Falk worm gear drive systems offer unique solutions to various applications while distinguishing themselves from other gearing options by delivering particular advantages only they can provide.
Let’s delve deeper into this topic.
What is a Worm Gear Drive System?
We occasionally refer to a worm gear reducer as a worm drive, hence why our Falk repair and renewal experts use those terms interchangeably. Generally, this piece of machinery is made up of a screw-like spur shaft—known as the worm—that engages with a toothed sprocket, with the worm advancing the gear one tooth at a time.
When powered by a motor, the worm-like shaft turns through the sprocket transmitting force to turn the wheel, either to increase torque, reduce speed, or both. Think of it like a guitar tuner on the instrument’s headstock. You turn the tuner peg to rotate the sprocket, tightening and adjusting the string. Worm gears work similarly, albeit motorized.
What Does a Worm Gearbox Do?
Falk designed their gearboxes to transmit high transmission ratios while ensuring they circulate in the correct direction without reversing. As a result, most industrial machinery depends on worm drive systems to increase torque or reduce speed without requiring multiple reductions.
For instance, our Falk repair service team shared the following examples to illustrate how businesses often use them:
- Conveying engineering
- Mining industry machines
- Lifts and elevators
- Manufacturing and packaging
- And various other uses in combination with different gear reducer types
9 Benefits of Worm Gear Reducers
Now that you have a foundational awareness of our topic, let’s dive into the benefits of worm gear speed reducers provided by our Falk technicians.
1. Higher Torque Output & Greater Speed Reduction
Falk continues to lead the industry by offering gearboxes that deliver more torque than their competitors. In the case of a worm gear drive system, the screw-like shaft rotates the sprocket to produce more power from a motor to the output source or reduce speed to achieve optimal momentum.
2. Greater Security & Safety
Mechanically, these gearboxes aren’t reversible, so the worm wheel cannot drive the worm-like shaft. For example, when abrupt disruptions occur, an output shaft won’t turn in the opposite direction, nor will it when powered down. Consequently, users gain better security by avoiding slippage.
3. Low Noise Levels
Falk’s worm speed reducers have become famous for being the smoothest and quietest gear systems when appropriately lubricated, making them ideal for applications where noise needs to be limited. This is partly due to their ability to reduce vibrations because of their concise, compact design.
4. More Versatility
Thanks to their compact design and low noise levels, many industries use worm gearboxes for a wide range of applications, including automotive systems, industrial machinery, conveyor systems, and even some household appliances.
5. Applicability in Right-Angle Drives
Worm gears are well-suited for right-angle drives, where the motion needs to be transferred at a 90-degree angle. This makes them useful in applications like conveyor systems, where space constraints may require such a design.
6. Moderate Cost for Certain Applications
Depending on the specific requirements of an application, worm drives can offer a cost-effective solution. While they may not be the most economical choice in all cases, their unique characteristics make them cost-effective for certain scenarios.
7. Position Holding in Vertical Applications
The self-locking property of worm gears is particularly beneficial in vertical applications where the load needs to be held in position without relying on external brakes or locking mechanisms.
8. Highly Dependable
Worm drives have a simple design with fewer components, leading to ease of maintenance. This simplicity often translates to increased durability and reliability, reducing the need for frequent repairs.
For over a century, Falk has established itself as the premier option for industrial gearing because of the remarkable durability offered by their speed reducers. Their worm gear drive systems maintain their signature excellence by performing reliably—even under the most rugged conditions.
9. Ease of Repair
Individuals looking to save money no longer need to spend more on a brand-new replacement. For those in need of repairs or system renewal, it’s easy to connect with an agent of Rexnord’s Industrial Services division, Like NW Industrial Sales, LLC. We have access to a nationwide network for repair, remanufacturing, and predictive maintenance services.
Disadvantages to Worm Gear Reducers
One significant drawback of choosing worm gears over standard gears is the lubrication issue. The interaction between the worm and wheel gear faces involves purely sliding motion, without any rolling component in the tooth contact. This makes lubrication a challenging task.
Typically, worm gears demand high-viscosity lubricants (ISO 320 and higher), which are difficult to filter. Moreover, these lubricants are specialized and require specific on-site products tailored to the equipment.
The primary concern with worm gears lies in how they transfer power—a double-edged sword. While the spiral motion allows for substantial reduction in a compact space compared to helical gears, it introduces a troublesome mode of power transfer known as sliding friction or sliding wear.
Unlike a typical gear set where power is transferred at the tooth’s peak load point, worm gears rely solely on sliding motion. As the worm slides across the wheel’s tooth, it gradually removes the lubricant film until none is left. Consequently, the worm rubs against the metal of the wheel in a boundary lubrication regime. Upon leaving the wheel surface, it picks up more lubricant, repeating the process with each revolution.
In contrast, rolling friction on a standard gear tooth requires minimal lubricant film to fill gaps and separate components. Since sliding occurs on either side of the gear tooth apex, a slightly higher viscosity lubricant is needed to overcome that load. Importantly, sliding in typical gears occurs at a relatively low velocity.
In a worm gear set, the worm turns and crushes against the wheel under load. To prevent direct contact, a lubricant film thickness must be sufficient to avoid wiping off the entire tooth surface before that part of the worm exits the load zone. This situation demands a specialized lubricant—high viscosity, adjusted for load and temperature, with properties to overcome the prevailing sliding condition.
Contact Our Falk Speed Reducer & Gearbox Distributors
With their dedication to customer satisfaction, Falk simplifies the entire process of finding surplus parts or a reliable repair technician for their gearboxes, ensuring minimal downtime and optimal performance.
If you wish to discover the difference partnering with a trusted gearbox supplier, distributor, and renewal specialist, we invite you to contact us today.
