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Hypoid gears are a unique category of spiral bevel gears that are used to transmit rotational power between two shafts at right angles. Invented by Ernest Wildhaber in the early s, hypoid gears were used predominantly in the drive trains of heavy trucks.

At the time, the genius of the invention was the offset between gear shafts, which allowed the truck frame to be lowered. This development had a profound impact on vehicle designs, leading to significant improvements in available space within the vehicle, roll stability, vehicle handling, safety, aerodynamics, and gas mileage. While hypoid gears are still used in this capacity, they also have a growing presence in the industrial power transmission and motion control industries.

What Are Hypoid Gears?

Hypoid gears can be classified as a type of bevel gear used to transmit rotational power, or torque, between two shafts at right angles. There are two primary categories of bevel gears: straight teeth and spiral teeth. Spiral teeth bevel gears have proven to run smoother and quieter than straight teeth bevel gears and it is these spiral bevel gears that hypoids most closely resemble.

In contrast to standard bevel gears, the mating gear shafts for hypoid gear sets do not intersect because the smaller gear shaft (referred to as the pinion) is offset from the larger gear shaft (referred to as the crown). It is these non-intersecting axes that Mr. Wildhaber designed with the rear axle in mind, leading to the vehicle performance improvements described above.

Worm gears can provide single-stage ratios up to 100:1 but are less efficient than hypoid gears.

The axis offset allows the pinion diameter to be larger and have a greater spiral angle than would otherwise be possible, which increases the contact area and tooth strength. The spiral angle between the pinion and crown causes the gears to mesh very smoothly. Increased contact area and tooth strengh allow for a wider range of gear ratios and the ability to transmit higher amounts of torque.

Additional benefits resulting from the increased spiral angle and contact area between hypoid gear sets include reduced wear and tear, lower friction, lower energy loss, and higher efficiency, all of which help extend the life of hypoid gears and gearboxes.

Benefits of Hypoid Gears Over Standard Bevel Gears

Due to their increased spiral angle and tooth strength, hypoid gears can carry load across several teeth simultaneously. The average number of hypoid gear teeth in contact at one time is 2.2:1 to 2.9:1. Bevel gears, on the other hand, are loaded one gear tooth at a time. More tooth-to-tooth contact allows hypoid gears to transmit greater torque compared to similarly sized bevel gears. In addition to transmitting more torque, hypoid gears and gearboxes tend to be smaller and more compact than bevel gearboxes with equivalent torque ratings, making them a better choice for applications involving tight spaces.

Bevel gears and bevel gearboxes are most common in ratios of 1:1 and 2:1, with some manufacturers providing ratios up to 5:1. By contrast, hypoid gears do not provide solutions for 1:1 and 2:1 applications. However, they efficiently achieve ratios from 3:1 up to 10:1, providing more ratio options with a single gear stage. Reduction ratios are relevant to speed, where hypoid gearboxes enjoy another significant advantage over bevel gearboxes. Most bevel gearboxes cannot handle speeds over 1,500 rpm without overheating, whereas hypoid gearboxes can reach continuous input speeds up to 3,000 rpm.

The mesh between hypoid gearsets involves a sliding action, resulting in a very smooth and quiet transmission. Subsequently, higher loads can be transmitted with lower noise levels compared to bevel gears, which become noisy at higher speeds.

Advantages of Standard Bevel Gears Over Hypoid Gears

Hypoid gears have offset pinions to increase contact area and tooth strength.

Hypoid gears offer more ratios, higher torque capacities, higher running speeds, and less noise than their bevel counterparts. However, hypoid gears are usually less efficient (90 to 95%) than a similar set of spiral bevel gears, which can have efficiency ratings up to 99%. The efficiency of hypoid gears decreases as the axis offset increases and special attention must be given to lubrication to prevent gear wear as a result of the sliding action of hypoid gear teeth. Hypoids require lubrication with extreme pressure additives, whereas bevel gears can operate with standard gear grease or oil.

Packaged bevel gearboxes have another advantage over hypoids. Bevel boxes offer multiple shaft options; many bevel gearboxes are available in 2, 3, and 4 shaft configurations. If an application requires a 1:1 or 2:1 transmission, a transmission with 3 or 4 outputs, or efficiency ratings above 95%, then bevel gears may be the best option. Outside of these criteria, hypoid gears are replacing bevel gears in a number of applications.

Hypoid Gears vs. Worm Gears

The other popular type of right-angle gearing that hypoids are encroaching upon is worm gear technology. For decades, worm gears were the popular choice for right-angle speed reduction because they are robust and relatively inexpensive. With a favorable cost-to-torque ratio and the ability to offer a large range of ratios in single stage &#; typically from 3:1 up to 100:1 &#; worm gearing is widely used across a number of manufacturing industries. Today, however, hypoid gears may be a better alternative for many reasons.

While hypoids enjoy a large speed advantage over worm gears, the most impactful difference between these two types of gearing is efficiency. Compared to worm gears, hypoids are far more efficient at transmitting power, especially at high reduction ratios and low speeds. Most hypoids are between 90% and 95% efficient versus similar sized worm gearing, which varies between 40% and 85%. Additionally, hypoid efficiency remains constant over a wide range of ratios and speeds, whereas the efficiency of worm gearing varies with both ratio and speed.

Standard bevel gears have mating gear shafts that intersect, while hypoid gear shafts do not.

Greater efficiency has many benefits, beginning with energy savings. More efficiency means smaller motors can be used to drive machines, reducing up-front purchasing costs as well as reducing long-term energy and maintenance costs. Efficiency also affects heat generation. Hypoid gears run much cooler than worm gears, which can lead to an advantage in the expected life of the gears.

The trend today is to make everything smaller and more efficient and hypoids help achieve these goals. The efficiency advantage that hypoids have over worm gearing is significant and hypoids are far more compact and can fit into tighter physical spaces than a worm gear arrangement with similar torque capacity. As mentioned above, machines can use smaller, less expensive motors as a result of higher efficiencies, further reducing the machine footprint. Time costs money and so does space, giving hypoids another advantage over worm gears.

When to Use Worm Gears

Worm and worm wheel gearing does have a few advantages over hypoid gears. Worm gears can provide ratios up to 100:1 or more with single-stage gearing, whereas in single stage, most manufacturers provide hypoid gearboxes up to 10:1. Also, due to the inefficiency and high ratios of worm gears, many worm gear drive applications are self-locking, eliminating the need for holding torque or an external brake. With efficiencies up to 95%, hypoid gears are not self-locking; it is possible for the transmission to backdrive in the absence of holding torque or a brake.

The up-front purchase price of hypoid gears may also be more expensive than comparable worm gears and gearboxes. However, the numerous performance benefits of hypoid gears &#; such as higher efficiency, higher precision, higher speed, higher torque capacity, and smaller footprint &#; may prove hypoid technology to be more cost effective over time. For premium performance and long-term cost savings, hypoid gears have become an attractive alternative to worm gears and the growth of hypoids in the power transmission industry is a testament to this fact.

Achieve Very Low Backlash

Another enormous advantage that hypoid gearing has over both bevel gears and worm gears is precision or accuracy measured in gear tooth backlash. Bevel gears, particularly spiral bevel gears, can be made in sets to be very accurate, down to about 6 arc minutes backlash. Most worm and worm wheel gearing, however, have far more backlash in the gear tooth mesh, making them unsuitable for many applications beyond power transmission.

Hypoid gears can achieve backlash specifications as low as 3 arc minutes, making them far more accurate than either bevel or worm gear arrangements. This level of precision, combined with the many other established advantages, has allowed hypoid gearing to go beyond power transmission and to penetrate the motion control market.

Hypoid Gears Have the Largest Range of Uses

Hypoid gears are now commonly used across a wide spectrum of automation and motion control applications. Their performance characteristics make them ideal for both low- and high-speed applications as well as high-cycle-rate applications that require extreme precision. Available in single- and two-stage arrangements, packaged with a planetary gear stage, hypoid gearboxes offer a wide range of ratios from 3:1 up to 100:1.

Precision planetary gearboxes have been present in the motion control industry for many years. In order to convert an inline planetary arrangement into a right-angle reducer, gearbox manufacturers incorporated a set of spiral bevel gears to make the 90-degree turn. In the past several years, these bevel gear sets inside multi-stage, right-angle planetary gearboxes are being replaced with hypoid gears, resulting in more compact, efficient, and precise gearboxes.

Most manufacturers have designed motor flanges on the input of these hypoid gearboxes to allow for a variety of motors, including metric and NEMA servo motors, to mount directly to the gearbox housing. Whether used in a single-stage right-angle gearbox or in conjunction with planetary stages, hypoid gears have a growing presence in the motion control industry.

Hypoids Are the Gears of the Future

It is unlikely that Ernest Wildhaber could have anticipated that his invention would travel well beyond vehicle drivetrains and into the world of industrial power transmission and motion control. Upon reviewing the design characteristics of hypoid gears, it is easy to see why this technology has experienced such significant growth.

Compact, high speed, high torque, high efficiency, extreme precision, low noise, low heat, and long life &#; these performance characteristics are synonymous with hypoid gears and gearboxes. The combination of these traits has made hypoid gearing an increasingly popular speed reduction solution for the growing demands of today&#;s power transmission and motion control industries.

This article was contributed by Candy Controls, Niles, IL. For more information, visit here .

8 Types of Gearmotors and Their Applications

Introduction to Gearmotors

Before we dive into the different types of gearmotors, let's start with a brief overview of what gearmotors are and how they work.  

Gearmotors are an essential component in many industrial applications.  

They are responsible for converting electrical energy into mechanical energy to drive machines and equipment. There are various types of gearmotors available, each designed to suit specific applications. In this beginner's guide, we'll cover the different types of gearmotors and their applications, so you can choose the right one for your operations. 

A gearmotor is a type of motor that is combined with a gearbox to produce mechanical energy. The gearbox is designed to reduce the speed of the motor and increase its torque output, which is the rotational force used to turn an object. By using gears to transfer power from the motor to the output shaft, a gearmotor is able to produce a higher torque output than a motor without a gearbox.  

Gearmotors are commonly used in industrial machinery and equipment, such as conveyors, cranes, and elevators, where a high torque output is required. They come in various types, including cycloidal, helical, bevel, helical-bevel, worm, and planetary gearmotors, each designed for specific applications. 

Cycloidal Gearmotors

Cycloidal gearmotors are a type of gearmotor that offer several benefits for industrial applications. In this blog post, we'll explore what cycloidal gearmotors are, how they work, and their advantages over other types of gearmotors. 

Cycloidal gearmotors consist of a motor and a gearbox that uses a cycloidal disc to transfer power. The cycloidal disc has a series of internal grooves that mesh with cycloidal pins on the output shaft. As the disc rotates, the pins move in a circular motion, providing power transfer to the output shaft. 

One of the main advantages of cycloidal gearmotors is their high torque output. The design of the cycloidal disc provides high torque output, making them an ideal choice for applications that require high torque and low speed, such as in mixers, conveyors, and bottling plants. 

Another benefit of cycloidal gearmotors is their smooth operation. The cycloidal disc and pins provide a smooth and uniform transfer of power, resulting in less noise and vibration compared to other types of gearmotors. This makes them an ideal choice for applications that require low noise levels, such as in medical equipment and automation. 

Cycloidal gearmotors also have a compact size, which makes them ideal for applications where space is limited. They can be designed to fit in tight spaces and have a low profile, making them a popular choice for robotics and automation. 

It's important to note that cycloidal gearmotors may have a higher initial cost compared to other types of gearmotors. However, their high torque output, smooth operation, and compact size make them a cost-effective choice for industrial applications in the long run. 

Overall, cycloidal gearmotors offer a reliable and efficient solution for industrial applications that require high torque output and smooth operation. With their compact size and low noise levels, cycloidal gearmotors are a popular choice for applications such as mixers, conveyors, and robotics. If you're looking for a gearmotor for your industrial operation, consider the benefits that cycloidal gearmotors can provide. Interested in Cycloidal Gearmotors? Our Cyclo is a perfect gear drive option for you.

Helical Bevel Gearmotors

Helical bevel gearmotors combine the benefits of both helical and bevel gearmotors, making them a popular choice for industrial applications that require high precision, low noise levels, and flexibility in power transfer angles.  

Helical bevel gearmotors consist of a motor and a gearbox that contains both helical and bevel gears. The helical gears are angled to reduce noise and vibration, while the bevel gears allow for power transfer at an angle. This combination of gears provides high efficiency, precision, and flexibility in power transfer angles. 

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One of the main advantages of helical bevel gearmotors is their precision. The angled teeth on the helical gears mesh smoothly and quietly, providing high precision and low noise levels. This precision makes helical bevel gearmotors an ideal choice for applications that require high accuracy, such as in automation and robotics. 

Another benefit of helical bevel gearmotors is their high efficiency. The combination of helical and bevel gears creates a larger contact area, reducing friction and energy loss. This makes helical bevel gearmotors an energy-efficient choice for applications that require high torque and speed. 

Helical bevel gearmotors are also highly customizable, allowing for flexibility in industrial design. They can be designed to fit a wide range of motor sizes and are available in various ratios and configurations, providing a versatile solution to industrial design challenges. 

It's important to note that helical bevel gearmotors may require more maintenance than other types of gearmotors due to the angled teeth on the helical gears. However, with proper lubrication and maintenance, helical bevel gearmotors can provide reliable and efficient operation for industrial applications. 

Overall, helical bevel gearmotors offer a versatile solution for industrial applications that require high precision, low noise levels, and flexibility in power transfer angles. With their precision, efficiency, and customization options, helical bevel gearmotors are a popular choice for applications such as conveyors, cranes, and hoists. If you're looking for a gearmotor for your industrial operation, consider the benefits that helical bevel gearmotors can provide. 

Spiral Bevel Gearmotors

Spiral bevel gearmotors consist of a motor and a gearbox that contains spiral bevel gears. These gears are angled and have a curved tooth profile, which provides a smooth and quiet transfer of power. The angled teeth also allow for power transfer at an angle, making spiral bevel gearmotors ideal for applications where the motor and output shaft are not in line. 

One of the main advantages of spiral bevel gearmotors is their high precision. The angled teeth on the spiral bevel gears mesh more smoothly and quietly than straight-cut gears, providing high precision and low noise levels. This precision makes spiral bevel gearmotors an ideal choice for applications that require high accuracy, such as in robotics and automation. 

Another benefit of spiral bevel gearmotors is their high efficiency. The angled teeth on the spiral bevel gears create a larger contact area than straight-cut gears, which helps reduce friction and energy loss. This makes spiral bevel gearmotors an energy-efficient choice for applications that require high torque and speed. 

Spiral bevel gearmotors are also highly customizable. They can be designed to fit a wide range of motor sizes and are available in various ratios and configurations, providing flexibility in designing and adapting industrial systems. 

It's important to note that spiral bevel gearmotors may require more maintenance than other types of gearmotors. The angled teeth on the spiral bevel gears can create more wear and tear over time, which may require more frequent lubrication and maintenance. 

Overall, spiral bevel gearmotors offer a reliable and efficient solution for industrial applications that require high precision, low noise levels, and flexibility in power transfer angles. With their precision, efficiency, and customization options, spiral bevel gearmotors are a popular choice for applications such as conveyors, cranes, and hoists. If you're looking for a gearmotor for your industrial operation, consider the benefits that spiral bevel gearmotors can provide. 

Does Sumitomo offer spiral bevel gear drives? Yes! The Cyclo® BBB4 combines the strength and flexibility of the Cyclo® gear reducer and a single-stage right-angle spiral bevel gearbox in a rugged right-angle gearbox design. Learn more about it here.

Hypoid Gearmotors

Hypoid gearmotors are a type of gearmotor that offer several benefits for industrial applications. In this blog post, we'll explore what hypoid gearmotors are, how they work, and their advantages over other types of gearmotors. 

Hypoid gearmotors consist of a motor and a gearbox that contains hypoid gears. These gears are similar to spiral bevel gears, but their axes are not intersecting, resulting in a more compact and efficient design. The hypoid gears also allow for power transfer at an angle, making hypoid gearmotors ideal for applications where the motor and output shaft are not in line. 

One of the main advantages of hypoid gearmotors is their high torque output. The design of the hypoid gears provides high torque output with a small envelope size, making them an ideal choice for applications that require high torque and limited space, such as in robotics and automation. 

Another benefit of hypoid gearmotors is their low noise levels. The hypoid gears mesh smoothly and quietly, resulting in less noise and vibration compared to other types of gearmotors. This makes them an ideal choice for applications that require low noise levels, such as in medical equipment and automation. 

Hypoid gearmotors also have high efficiency. The design of the hypoid gears allows for a larger contact area, reducing friction and energy loss. This makes hypoid gearmotors an energy-efficient choice for applications that require high torque and speed. 

It's important to note that hypoid gearmotors may require more maintenance than other types of gearmotors due to their complex design. However, with proper lubrication and maintenance, hypoid gearmotors can provide reliable and efficient operation for industrial applications. 

Overall, hypoid gearmotors offer a compact, efficient, and low noise solution for industrial applications that require high torque output and flexibility in power transfer angles. With their high torque output, low noise levels, and efficiency, hypoid gearmotors are a popular choice for applications such as robotics, automation, and material handling. If you're looking for a gearmotor for your industrial operation, consider the benefits that hypoid gearmotors can provide. 

Helical Gearmotors 

One of the most common types of gearmotors is the helical gearmotor. It features helical gears that are angled to reduce noise and improve efficiency.  

Helical gearmotors are ideal for applications that require high precision and low noise levels, such as conveyor systems, cranes, and hoists. 

Helical gearmotors are a popular type of gearmotor that offer several benefits for industrial applications. In this blog post, we'll explore what helical gearmotors are, how they work, and their advantages over other types of gearmotors. 

At their core, helical gearmotors consist of a motor and a gearbox, just like other types of gearmotors. However, the gearbox in a helical gearmotor contains helical gears instead of the straight-cut gears found in other gearmotors. These gears are angled, which helps reduce noise and vibration while improving efficiency. 

One of the main advantages of helical gearmotors is their precision. The angled teeth on the helical gears mesh more smoothly and quietly than straight-cut gears, which makes helical gearmotors ideal for applications that require high precision and low noise levels. This precision also makes them an excellent choice for use in automation and robotics, where high accuracy is critical. 

Another benefit of helical gearmotors is their high efficiency. The angled teeth on the helical gears create a larger contact area than straight-cut gears, which helps reduce friction and energy loss. This makes helical gearmotors an energy-efficient choice for applications that require high torque and speed. 

In addition to their precision and efficiency, helical gearmotors are also highly customizable. They can be designed to fit a wide range of motor sizes and are available in various ratios and configurations, allowing for flexibility in designing and adapting industrial systems. 

However, it's important to note that helical gearmotors may require more maintenance than other types of gearmotors. The angled teeth on the helical gears can create more wear and tear over time, which may require more frequent lubrication and maintenance. 

Overall, helical gearmotors are a reliable and efficient choice for industrial applications that require high precision and low noise levels. With their customizable options and energy efficiency, helical gearmotors are a popular choice for applications such as conveyors, cranes, and hoists. 

Bevel Gearmotors

Bevel gearmotors have bevel gears that allow them to transfer power at an angle. This makes them ideal for applications where the motor and output shaft are not in line, such as in paper mills, steel mills, and mining equipment.  

Bevel gearmotors are also known for their high efficiency and low maintenance requirements. 

Bevel gearmotors are a type of gearmotor that offer several benefits for industrial applications. Bevel gearmotors consist of a motor and a gearbox, just like other types of gearmotors. However, the gearbox in a bevel gearmotor contains bevel gears instead of straight-cut or helical gears. These gears are angled and allow for power transfer at an angle, making them ideal for applications where the motor and output shaft are not in line. 

One of the main advantages of bevel gearmotors is their versatility. The ability to transfer power at an angle makes them ideal for use in industrial applications such as paper mills, steel mills, and mining equipment, where the motor and output shaft are often not in line. Bevel gearmotors can also be used in other applications where the power transfer angle needs to be adjusted, providing a flexible solution to industrial design challenges. 

Another benefit of bevel gearmotors is their high efficiency. Bevel gears have a larger contact area than other types of gears, which helps reduce energy loss and increase efficiency. This makes bevel gearmotors an energy-efficient choice for applications that require high torque and speed. 

Bevel gearmotors also require less maintenance than other types of gearmotors. The angled teeth on the bevel gears create less wear and tear, resulting in less frequent lubrication and maintenance requirements.  

This can lead to reduced downtime and maintenance costs over time. 

It's important to note that bevel gearmotors may have higher initial costs compared to other types of gearmotors. However, the versatility, efficiency, and reduced maintenance requirements make them a cost-effective choice for industrial applications in the long run. 

Overall, bevel gearmotors are a reliable and versatile choice for industrial applications where power transfer angles need to be adjusted. With their high efficiency, reduced maintenance requirements, and flexibility in industrial design, bevel gearmotors are a popular choice for applications such as paper mills, steel mills, and mining equipment. If you're looking for a gearmotor for your industrial operation, consider the benefits that bevel gearmotors can provide. 

Worm & Planetary Gearmotors

Worm gearmotors use a worm gear to transfer power, which provides high torque output and low-speed operation. They are ideal for applications that require a high reduction ratio, such as in mixers, conveyors, and bottling plants. Worm gearmotors are also known for their quiet operation and compact size. 

Planetary gearmotors use planetary gears to transfer power, which provides high torque output and low-speed operation. They are ideal for applications that require a high reduction ratio and compact sizes, such as in robotics, medical equipment, and automation. Planetary gearmotors are also known for their high efficiency and low noise levels. 

 

In conclusion, understanding the different types of gearmotors and their applications is essential for choosing the right one for your operations. Whether you need a high reduction ratio, low noise levels, or high torque output, there is a gearmotor that can meet your requirements. By choosing the right gearmotor, you can improve efficiency, reduce maintenance costs, and increase the lifespan of your equipment. 

About Sumitomo Drive Technologies

At Sumitomo Drive Technologies, we work hand-in-hand with our customers to ensure that their industrial gearboxes, speed reducers, and accessories remain operational for years to come. Many of our products have been in high-speed and harsh environments for years. Clients make the switch to Sumitomo to experience that durability and decrease the amount of unscheduled downtime and maintenance in their facility. We ensure that every unit we design or repair leaves our Unites States' facilities quickly to keep your application up and running. Please call us at 1.800.762. or contact us by to receive a quote for your facility or information about our industrial gearbox repair services. We will be glad to tell you more about our products and connect you to a representative in your area.

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