HB-Series Industrial Gear Reducer (B4FH/H2KV/H2FV/H3KV/H3FV/H4KV): Explosion-Proof & Dust-Resistant, Empowering Heavy-Duty Operation in Extreme Harsh Environments
I. Product Overview: Explosion-Proof & Dust-Resistant Graded Configuration, Meeting Extreme Harsh Environment Transmission Needs
Weigao’s HB-Series Industrial Gear Reducer, covering updated core models B4FH, H2KV, H2FV, H3KV, H3FV and H4KV, is a high-reliability power transmission device specialized in core industrial scenarios requiring explosion-proof, dust-resistant performance and stable operation in extreme harsh environments. Based on an upgraded dual-series (KV/FV) explosion-proof & dust-resistant adaptive configuration design platform, this series integrates advanced explosion-proof heavy-duty helical gear technology, dust-resistant enhanced structural design, wide-temperature adaptive material modification and modular explosion-proof assembly technology, realizing an excellent balance of graded explosion-proof adaptation, high torque transmission, dust-resistant protection and wide-temperature compatibility. It effectively solves the pain points of traditional reducers such as poor explosion-proof performance, weak dust resistance, easy failure under extreme temperature and harsh dust environments, and difficult matching with hazardous area equipment, and can maintain stable and reliable power output in working conditions involving heavy load, continuous operation, high dust concentration, flammable and explosive gas, and large temperature difference. With its explosion-proof & dust-resistant advantages and wide-temperature adaptive performance, it has become a core transmission component in industries such as coal mining, chemical engineering, hazardous waste treatment, outdoor high-dust construction and oil and gas exploitation, providing high-reliability power support for heavy-duty industrial production in extreme harsh environments. As an upgraded explosion-proof heavy-duty transmission product of Weigao, this series has been exported to more than 80 countries and regions around the world, winning wide recognition from global customers with its explosion-proof reliability and harsh environment adaptation value.
II. Core Advantages: Six Core Strengths, Shaping Heavy-Duty Transmission Benchmarks
1. Graded Explosion-Proof Helical Transmission, Safe & Efficient
Adopting precision-ground explosion-proof heavy-duty helical gears with optimized tooth profile and anti-static modification, high-strength explosion-proof modulus design, advanced multi-stage carburizing quenching technology and anti-wear nitriding treatment, the series achieves meshing accuracy up to GB/T 10095.2 Class 4 standard. The parallel-axis helical transmission structure with reinforced explosion-proof rib, static-dissipative wall and enhanced heat dissipation optimization design ensures smooth and uniform meshing between gears, balanced force distribution and minimal friction spark risk, reducing transmission backlash to ≤2.2arcmin. The transmission efficiency reaches 96%-98% for single-stage transmission and 94%-97% for multi-stage transmission, effectively reducing energy loss in long-term heavy-duty operation in harsh environments. The fully enclosed integral cast iron housing with integrated explosion-proof coating and static-dissipative treatment combines excellent structural rigidity, explosion-proof toughness and heat dissipation functions, with operating noise ≤70dB at 1m distance, ensuring safe and efficient operation even in high dust, flammable and explosive gas, and large temperature difference harsh working environments.
2. Dual-Series Explosion-Proof & Dust-Resistant Graded Configuration, Precise Harsh Environment Adaptation
The six core models of the series are divided into KV and FV dual explosion-proof & dust-resistant series with targeted graded configuration to meet differentiated harsh environment transmission needs: KV-series models (H2KV, H3KV, H4KV) are standard explosion-proof & dust-resistant models, integrating high-strength explosion-proof material and basic dust-resistant structure, suitable for general harsh environment heavy-duty equipment such as coal mine auxiliary conveyors, chemical workshop agitators and outdoor high-dust construction machinery; among them, H2KV is small-medium torque explosion-proof model, H3KV/H4KV are large torque explosion-proof enhanced models. FV-series models (H2FV, H3FV, B4FH) are ultra-heavy load explosion-proof & enhanced dust-resistant models with reinforced explosion-proof shaft, anti-static wear-resistant gear, high-precision dust-resistant bearing and integrated explosion-proof monitoring design, ideal for ultra-heavy-load extreme harsh environment equipment such as coal mine main conveyors, oil and gas field exploitation machinery, hazardous waste incineration equipment and large chemical reactor agitators. This dual explosion-proof & dust-resistant series graded design ensures precise matching of different heavy load levels, explosion-proof grades and dust concentration requirements, further improving equipment operation stability and service life in extreme harsh environments.
3. Ultra-High Torque & Explosion-Proof Bearing Capacity, Durable Harsh Environment Operation
Gears and transmission shafts are made of high-strength 42CrMo alloy steel with explosion-proof toughening treatment (KV-series) and 34CrNiMo6 ultra-high-strength alloy steel with multi-layer explosion-proof & anti-static treatment (FV-series), processed through precision forging, multi-stage heat treatment, precision grinding and explosion-proof coating processes (including anti-static ceramic coating and anti-corrosion passivation treatment). The surface hardness reaches HRC 64-67, and the core hardness is HRC 39-43, ensuring excellent explosion-proof performance, super load-bearing capacity, dust resistance and torque transmission stability even under long-term high dust, flammable and explosive gas and large temperature difference environments. The optimized gear modulus, tooth width, shaft diameter and explosion-proof structure design for each model ensures that the rated output torque of the series is precisely graded from 2500N·m to 48000N·m (H2KV: 2500-5500N·m; H3KV: 5500-20000N·m; H4KV: 20000-38000N·m; H2FV: 25000-35000N·m; H3FV: 35000-42000N·m; B4FH: 42000-48000N·m). The integral cast iron housing with high rigidity, thickened wall and explosion-proof design ensures no deformation or explosion risk under ultra-heavy load and harsh environment impact, ensuring a service life of more than 18 years under normal maintenance in extreme harsh environments.
4. Modular Explosion-Proof Installation, Flexible Hazardous Area Layout Adaptation
The series adopts an upgraded modular explosion-proof design, supporting multiple installation modes such as base-mounted with explosion-proof base, flange-mounted (B5/B14) with explosion-proof seal, torque arm-mounted with anti-static buffer pad, shaft-mounted with explosion-proof coupling, flange-output mounted and mobile base-mounted with dust-proof shock absorption, which can be flexibly selected according to the diversified layout requirements of hazardous area heavy-duty industrial equipment. The output shaft is configured with ultra-heavy-duty explosion-proof reliable options such as extra-large-diameter explosion-proof solid shaft with flat key, high-strength anti-static spline solid shaft, extra-large-torque explosion-proof hollow shaft with locking disk and dust-resistant sleeve-equipped shaft. It can be precisely matched with motors with power ranging from 11kW to 450kW and reduction ratios of 7-500 (single-stage/multi-stage combination). The standardized explosion-proof interface design with reinforced anti-static connection parts and enhanced dust-proof protection facilitates quick installation, replacement and debugging in coal mines, chemical plants and oil and gas fields, reducing construction difficulty and time cost, and adapting to the layout needs of various extreme harsh environment core heavy-duty industrial equipment.
5. Enhanced Explosion-Proof Sealed & Wide-Temperature Heat Dissipation, Wide Harsh Environment Adaptability
Equipped with an eight-layer enhanced explosion-proof sealed dust-proof system composed of heavy-duty explosion-proof double-lip oil seal, labyrinth seal with anti-static coating, high-elasticity explosion-proof O-ring, high-temperature resistant explosion-proof sealant, stainless steel dust-proof cover with explosion-proof filter and anti-impact gasket, the reducer achieves IP69K explosion-proof protection level (Ex d IIC T4 Gb explosion-proof grade, customizable for higher explosion-proof grades). This sealing structure can effectively prevent the intrusion of dust, flammable gas, corrosive liquid and ore particles in harsh environments, avoid oil leakage, internal component wear and explosion risk, and achieve long-term reliable explosion-proof and dust-proof protection. The optimized internal oil circuit design with multi-point forced lubrication, high-precision explosion-proof oil filter, intelligent temperature-controlled oil cooler and large-area integrated heat dissipation fins on the housing ensures sufficient lubrication, impurity filtration, adaptive temperature control and explosion-proof protection of all transmission components during high-load, high dust, flammable and explosive gas and large temperature difference operation, and the product can work normally in the operating temperature range of -40℃ to +140℃, adapting to most extreme harsh working conditions such as coal mines, chemical plants, oil and gas fields and outdoor high-dust construction sites.
6. Explosion-Proof Convenient Maintenance, Cost-Effective Harsh Environment Operation
The modular explosion-proof structural design with dust-proof protection makes component disassembly and maintenance more convenient, and the high interchangeability of explosion-proof dust-resistant spare parts between the same series reduces maintenance difficulty and time cost in hazardous areas. The centralized and protected explosion-proof oil filling port, oil drainage port, high-temperature resistant explosion-proof transparent oil level observation window with static-dissipative function and built-in high-precision explosion-proof oil filter facilitate daily lubrication management, real-time oil level monitoring, impurity cleaning and explosion-proof maintenance. It is recommended to use 320#/460#/680# explosion-proof anti-static ultra-heavy-duty industrial gear oil, which further enhances the explosion-proof performance, dust resistance, load-bearing capacity and high-temperature resistance of internal components; the first oil change is after 1000 hours of operation (due to harsh environment working conditions), and regular maintenance and oil change are performed every 4500 hours thereafter for extreme harsh working conditions. The high reliability, long service life, ultra-strong explosion-proof & dust-resistant capacity and durable performance of the product effectively reduce the frequency of maintenance and replacement in harsh environments, significantly lowering the total operation cost of customers.
III. Application Fields: Extreme Harsh Environment Coverage, Boosting Safe Industrial Production
With its dual explosion-proof & dust-resistant series graded configuration, ultra-high torque bearing capacity, explosion-proof installation adaptation, reliable transmission and wide harsh environment adaptability, Weigao’s HB-Series Industrial Gear Reducer (B4FH/H2KV/H2FV/H3KV/H3FV/H4KV models) has been widely applied in various extreme harsh environment core heavy-duty industrial fields:
- Coal Mining: Coal mine main conveyors, underground mining excavators, coal washing plant equipment, adapting to ultra-heavy-load, high dust, flammable gas and humid working environments;
- Chemical Engineering: Large chemical reactor agitators, chemical raw material conveyors, corrosive liquid transfer pumps, adapting to heavy-load, corrosive gas, flammable and explosive working environments;
- Oil and Gas Exploitation: Oil field drilling machinery, gas field gathering and transportation equipment, oil refining plant auxiliary systems, adapting to ultra-heavy-load, flammable gas, high temperature and sand dust working environments;
- Hazardous Waste Treatment: Hazardous waste incineration equipment, toxic waste treatment conveyors, medical waste disposal systems, adapting to heavy-load, toxic gas, high temperature and high dust working environments;
- Outdoor High-Dust Construction: Large open-pit mining machinery, desert area engineering equipment, road construction dust removal systems, adapting to heavy-load, high dust, large temperature difference and strong wind working conditions;
IV. Technical Parameters: Precise Matching, Meeting Diverse Needs
| Item | Specification Range |
| Motor Power Adaptation | 11kW - 450kW |
| Reduction Ratio | 7 - 500 (Single-stage/Multi-stage Combination) |
| Rated Output Torque | 2500N·m - 48000N·m (Dual Explosion-Proof & Dust-Resistant Series Graded) |
| Transmission Efficiency | 94% - 98% (Single-stage/Multi-stage) |
| Operating Noise | ≤70dB (Measured at 1m Distance) |
| Protection Level | IP69K (Ex d IIC T4 Gb, Higher Explosion-Proof Grade Customizable) |
| Operating Temperature | -40℃ - +140℃ |
| Installation Method | Base-mounted with Explosion-Proof Base, Flange-mounted (B5/B14) with Explosion-Proof Seal, Torque Arm-mounted with Anti-Static Buffer Pad, Shaft-mounted with Explosion-Proof Coupling, Flange-output Mounted, Mobile Base-mounted with Dust-Proof Shock Absorption |
| Output Shaft Type | Extra-Large-Diameter Explosion-Proof Solid Shaft (Flat Key/Spline), High-Strength Anti-Static Spline Solid Shaft, Extra-Large-Torque Explosion-Proof Hollow Shaft (Locking Disk), Dust-Resistant Sleeve-Equipped Shaft |
V. Installation and Maintenance: Scientific Operation, Maximizing Performance
During installation, ensure that the coaxiality error between the reducer and the motor is ≤0.08mm to avoid affecting transmission stability, explosion-proof performance and ultra-heavy load-bearing capacity. For ultra-heavy-duty, high dust, flammable and explosive gas environment installation, adopt reinforced concrete installation base with explosion-proof isolation layer and high-performance anti-static buffer pads to reduce vibration impact and explosion risk. Ensure that all connection parts are fully sealed and reinforced with explosion-proof sealant to avoid dust, flammable gas intrusion and loosening under harsh environment impact. Select the appropriate lubricating oil according to the working conditions: use 320# explosion-proof anti-static ultra-heavy-duty industrial gear oil for normal temperature and medium-heavy load, 460# for high temperature and heavy load, and 680# for ultra-high load, high-temperature and continuous operation in flammable and explosive environments. Regularly check the oil level, oil quality, gear meshing status, fastener tightness, heat dissipation fin cleanliness, oil filter blockage and explosion-proof coating integrity; replace the lubricating oil after the first 1000 hours of operation, and perform comprehensive maintenance every 4500 hours thereafter for extreme harsh working conditions, including checking bearing temperature, sealing performance, housing deformation, gear wear and explosion-proof toughness status. If abnormal phenomena such as excessive noise, obvious vibration, oil leakage, overheating, torque fluctuation or static accumulation occur during operation, stop the machine immediately for inspection and troubleshooting.
VI. Conclusion: Explosion-Proof & Dust-Resistant Driven, Creating Harsh Environment Industrial Transmission Value
Adhering to the design philosophy of "Explosion-Proof & Dust-Resistant Grading, Ultra-Heavy-Duty Reliability, Harsh Environment Adaptation and Safety Efficiency", Weigao’s HB-Series Industrial Gear Reducer (B4FH/H2KV/H2FV/H3KV/H3FV/H4KV models) focuses on the stable and safe transmission needs of extreme harsh environment core heavy-duty industrial fields, and continuously optimizes product structure and explosion-proof dust-resistant technology. Whether in high dust explosion-proof heavy-duty transmission, ultra-heavy load harsh environment operation or complex large temperature difference scenarios, this series can provide stable, efficient and safe power transmission solutions for customers with its dual explosion-proof & dust-resistant series graded configuration, ultra-high torque bearing capacity and wide harsh environment adaptation advantages, helping to improve production safety and efficiency of extreme harsh environment core industrial equipment. We will continue to focus on the research and development of explosion-proof & dust-resistant heavy-duty transmission technology, deeply explore the needs of different extreme harsh environment heavy-duty industrial fields, provide customized product solutions and global after-sales service support, and work with global customers to build a more reliable and efficient extreme harsh environment core industrial production system. All export products of this series have passed international certifications such as ROHS, CE, ISO9001 and explosion-proof certification (ATEX, IECEx), fully complying with the technical standards and safety requirements of various countries and regions for hazardous area equipment, ensuring smooth application in global extreme harsh environment heavy-duty industrial markets.
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