Brake Worm Gear Motor

The Industrial AC Brake Worm Gear Motor integrates an AC induction motor, a fail-safe electromagnetic brake, and a right-angle worm gear speed reducer into a single compact housing. Standardized according to IEC and NEMA metric mounting dimensions, this system is engineered for industrial automation, vertical lifting, and dynamic mechanical transmission systems requiring rapid stopping, high reduction ratios, and static self-locking performance.
By combining precision-ground worm shaft geometry with high-purity phosphor bronze gearing, this unit delivers high continuous output torque while occupying minimal axial footprint. The direct-coupled power-off brake provides instant static load holding, eliminating overrun during unexpected electrical failures or repeated positioning cycles.

Fail-Safe Electromagnetic Brake: Spring-applied DC brake mechanism automatically locks the motor shaft upon power loss to maintain load stability.

Self-Locking Right-Angle Design: High reduction ratio profile reduces or eliminates reverse back-driving from the load side without continuous electrical holding power.

Class F Thermal Insulation Rating: Stator winding insulation engineered to handle operating temperatures up to 155°C (with Class B temperature rise limits), supporting S1 continuous duty and frequent start-stop cycles.

Hardened Steel & Phosphor Bronze Gearing: 20CrMnTi alloy steel worm shaft paired with ZCuSn10Pb1 phosphor bronze worm rim delivers minimal tooth friction, reduced backlash, and low operating noise (<65 dBA).

IP55 Ingress Protection Standard: Die-cast housing with high-grade nitrile seals prevents particulate contamination and low-pressure water jet penetration in harsh industrial environments.

Mounting Structures: B3 (Foot Mount), B5 (Output Flange), B14 (Face Mount), or Universal pad mounting.

Shaft Styles: Hollow shaft with keyway, single/double solid output shafts, or shrink-disc clamping sets.

Brake Release Mechanism: Optional hand-release lever for manual axis manipulation during power outages or system setup.

Input Interfaces: Standard IEC motor flanges, solid input shaft extensions, or custom mounting plates for NEMA / Servo motor coupling.

Cooling Options: Totally Enclosed Fan Cooled (TEFC - IC411) with bi-directional polymer or aluminum cooling fans.

Conveyor & Material Handling Lines: Stops belts and roller conveyors under load without position drift.

Scissor Lifts & Hoisting Units: Holds mechanical payloads safely when power is disconnected.

Automated Industrial Doors & Gates: Provides slow-speed, high-torque drive with instant dynamic stopping for security barriers and heavy overhead doors.

Packaging & Indexing Equipment: Ensures exact cycle indexing for cartoners, palletizers, and stretch wrapping machinery.

Agitators & Mixers: Supports right-angle fluid tank mixing systems operating in space-constrained production cells.

To determine the correct drive sizing for your application, calculate output torque (T₂), motor efficiency (η), and load service factors (SF) using the standard formulas below:
Calculation Formulas
T₂ = (9550 × P₁ × η) / n₂
P₁ = Motor Input Power (kW)
n₂ = Gearbox Output Speed (RPM)
η = Efficiency of Worm Gear Pair (Typically 0.60 - 0.88 depending on speed ratio)
T_required = T₂ × SF
Service Factor (SF) Reference
Select a minimum Service Factor based on operational characteristics:
Uniform Load / S1 Duty (8 hours/day): SF ≥ 1.0 - 1.25
Moderate Shock / Continuous Duty (24 hours/day): SF ≥ 1.3 - 1.5
Heavy Shock / Frequent Start-Stop (>300 cycles/hour): SF ≥ 1.75 - 2.0
Static Brake Torque Matching
Ensure the static brake torque (Tb) satisfies:
Tb ≥ 1.5 × T_motor rated

Raw Material Inspection → CNC Turning & Gear Hobbing → Carburizing & Thread Grinding

Final Testing & Dispatch ← 100% Automated Testing Bench ← VPI Stator Assembly

Gear Machining & Heat Treatment: Worm shafts are machined from 20CrMnTi alloy steel, carburized to a case depth of 0.8–1.2 mm (HRC 58–62), and precision ground on CNC thread grinding machinery to ensure smooth surface finish and minimum tooth friction. Worm rims are centrifugal-cast from ZCuSn10Pb1 bronze to maximize wear resistance under heavy sliding loads.

Automated Stator Winding & Impregnation: Stator coils are wound via automated dual-flyer winding equipment using 180°C enamel-insulated copper wire. Assembled stators undergo Vacuum Pressure Impregnation (VPI) with solvent-free epoxy resin to prevent internal coil vibration and moisture buildup.

Quality Assurance & Testing: Every unit undergoes a 100% automated end-of-line test prior to packaging:

• No-Load / Full-Load Current Test: Verifies phase balance and power efficiency.
• Dielectric Withstand Voltage Test: 1800V AC applied for 1 second to ensure insulation integrity.
• Brake Response & Drag Test: Verifies air gap dimensions, millisecond release/engagement times, and zero dynamic drag torque.
• Noise Level & Vibration Run-In: Checked via digital sound level meters and tri-axial accelerometer sensors.

Certifications: ISO 9001 quality system compliance; product marks include CE, CCC, RoHS, and IE1/IE3/IE4 energy efficiency classifications.

Please provide your required power (kW/HP), output speed or gear ratio, voltage, mounting type, and estimated quantity below to receive a formal quotation, technical datasheet, and 3D CAD models within 24 hours.

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