ZDY Single-stage Cylindrical Gear Reducer: High-Rigidity Hard Tooth Surface Precision Transmission, Leading General Heavy-Duty Application
I. Product Overview: High-Efficiency Single-Stage Configuration, Meeting General Heavy-Duty Transmission Needs
Weigao’s ZDY Single-stage Cylindrical Gear Reducer is a high-reliability power transmission device specially developed for general industrial scenarios requiring efficient single-stage speed reduction, high torque output and stable heavy-duty operation, such as general machinery transmission systems, metallurgical auxiliary equipment, and mining light-duty conveying equipment. Targeting the pain points of traditional single-stage reducers such as low transmission efficiency, poor rigidity, and short service life in heavy-duty scenarios, this product integrates high-rigidity integral casting housing design, precision hard tooth surface cylindrical gear transmission technology, enhanced bearing system configuration and efficient heat dissipation optimization. It realizes a perfect combination of high-efficiency single-stage transmission, strong load-bearing capacity, stable operation and long service life, and can stably operate in complex working conditions involving continuous heavy load, moderate impact, and long-term operation. As a core universal transmission component for general industrial equipment, the ZDY Single-stage Cylindrical Gear Reducer is widely applied in metallurgical roller tables, light-duty mining conveyors, general machinery main transmission systems, and textile machinery main drives, providing efficient, stable and reliable power support for global general industrial production projects. The product has passed international certifications such as ISO 6336 gear strength certification, IP54 protection certification, and ISO 9001 quality management system certification, and is trusted by more than 50 countries and regions for its excellent general heavy-duty scenario adaptation performance.
II. Core Advantages: Five High-Reliability Transmission Strengths, Defining General Heavy-Duty Standards
1. High-Rigidity Integral Casting Housing, Strong Load-Bearing Capacity
The reducer adopts a high-rigidity integral casting housing made of high-quality HT250 cast iron, which is formed by one-time casting and precision machining. The internal structure is optimized by finite element analysis, and the key stress-bearing parts are equipped with reinforced ribs, which effectively improves the overall rigidity and vibration resistance of the housing. The housing wall thickness is evenly distributed, with a maximum thickness of 25mm, which can withstand large radial and axial loads. The maximum radial load bearing capacity reaches 28kN, which is 30% higher than that of ordinary single-stage cylindrical gear reducer housings. The housing surface is treated with anti-rust painting, which has good anti-corrosion and anti-pollution performance, adapting to the harsh environment of general industrial workshops. The integral casting structure avoids the assembly gap caused by split housing, ensures the coaxiality of the input and output shafts, and lays a solid foundation for the stable operation of the transmission system.
2. Precision Hard Tooth Surface Transmission, High-Efficiency & Wear-Resistant
The core transmission pair adopts precision hard tooth surface cylindrical gears, which are made of 20CrMnTi alloy steel. The gears are processed by integral forging, carburizing and quenching, and super-precision grinding. The surface hardness reaches HRC 58-62, and the tooth surface roughness is ≤Ra 0.2μm. The gear tooth profile is modified by precision, which effectively improves the meshing performance and reduces the impact load during operation. The meshing contact area of the gear pair reaches more than 95%, realizing uniform force transmission and high-precision operation. The single-stage transmission efficiency is as high as 96%-98%, which is 3%-5% higher than that of ordinary soft tooth surface single-stage cylindrical gear reducers, meeting the high-efficiency energy-saving requirements of general industrial production. The hard tooth surface design has excellent wear resistance and impact resistance, and the gear service life is increased by more than 60% compared with soft tooth surface gears, which can adapt to the long-term continuous operation needs of heavy-duty scenarios.
3. Enhanced Bearing System, Stable & Reliable Operation
The product is equipped with an enhanced bearing system, and the input and output shafts adopt high-precision self-aligning roller bearings with double-sided sealing. The bearing has a large load-bearing capacity, good self-aligning performance, and can automatically compensate for the slight deflection of the shaft during operation. The bearing is preloaded during assembly, which improves the rigidity and stability of the shaft system, and effectively reduces the vibration and noise during operation. The bearing is lubricated by circulating oil, and the built-in oil guide groove ensures sufficient lubrication of the bearing, avoiding bearing damage caused by lack of lubrication. The bearing service life reaches more than 15,000 hours under normal working conditions, which ensures the long-term reliable operation of the reducer. In addition, the shaft extension is processed by precision grinding, with high surface finish and dimensional accuracy, which is convenient for connection with the driven equipment and ensures the transmission efficiency.
4. Efficient Heat Dissipation Design, Adapt to Long-Term Operation
The heat dissipation system adopts an optimized integral fin design. The outer surface of the housing is distributed with dense heat dissipation fins, which increase the heat dissipation area by 40% compared with ordinary models. The heat dissipation fins are designed with a reasonable angle, which can effectively enhance the air flow and improve the heat dissipation efficiency. For high-power models, an optional forced cooling fan can be configured to further improve the heat dissipation effect, ensuring that the reducer can operate stably for a long time under full load conditions. The built-in high-precision oil filter and oil temperature sensor monitor the lubricating oil status in real time. The lubricating oil adopts high-quality extreme pressure industrial gear oil, which has good thermal stability and lubricating performance. The product can work normally in the operating temperature range of -10℃ to +100℃, adapting to the temperature fluctuation environment of general industrial workshops.
5. Universal Installation & Easy Maintenance, Cost-Saving Operation
The product supports multiple universal installation modes such as horizontal foot-mounted, horizontal flange-mounted, and vertical flange-mounted. The housing is equipped with multi-directional precision positioning holes and standard flange interfaces, which are compatible with most general industrial equipment, and can be flexibly adjusted according to the equipment layout. The installation positioning accuracy error is ≤0.1mm, ensuring the reliable connection of the transmission system. The centralized oil filling port, large-diameter oil drain port and transparent oil level observation window are designed on the housing, which facilitates daily lubrication management and maintenance operations. The key components are standardized and serialized, which makes the replacement of vulnerable parts more convenient and reduces the equipment downtime. The rated service life reaches more than 15 years under normal maintenance conditions, and the maintenance cycle is extended by 50% compared with ordinary models. The overall maintenance cost is reduced by 35% compared with similar products, significantly saving the user's operation and maintenance costs.
III. Typical Application Fields: Focus on General Industry, Empowering Stable Production
With its exclusive high-rigidity integral casting housing, precision hard tooth surface transmission, enhanced bearing system and universal installation adaptation advantages, Weigao ZDY Single-stage Cylindrical Gear Reducer has become the core transmission choice for general industrial equipment, and its typical application fields include:
- Metallurgical Auxiliary Equipment Industry: Metallurgical roller table transmission systems, steel billet conveying mechanism drives, adapting to heavy load transmission, continuous operation and high temperature resistance requirements;
- Light-Duty Mining Industry: Light-duty mining conveyor drives, ore sorting equipment transmission systems, adapting to heavy load impact, harsh environment and stable operation needs;
- General Machinery Industry: General machine tool main transmission systems, blower and pump drives, adapting to high-efficiency transmission, precise speed control and reliable operation requirements;
- Textile Machinery Industry: Textile machine main drives, fabric rolling machine transmission systems, adapting to continuous operation, low noise and stable transmission conditions;
IV. Technical Parameters: Precise Matching, Meeting Diverse Needs
- Building Materials Industry: Cement packaging machine drives, concrete mixer auxiliary transmission systems, adapting to heavy load, dusty environment and long-term operation needs;
| Item | Specification Range |
| 1.5kW - 90kW | 1.5kW - 75kW |
| 3 - 50 (Single-stage, Stepless Selection) | 10 - 80 (Single-stage); 100 - 1500 (Customized Double-stage) |
| 120N·m - 8500N·m (Graded by Model) | 800N·m - 12000N·m (Graded by Model) |
| 96% - 98% (Depending on Reduction Ratio) | 85% - 93% (Depending on Model and Reduction Ratio) |
| ≤60dB - ≤68dB (Measured at 1m Distance) | ≤58dB - ≤65dB (Measured at 1m Distance) |
| Protection Level | IP54, ISO 6336 Gear Strength Certification, ISO 9001 Quality Management System Certification |
| -10℃ - +100℃ | -30℃ - +120℃ |
| Horizontal Foot-mounted, Horizontal Flange-mounted, Vertical Flange-mounted, ZDY (Single-stage Cylindrical Gear Universal Type) | Horizontal-mounted, Vertical-mounted, Wall-mounted, Ceiling-mounted, WPWK (Standard Heavy-Duty Universal Type), WPWKA (Heavy-Duty Universal Type with Input Shaft Downward), WPWKS (Heavy-Duty Universal Type with Input Shaft Upward), WPWKO (Heavy-Duty Universal Type with Output Shaft Upward), WPWKV (Heavy-Duty Universal Type with Input Shaft Vertical), WPWKT (Heavy-Duty Universal Type with Output Shaft Vertical) |
| Solid Shaft Output (Flat Key/Spline), Hollow Shaft Output (Locking Disk Connection), Flange Output (Standard IEC Interface) | Solid Shaft Output (Flat Key/Spline), Hollow Shaft Output (Locking Disk Connection), Reinforced Shaft Extension (For High-Power Motor Matching), Explosion-Proof Shaft Output (For Hazardous Environment) |
V. Installation and Maintenance: Scientific Operation, Maximizing Performance
During installation, select the appropriate installation mode according to the equipment layout and transmission requirements, and ensure that the coaxiality error between the reducer and the motor/driven equipment is ≤0.1mm. Use high-strength bolts to fix the reducer firmly on the mounting base to avoid vibration during operation. Strictly follow the installation specifications to check the cleanliness of the connection parts and ensure reliable connection. Select the appropriate extreme pressure industrial gear oil according to the working conditions: use 220# for normal temperature and general load, 320# for high temperature and heavy load. Regularly check the oil level, oil quality, sealing performance and heat dissipation status; replace the lubricating oil after the first 2000 hours of operation, and perform comprehensive maintenance every 5000 hours thereafter, including checking gear meshing status, bearing temperature, fastener tightness and housing integrity. If abnormal phenomena such as excessive noise, vibration, oil leakage or overheating occur during operation, stop the machine immediately for inspection and troubleshooting.
VI. Conclusion: General Heavy-Duty Transmission Leader, Empowering Industrial Production Upgrade
Adhering to the design philosophy of "High Rigidity & Precision, High Efficiency & Durability, Universal Adaptation & Reliable Operation", Weigao ZDY Single-stage Cylindrical Gear Reducer focuses on the core transmission needs of general industrial equipment, integrating multiple exclusive technologies such as high-rigidity integral casting housing design, precision hard tooth surface transmission and enhanced bearing system configuration. It breaks through the performance limitations of traditional single-stage cylindrical gear reducers in general heavy-duty multi-scenario applications, providing efficient, stable and reliable power transmission solutions for metallurgical auxiliary equipment, light-duty mining, general machinery and other key industries. We will continue to rely on advanced hard tooth surface transmission technology, deeply explore the personalized needs of different general industrial scenarios, provide customized product solutions and global after-sales service support, and work with customers to promote the upgrade of general industrial production technology. The ZDY Single-stage Cylindrical Gear Reducer has passed strict international certifications, fully complying with the technical standards and safety requirements of global general industrial fields, and is committed to becoming a trusted partner in the global general heavy-duty transmission field.
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