Discover the advantages, applications, and selection criteria for worm gearboxes in drive technology.
What are the key advantages of ATEK worm gearboxes for my machine?
ATEK worm gearboxes offer high ratios in a compact space, often with self-locking for increased safety, and are part of our modular system for quick, flexible solutions. They enable a torque transmission at a 90-degree deflection and are known for their robustness.
When is self-locking particularly useful in worm gearboxes, and what should I consider?
Self-locking is especially advantageous in safety applications such as hoists, as it can prevent the load from rolling back. It primarily occurs with high ratios and efficiencies below 50% . A drive through the worm wheel is usually no longer possible.
What materials are typically used for worms and worm wheels at ATEK?
For optimal lifespan and wear resistance, ATEK typically uses hardened steel for the worm und high-quality bronze alloys (e.g., CuSn12) for the worm wheel. This material pairing ensures good sliding properties and load capacity.
My current worm gearbox overheats during continuous operation. How can ATEK help me here?
Overheating is a known issue with worm gearboxes due to sliding friction. ATEK analyzes your application and can help through optimal design of the gearbox, selection of suitable lubricants, or integration of cooling measures (e.g., cooling fins) to ideally keep the operating temperature of your drive unit below 90°C .
I need a worm gearbox with very little play for a precision application. Does ATEK offer this?
Yes, for precision applications such as positioning tasks in machine tool construction or robotics, ATEK offers play-free duplex worm gearboxes . These allow for a highly accurate power transmission with minimized torsion play.
How do I select the right worm gearbox for my specific machine?
In addition to the required output torque and ratio , size, connection dimensions (e.g., IEC motor flange), operating mode (e.g., S1 continuous operation), and environmental conditions are crucial. Use our online product configurator or contact our experts for a comprehensive technical consultation..
Are ATEK worm gearboxes maintenance-intensive?
Many of our worm gearboxes are designed to be low-maintenance or maintenance-free for the intended lifespan, often with lifetime lubrication. Proper assembly to avoid stresses is important, as well as adherence to operating conditions. Regular external inspections for leaks and unusual noises are still recommended. und die Beachtung der Betriebsbedingungen. Regelmäßige äußere Inspektionen auf Dichtheit und ungewöhnliche Geräusche sind dennoch empfehlenswert.
What if standard worm gearboxes do not fit my design perfectly? Does ATEK also offer custom solutions?
Yes, ATEK Drive Solutions specializes in the development of custom special gearboxes, even in small series. Thanks to our decades of experience and our flexible modular system with nearly 500,000 individual parts, we find the tailored solution.
Worm gearboxes enable high ratios of up to 100:1 and more in a single stage and are characterized by a very compact design , ideal for applications with limited installation space. Many models also provide safety-related self-locking..
The efficiency of worm gearboxes typically ranges between 50% and 90%, which requires careful thermal design to dissipate the generated power loss as heat and ensure a long lifespan of, for example, over 15,000 operating hours. ATEK Drive Solutions, as a system provider, offers not only standard worm gearboxes but also
ATEK Drive Solutions bietet als Systemanbieter neben Standard-Schneckengetrieben auch customized special solutions from a modular system with nearly 500,000 individual parts, supported by comprehensive technical consultation. to optimize your drive technology.Learn everything about worm gearboxes: from the basics to the advantages and disadvantages, as well as the latest innovations and application areas. Optimize your drive solutions with our expert knowledge!
Are you looking for a compact and powerful drive solution? Worm gearboxes offer high ratios in a compact space. Discover the diverse applications now and contact us for personalized advice at Contact!
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Introduction to worm gearboxes
worm gearboxes achieve high ratios in a small space with reliable operation. This article covers their function, advantages, selection, and optimization for machines.
What are worm gearboxes?
worm wheel gearboxes which turn rotational movements by 90 degrees and significantly reduce speeds. They consist of a screw-shaped worm and a meshing worm wheel; ATEK Drive Solutions GmbH implements these drive solutions into customer solutions.
Advantages of worm gearboxes
Designers frequently use this type of gearbox , for example, for conveyors. Their ability to achieve high ratios up to 100:1+ in one stage is a significant advantage in limited space, which worm gearboxes they provide.
Disadvantages of worm gearboxes
When operating continuously under full load, certain aspects must be considered with these reduction gearboxes. The lower efficiency (often 50-90%) compared to spur gearboxes and the heat generation are important design points. Understanding angular gearboxesWinkelgetriebe verstehenFunctionality and designs of worm gearboxes
Power transmission in detail
The worm converts fast motor rotations into slow, powerful output movements. Characteristic of a worm gearboxes is the sliding friction between the worm and worm wheel flanks, which allows for high ratios; the ratio is determined by the number of teeth / number of threads.
- Power transmission occurs through sliding friction between the worm and the worm wheel.
- High ratios are achieved through the ratio of the number of teeth (worm wheel) to the number of threads (worm).
- Many worm gearboxes offer self-locking, which allows loads to be held without a brake.
- Self-locking is particularly pronounced at high ratios and efficiencies below 50%.
- Types include cylindrical –worm gearboxes for standard applications.
- Globoidgetriebe are used for higher torque transmission.
- Duplex –worm gearboxes offer play-free solutions for precision applications.
Self-locking: A safety aspect
worm gearboxes can hold loads without external brakes, e.g., in lift tables. Many of these drive components are self-locking, especially at high ratios and efficiency <50%, meaning a drive through the worm wheel is not possible.
Types and their specializations
Variants for special requirements, e.g., in precision machines, exist. In addition to cylindrical worm gearboxes, there are Globoidgetriebe for higher torques and duplex worm gearboxes for play-free applications, which ATEK offers for positioning tasks.More on worm gearboxesMaterial selection, lubrication and design aspects in worm gearboxes
The importance of the right materials
The choice of material affects the lifespan and function of a worm gearbox, even under harsh industrial conditions. We typically use hardened steel for the worm and high-quality bronze (often CuSn12) for the worm wheel for optimal sliding/wear resistance, similar to Ganter standards.
Lubrication: Oil or grease?
To minimize friction, dissipate heat, and achieve the lifespan (e.g., 15,000 operating hours), lubrication is important for worm wheel sets. The choice of oil/grease depends on the application; synthetic PAO or PAG oils are commonly used (PAG is not compatible with all seals/non-ferrous metals like brass). Die Öl-/Fettwahl ist anwendungsabhängig; synthetische PAO- oder PAG-Öle sind verbreitet (PAG nicht mit allen Dichtungen/Buntmetallen wie Messing kompatibel).
Design aspects: Axial forces and heat generation
When designing machines with a worm gearboxes , axial forces and heat generation must be considered. Axial forces on the worm shaft require robust bearing; heat generation may necessitate cooling measures (cooling fins, external coolers) to keep oil temperatures at the drive unit below 90°C.Gearbox technology basicsApplications, advantages, and disadvantages of worm gearboxes in detail
Diverse areas of application
worm gearboxes are used industrially in various ways, from packaging machines to solar trackers. They find application in conveyor technology (belt drives), packaging machines (precise movements), machine tools (feeds), and medical technology (ATEK solutions for adjustments with these gearboxes.).
- Conveyor technology, for example in belt drives and material handling.
- Packaging machines that require precise and repeatable movements.
- Machine tools, especially for feed drives and positioning tasks.
- Medical technology, e.g., for adjusting mechanisms in patient lifts or treatment tables (ATEK solutions).
- Compactness is a core advantage that enables installation in tight spaces.
- The inherent self-locking of many models provides increased safety and can make external brakes unnecessary. worm gearboxes bietet erhöhte Sicherheit und kann externe Bremsen überflüssig machen.
- The efficiency (typically 40-92%) must be considered in the design, as it affects power loss and heat generation.
Practical advantages: Compactness and safety
A lifting application with an 80:1 ratio in the tightest space is achievable with a worm gearboxes . Compactness is a core advantage; self-locking of many models provides safety and can save brakes.
Disadvantages and their management
In continuous operation at 3 kW output, the efficiency of such drives is critical. The efficiency (40-92% depending on the gear ratio/design of the worm gear) results in power losses as heat; careful thermal design is necessary.Selection criteria, manufacturers, and future trends for worm gearboxes
Making the right choice
For a project (e.g., 150 Nm output torque, i=40), several parameters are crucial when selecting a worm gearbox gearmotor. In addition to torque/gear ratio, size, connection dimensions (e.g., IEC flange), operating mode (S1 continuous operation), and environment must be considered; our online configurator helps in choosing the suitable worm gear.
Utilize manufacturer expertise
A partner that supports the design of the worm gearbox system is important. We at ATEK Drive Solutions provide comprehensive consulting as a system provider to configure the optimal gear solution from our modular system (almost 500,000 parts), including special gears.
Innovations in the field of worm gearboxes
The technology of these drive components is evolving for greater performance. Research targets improved materials, optimized tooth geometries for higher efficiencies (>90%), and sensor integration for condition monitoring for better maintenance of worm gears.worm wheel gearboxes selectMaintenance, troubleshooting, and conclusion on worm gearboxes
Tips for a long service life
Although worm gearboxes they are often low-maintenance, certain measures ensure longevity (e.g., 20,000 h). Correct assembly (avoids tension) and checking for noises/temperatures are important for this type of gear.
- Proper installation is fundamental to avoid tensions and premature wear.
- Regular acoustic checks for unusual noises can reveal early signs of damage.
- Monitoring operating temperatures helps to detect overheating and lubricant issues early.
- Strict adherence to specified load limits to prevent overload damage.
- Use of the correct type and amount of lubricant according to manufacturer specifications.
- Avoid mixing different types of lubricants to prevent chemical reactions and performance losses.
- Ensure adequate heat dissipation, especially in continuous operation under high load.
Common causes of failure
Premature failure of correctly sized worm gearboxes has typical causes: Overloading, incorrect/insufficient lubrication (oil mixing), or inadequate heat dissipation.
worm gearboxes: A proven technology with a future
worm gearboxes remains relevant despite new drive developments. Compactness, high gear ratios, and self-locking ensure these drive systems their place; continuous optimization (ATEK) makes them future-proof.
worm gearboxes are effective for drives with compactness and gear reduction requirements. Understanding efficiency/self-locking is important. For consultation on your worm gearboxes-project, please contact us.
