solid shaft as well as a total of five gear ratios. The torsional backlash of 10 to ≤ 15 arcmin is specified for all versions.

The special geometry and design of the gearing in V Drive Basic ensures a high speed reserve and high efficiency. This also makes the servo worm gears very smooth and quiet with a maximum of 65 dbA at full load and only around 50 dbA at medium speeds.

The Upgrade versions V-Drive Value and V-Drive Advanced are fully compatible with the V-Drive eco and V-Drive+, but offer increased torques and significantly reduced backlash. In addition, both V-Drive versions are specified for a lifetime of over 20.000 operating hours - a value that is about 25 to 50% above the current market standard.

Small angle and worm gears now in the webshop

Maedler worm gearApril 16.04.2014, XNUMX | In addition to the well-known cubic bevel gears and the miniature gears Madler now also offers the KEK bevel gear units. They are available in seven sizes with a gear ratio of 1:1 with shaft diameters of 6 to 12 mm. The new KES worm gear units offer a particularly small center distance of 20 mm in seven gear ratios.

In addition, these two offer Angle gear-Designs from German production ensure high torque transmission with small dimensions. They can be mounted in all construction positions and allow various mounting options in various housing designs. By using these maintenance-free grease-lubricated gearboxes, the dimensioning and production costs of systems and devices can be further optimized. The gearboxes are now also available online.

Precise combination of worm gear and encoder

October 31.10.2013, XNUMX | Expanded with two new worm gears and two new encoders Buehler its flexible solution matrix of motors, gearboxes, encoders and brakes. The design of the new worm gear transmission, which is equipped with brass gears, stands for maximum load capacity and reductions of up to 50:1. The version with plastic gear covers the reduction ranges from 10: 1 to 15: 1 and is particularly recommended as a cost-effective variant.

These gearboxes, in which the output shaft is perpendicular to the motor, can be optimally combined with the brushed 52 mm and 63 mm DC motors as well as with the brushless 63 mm EC motor. The two encoders can also be combined with these drives. Available as a high-resolution optical encoder with 2 channels and 100 signals per revolution or as a particularly robust 2-channel 2 cpr magnetic encoder for use even under particularly harsh environmental conditions. With an additional cap, a protection class of IP 54 can be achieved. Such drives are used in building automation, agricultural technology and transport.

Powerful worm gear with backlash from 3,3 arcmin

Systec worm gearNovember 18.11.2011, XNUMX | New in the portfolio of System is the worm gear S030-50, which offers force deflection by 90 degrees with the highest precision. The mechatronics team managed to put together a particularly precise and powerful worm gear. The ratio of 50:1 converts the maximum drive torque of 0,24 Nm into an output torque of 12 Nm. The high-precision gear doesn't just shine with its maximum backlash of just 3,3 arcmin.

The 1kg gearbox in the Aluminum housing Measuring 92 x 44,5 x 92 mm, it has a worm made of steel and a worm wheel made of aluminum bronze with a 14 millimeter diameter hollow shaft. With its integrated Hall sensor, which defines the reference point, it is particularly suitable for precise angular positioning.

The reason for developing the drive component was to design it ready for installation positioning system "Driveset M108R". This is a linear system with an additional rotation module. This automation component is very suitable for image processing or test automation applications. The designers discovered that the market did not offer a suitable worm gear for the required rotation module. Class characteristics of 5 min were required-1 and a thrust force of 30 N of linear motion at a repeat accuracy of 0,25 degrees of rotation.


Harmonic gears for industrial robots, cobots and handling


For the drive set, the gearbox works as the first tool-moving axis in a kinematic structure with a two-phase stepping motor. The linear axis is also driven by a stepper motor. The motor drivers are integrated into the system's "Xemo" control. 

Worm gearbox with high efficiency

Groschopp efficiency13.05.2011 | Groschopp now has the powerful VE40 worm gearboxes in its range with a nominal torque of up to 45 Nm depending on the selected gear ratio. These have a similar modular structure to the VE31 and can be combined with flanges and gear feet and can be operated variably in all positions on the engine. Especially in the low gear ratios, the VE gearboxes achieve a remarkable degree of efficiency for worm gearboxes. The VE40DB version with ratios of up to i=15 has values ​​of 0,8 and above.

VE gearbox are characterized by their longevity and their particularly quiet operation. Compared to the previous model, the maximum permissible power loss has been increased, which is now 95 W, four times higher than the VE31. In addition to a large selection of gear ratios, there is a corresponding variety of housings. The VE series is available with a cover, foot or various flanges and is therefore also compatible with standard motors. Custom-made versions of these series are available as an option.

The output shaft of the Full shaft version can protrude freely on one or both sides as required by the application. At the hollow shaft version The input shaft is mounted and allows standard drives to be easily attached. The hollow shaft design can also be easily converted into a solid shaft design using a separate plug-in shaft, thus offering maximum flexibility. This stub shaft can be mounted on the right or left. As a solid shaft version, the gearbox has an even higher efficiency than the hollow shaft version.

Frequently asked questions

How does a worm gear work?

A worm gear works by having a helical snail, which rotates, engages the teeth of a worm wheel. This configuration allows torque to be transferred from the worm to the wheel. The main advantages of a worm gear are a high gear ratio in a compact design, the ability to move large loads with low noise, and often a self-locking mechanism that prevents the system from spinning back under load.

Where is a worm gear used?

Worm gears are used in Applications used that require high gear ratios in a compact format. Typical areas of application include conveyor systems, elevators, automated doors, telescopes, in automation technology for precise motion control and wherever low-noise and low-friction transmission of large loads is necessary. Their ability to self-lock makes them particularly useful for applications that require a safety feature to prevent movement when no motive force is applied.

When are worm gears self-locking?

Worm gears are self-locking, if the slope of the worm is so low that the friction between the worm and the worm wheel prevents the gear from turning back under load. This depends on the geometry of the screw, the coefficient of friction of the materials and the angle of the screw pitch. 

Source: This article is based on information from the following companies: Bühler, FVA, Groschopp, Mädler, Systec, Wittenstein.

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