TECHNICAL INFORMATION

Selection

Care should be taken when selecting a Worm wheel reduction gearbox for a new application. There are many factors that can affect the service life of the unit. The correct selection must be made to ensure the efficiency of the reducer.

Some of these factors including service, load, torque etc. are shown in the following information.

Note: THESE RATINGS ARE ONLY A GUIDE. Ratings shown are compiled using standard engineering procedures. Aline Trading P/L does not guarantee ratings in specific applications. Prototype testing of every application is recommended before production.  

 

Size

Worm wheel reduction gearboxes are made in many styles and sizes. The size of the gearbox is referred to as the “Frame Size”. The frame size is the distance measured between the centre lines of the input and output shafts in mm. This size increases with the capacity of the gearbox and is often shown on the side of the main housing as a number in raised lettering. E.G., 60.

The standard frame sizes offered in our range of single start boxes are:

40 – 50 – 60 – 70 – 80 – 100 – 120 – 135 – 155 – 175 – 200 – 250

 

Gear Ratio.

Once the frame size has been established you must then select the gear ratio. Gear ratios offered in our range of single reduction boxes are:

5:1 – 10:1 – 15:1 – 20:1 – 25:1 – 30:1 – 40:1 – 50:1 – 60:1

These ratios are available in all frame sizes.  

 

Larger ratios are available in the more advanced models.  

 

 Input Shaft Speed

General input shaft speed is 600-1500 RPM. The maximum is 1800 RPM.

The minimum speed of 300 RPM is shown on most charts does not illustrate the lowest recommended input speed. The unit will run efficiently at speeds down to and below 100 rpm with greatly reduced horsepower capacity. Low speeds may also affect the efficiency of lubrication.

Worm boxes are generally driven by a drive motor but can also be used with a hand drive device when required.

Output Shaft Speed.

Depends on the input shaft speed and the reduction ratio.

Torque

The transmission torque of the reducer depends upon the force that causes the output shaft to rotate and the rotary radius. See diagram below.

Note:

Maximum momentary (starting) torque is limited to 25% of rated capacity.

Efficiency

Efficiency calculations may be made by dividing HP OUTPUT by HP INPUT.

When only the output torque and input horsepower is known, the output torque may be converted to HP by the following:

HP Output = Output Torque x RPM Output divided by 63,025

Thermal Capacity

The thermal capacity of the Aline unit = the maximum capacity that it can operate at a temp not exceeding 80 deg C. Operation over this temp will require additional cooling provisions.

A run in period of approx. 50 hours is normally required for worm type reducers.

Lubrication.

The reducer should be filled with the appropriate oil to the centre of the oil gauge before putting into service.

Excessive oil levels result in higher operating temperatures and are as undesirable as using too little oil.

After approximately 85 hours of operation the reducer must be drained, flushed thoroughly with light oil and refilled with fresh recommended oil.

This flushing and refilling should be repeated every 2500 hours.

We use and recommend SAE 320 oil for most normal applications.

Overhung Load

Shaft or housing damage can be caused by excessive overhung load on the output shaft. The O.H.L should be included in calculations for new applications.

         

OVERHUNG LOAD FACTOR
Type of Drive O.H.L factor
Sprocket 1.00
Gear 1.25
V-Belt 1.50
Flat Belt 2.50
 LOAD CLASSIFICATIONS
Uniform Load Free From Shock
Conveyors Uniform Loads
Pumps

Centrifugal, Rotary

Compressors Vane Type
Mixers Constant Density
 
Moderate Shock

Occasional Light

Conveyors Not Unifom feed
Pumps Reciprocating
Mixers Variable Density
 
Heavy Shock Load Constant Shock
Conveyors Not uniform feed
Hammer Mills
Crushers
SERVICE FACTORS
Prime Mover

Duration of Service

Per Day. (1)

Driven Machine

Load Classification

Uniform

Medium

Shock

Heavy

Shock

 Electric

Motor

   
 Intermittent 2 hrs
 0.9  1.00  1.25
 Occasional 1/2 hr
 0.8  0.9  1.00
 10 hrs
 1.00  1.25  1.50
 24 hrs
 1.25  1.50  1.75

 Electric Motor

With Frequent

Starts & Stops

   
 Intermittent 2 hrs
 1.00  1.25  1.50
 Occasional 1/2 hr
 0.9  1.00  1.25
 10 hrs
 1.25  1.50  1.75
 24 hrs
 1.50  1.75  2.00

 Multi Cylinder

Combustion

Engine.

   
 Intermittent 2 hrs
 1.00  1.25  1.50
 Occasional 1/2 hr
 0.90  1.00  1.25
 10 hrs
 1.25  1.50  1.75
 24 hrs
 1.50  1.75  2.00

 Single Cylinder

Combustion

Engine

   
 Intermittent 2 hrs
 1.25  1.15  1.75
 Occasional 1/2 hr
 1.00  1.25  1.50
 10 hr
 1.50  1.75  2.00
 24 hrs
 1.75  2.00  2.25

 Note: Intermittent & occasional service refers to TOTAL operating period per day.

"Frequent Start & Stops" refers to more than 10 starts per hr

    

When Ordering a Worm Wheel Reduction Gearbox please specify the following:

1.    Worm frame size.

2.    Gear ratio.

3.    Input motor information. Power, speed (RPM), type. If flange mount electric motors please specify the mount details/dimensions required.

4.    Mounting arrangement required.

5.    Output shaft arrangement.

 

Horsepower and Torque Rating Tables.

These figures are indicative for standard worm drive boxes like FCA or FCWA models and reflect conditions under perfect drive. Refer to the factor chart for various applications.

Based on a Duty Cycle of 8-10 Hours per day continuous.

Torque is in kg-Metres

OHL is Overhung Load in Kgs.

SIZE RATIO 10:1
INPUT RPM 1800 1500 1200 900 600 300
50 INPUT HP 1.23 1.16 1.01 .86 .58 .31
OUTPUT HP .99 .93 .84 .67 045 .23
OUTPUT TORQUE kg-m
3.95 4.47 4.80 5.33 5.43 5.43
OUTPUT  OHL  kg
90 100 110 120 140 200
 60     INPUT HP  2.52  2.01  1.76  1.52  1.19  .64
 OUTPUT HP  1.78  1.63  1.41  1.20  .92  .48
 OUTPUT TORQUE kg-m
 7.09  7.82  8.45  9.62  11  11.6
 OUTPUT  OHL kg
 90  100  110  120  140  200
 70     INPUT HP
 3.27  3.01  2.68  2.24  1.75  1.15
 OUTPUT HP
 2.69  2.45  2.16  1.79  1.36  .86
 OUTPUT TORQUE kg-M
 10.7  11.7  12.9  14.3  16.3  20.7
 OUTPUT OHL kg
 140  150  160  170  200  300
 80     INPUT HP
 4.50  4.36  3.81  3.20  2.57  1.56
 OUTPUT HP
 3.27  3.55  3.08  2.56  2.01  1.18
 OUTPUT TORQUE kg-m
 14.8  17.0  18.4  20.5  24.0  28.3
 OUTPUT OHL kg
 160  180  200  230 270
 400
 100     INPUT HP
 6.50  5.98  5.26  4.49  3.51  2.27
 OUTPUT HP
 5.37  4.90  4.30  3.64  2.78  1.74
 OUTPUT TORQUE kg-m
 21.4  23.4  25.7  29.0  33.2  41.5
 OUTPUT OHL kg
 190  200  220  240  300  440
 120     INPUT HP
 10.7  10.1  8.58  7.40  5.75  3.74
 OUTPUT HP
 8.89  8.35  7.03  6.01  4.60  2.89
 OUTPUT TORQUE kg-m
 35.4  39.9  42.0  47.9  55.0  69.1
 OUTPUT OHL kg
 250  260  280  300  350  520
 135      INPUT HP
 17.7  16.5  14.2  12.0 9.54
 6.20
 OUTPUT HP
 15.0  13.9  11.9  10.0  7.83  4.94
 OUTPUT TORQUE kg-m
 59.7  66.4  71.0  79.6  93.5  117
 OUTPUT OHL kg
 330  340  360  440  500  800
SIZE RATIO 20:1
INPUT RPM 1800 1500 1200 900 600 300
50 INPUT HP  0.71  0.63  0.55  0.48  0.35  0.17
OUTPUT HP  0.50  0.44  0.38  0.32  0.23 0.11
OUTPUT TORQUE kg-m
4.00  4.25  4.58  5.07  5.43 5.43
OUTPUT  OHL  kg
130  140  155  170  200 200
 60     INPUT HP  1.18  1.06  0.95 0.79
 0.64  0.37
 OUTPUT HP  0.89  0.79  0.69  0.57  0.44  0.24
 OUTPUT TORQUE kg-m
7.09
 7.58  8.20  9.00  10.4  11.6
 OUTPUT  OHL kg
 130  140  155  170  200  200
 70     INPUT HP
 1.83  1.66  1.44  1.17  0.86  0.50
 OUTPUT HP
 1.42  1.27  1.09  0.87  0.62  0.34
 OUTPUT TORQUE kg-M
 11.3  12.1  13.0  13.9  14.7 16.0
 OUTPUT OHL kg
 210  230  250  270  300  300
 80     INPUT HP
 2.48  2.25  1.97  1.65  1.32  0.87
 OUTPUT HP
 1.91  1.71  1.47  1.21  0.93  0.57
 OUTPUT TORQUE kg-m
 15.2  16.3  17.5  19.2  22.3  27.3
 OUTPUT OHL kg
 270  280  320  360  400  400
 100     INPUT HP
 4.42  3.99  3.48  2.92  2.31  1.51
 OUTPUT HP
 3.52  3.14  2.71  2.23  1.73  1.06
 OUTPUT TORQUE kg-m
 28.0  30.0  32.3  35.5  41.3  50.0
 OUTPUT OHL kg
 250  270  300  340  450  450
 120     INPUT HP
 6.85  6.31  5.53  4.68  3.70  1.95
 OUTPUT HP
 5.40  4.92  4.26  3.53  2.71  1.68
 OUTPUT TORQUE kg-m
 43.0  47.0  50.9  56.2  64.6  80.0
 OUTPUT OHL kg
 370  390  420  460  520  520
 135      INPUT HP
 10.3  9.26  8.14  6.79  5.36  3.47
 OUTPUT HP
 8.39  7.47  6.48  5.33  4.13  2.54
 OUTPUT TORQUE kg-m
 66.8  71.3  77.4  84.9  98.6  121
 OUTPUT OHL kg
 570  600  660  760  810  810
SIZE RATIO 30:1
INPUT RPM 1800 1500 1200 900 600 300
50 INPUT HP  0.62  0.55  0.45  0.36  0.25 0.13
OUTPUT HP 0.42  0.37  0.30  0.23  0.16 0.08
OUTPUT TORQUE kg-m
5.02  5.31  5.43  5.49  5.43 5.43
OUTPUT  OHL  kg
150  170  180  200  200 200
 60     INPUT HP 1.07  0.98  0.87  0.74 0.52
0.28
 OUTPUT HP 0.75  0.67  0.58  0.48  0.32 0.16
 OUTPUT TORQUE kg-m
9.0  9.60  10.3  11.15  11.6 11.6
 OUTPUT  OHL kg
150  170  180  200  200 200
 70     INPUT HP
1.56  1.41  1.26  1.06  0.85 0.43
 OUTPUT HP
1.12  0.98  0.85  0.71  0.53 0.29
 OUTPUT TORQUE kg-M
13.4  14.2  15.2  17.0  19.0 20.5
 OUTPUT OHL kg
240  260  280  300  300 300
 80     INPUT HP
2.09  1.90  1.65  1.43  1.14 0.75
 OUTPUT HP
1.51  1.34  1.14  0.96 0.73
0.44
 OUTPUT TORQUE kg-m
18.1  19.2  20.5  22.9  26.2 31.4
 OUTPUT OHL kg
320  340  360  400  400 400
 100     INPUT HP
3.69  3.33  2.93  2.47  1.97 1.15
 OUTPUT HP
2.70  2.40  2.06  1.71  1.30 0.70
 OUTPUT TORQUE kg-m
32.2  34.4  36.9  40.8  46.8 50.0
 OUTPUT OHL kg
320  340  370  450  450 450
 120     INPUT HP
6.27  5.68  5.00  4.18  3.39 1.89
 OUTPUT HP
4.64  4.15  3.59  2.92  2.27 1.17
 OUTPUT TORQUE kg-m
55.4  59.4  64.3  69.8  81.4 84.0
 OUTPUT OHL kg
450  470  500  520  520 520
 135      INPUT HP
8.76  7.87  6.86  5.82  4.64 3.02
 OUTPUT HP
6.65  5.90  5.07  4.20  3.23 1.96
 OUTPUT TORQUE kg-m
79.4  84.5  90.8  100  116 140
 OUTPUT OHL kg
680  710  710  810  810 810
SIZE RATIO 40:1
INPUT RPM 1800 1500 1200 900 600 300
50 INPUT HP  0.47 0.43  0.39 0.32
 0.22 0.11
OUTPUT HP .028  0.25  0.22  0.17  0.12 0.06
OUTPUT TORQUE kg-m
4.53  4.82  5.41  5.43  5.43 5.43
OUTPUT  OHL  kg
170  180  200  200  200 200
 60     INPUT HP 0.78  0.71  0.64  0.54  0.43 0.24
 OUTPUT HP 0.51  0.45  0.39  0.32  0.24 0.12
 OUTPUT TORQUE kg-m
8.06  8.60  9.20  10.3  11.5 11.6
 OUTPUT  OHL kg
170  180  200  200  200 200
 70     INPUT HP
1.18  1.07  0.94  0.77  0.56 0.33
 OUTPUT HP
0.81  0.72  0.62  0.49  0.34 0.18
 OUTPUT TORQUE kg-M
12.9  13.7  14.8  15.5  16.2 17.4
 OUTPUT OHL kg
270  280  300  300  300 300
 80     INPUT HP
1.60  1.47  1.29  1.10  0.86 0.54
 OUTPUT HP
1.08  0.96  0.83  0.68  0.52 0.30
 OUTPUT TORQUE kg-m
17.2  18.3  19.7  21.8  24.7 28.0
 OUTPUT OHL kg
340  360  400  400  400 400
 100     INPUT HP
2.78  2.52  2.20  1.88  1.48 0.89
 OUTPUT HP
2.00  1.77  1.52  1.26  0.96 0.52
 OUTPUT TORQUE kg-m
31.8  33.8  36.3  40.2  45.7 50.0
 OUTPUT OHL kg
350  380  450  450  450 450
 120     INPUT HP
4.48  4.07  3.56  3.03  2.44 1.57
 OUTPUT HP
3.13  2.79  2.99  1.97  1.51 0.88
 OUTPUT TORQUE kg-m
49.8  53.2  57.1  62.8  72.2 84.0
 OUTPUT OHL kg
500  500  520  520  520 520
 135      INPUT HP
6.44  5.74  5.06  4.38  3.40 2.18
 OUTPUT HP
4.79  4.22  3.64  3.06  2.31 1.36
 OUTPUT TORQUE kg-m
76.3  80.7  86.9  97.4  110 130
 OUTPUT OHL kg
710  770  810  810  810 810
SIZE RATIO 50:1
INPUT RPM 1800 1500 1200 900 600 300
50 INPUT HP  0.39  0.37  0.31  0.26  0.18 0.09
OUTPUT HP 0.23  0.21  0.17  0.14  0.09 0.04
OUTPUT TORQUE kg-m
4.62  4.91  5.19  5.43  5.43 5.43
OUTPUT  OHL  kg
200  200  206  200 200
200
 60     INPUT HP 0.61  0.55  0.51  0.43  0.35 0.20
 OUTPUT HP 0.36  0.32  0.28  0.23  0.17 0.09
 OUTPUT TORQUE kg-m
7.10  7.60  8.30  9.10  10.2 11.6
 OUTPUT  OHL kg
180  200  200  200  200 200
 70     INPUT HP
0.87  0.79  0.71  0.61  0.50 0.30
 OUTPUT HP
0.52  0.46  0.40  0.33  0.25 0.15
 OUTPUT TORQUE kg-M
10.4  11.0  11.9  13.1  14.8 17.4
 OUTPUT OHL kg
280  300  300  300  300 300
 80     INPUT HP
1.28  1.17  1.05  0.88  0.72 0.45
 OUTPUT HP
0.84  0.75  0.65  0.53  0.40 0.23
 OUTPUT TORQUE kg-m
16.8  17.8  19.3  21.2  23.9 28.0
 OUTPUT OHL kg
360  400  400  400  400 400
 100     INPUT HP
2.78  2.52  2.20  1.88  1.48 0.89
 OUTPUT HP
2.00  1.77  1.52  1.26  0.96 0.52
 OUTPUT TORQUE kg-m
31.8  33.8  36.3  40.2  45.7 50.0
 OUTPUT OHL kg
350  380  450  450  450 450
 120     INPUT HP
3.64  3.28 2.90
 2.47  1.91 1.19
 OUTPUT HP
2.61  2.31  2.01  1.66  1.24 0.70
 OUTPUT TORQUE kg-m
52.0  55.2  60.1  66.0  74.2 84.0
 OUTPUT OHL kg
500  520  520  520  520 520
 135      INPUT HP
4.84  4.41  3.90  3.34  2.61 1.69
 OUTPUT HP
3.52  3.16  2.73  2.26  1.71 1.01
 OUTPUT TORQUE kg-m
70.0  75.5  81.4  90.1  102 120
 OUTPUT OHL kg
770  810  810  810  810 810
SIZE RATIO 60:1
INPUT RPM 1800 1500 1200 900 600 300
50 INPUT HP  0.33  0.30  0.26  0.23  0.15 0.07
OUTPUT HP 0.18  0.16  0.13  0.11  0.07 0.03
OUTPUT TORQUE kg-m
4.31  4.61  4.83  5.41  5.43 5.43
OUTPUT  OHL  kg
200  200  200  200  200 200
 60     INPUT HP 0.51  0.47  0.42  0.35  0.29 0.19
 OUTPUT HP 0.29  0.26  0.22  0.18  0.14 0.08
 OUTPUT TORQUE kg-m
6.90  7.40  8.00  8.70  9.70 11.3
 OUTPUT  OHL kg
200  200  200  200  200 200
 70     INPUT HP
0.75  0.68  0.63  0.51  0.43 0.28
 OUTPUT HP
0.44  0.39  0.34  0.27  0.21 0.12
 OUTPUT TORQUE kg-M
10.4  11.1  12.0  13.1  14.7 17.1
 OUTPUT OHL kg
300  300  300  300  300 300
 80     INPUT HP
1.03  0.95  0.85  0.73  0.58 0.39
 OUTPUT HP
0.62  0.55  0.48  0.39  0.29 0.17
 OUTPUT TORQUE kg-m
14.9  15.7  17.2  18.7  21.0 24.6
 OUTPUT OHL kg
400  400  400  400  400 400
 100     INPUT HP
1.87  1.70  1.53  1.28  1.02 0.65
 OUTPUT HP
1.26  1.12  0.97  0.80  0.59 0.34
 OUTPUT TORQUE kg-m
30.0  32.0  34.6  38.0  42.4 49.3
 OUTPUT OHL kg
400  450  450  450  450 450
 120     INPUT HP
2.89  2.65  2.36  2.04  1.45 0.96
 OUTPUT HP
1.98  1.76  1.53  1.26  0.94 0.56
 OUTPUT TORQUE kg-m
47.4  50.4  54.9  60.1  67.6 80.0
 OUTPUT OHL kg
 520  520  520  520  520 520
 135      INPUT HP
 3.65  3.58  3.16  2.74  2.11  1.37
 OUTPUT HP
 2.55  2.40  2.12  1.76  1.32  0.77
 OUTPUT TORQUE kg-m
 60.8  70.0  76.0  83.9  94.4  111
 OUTPUT OHL kg
 810  810  810  810  810  810