ZLY Two-Stage Cylindrical Gear Reducer: High-Ratio Precision Transmission, Leading Heavy-Duty Impact-Resistant Applications
I. Product Overview: Two-Stage High-Ratio Configuration, Meeting Heavy-Duty Precision Transmission Needs
Weigao’s ZLY Two-Stage Cylindrical Gear Reducer is a high-performance power transmission device specially developed for industrial scenarios requiring large reduction ratio, high torque output, and stable operation under heavy-duty impact conditions, such as heavy-duty conveyors, plastic extrusion machinery, metallurgical rolling equipment, and mining hoisting auxiliary systems. Targeting the pain points of traditional reducers such as narrow reduction ratio range, insufficient torque capacity, and poor impact resistance in high-demand heavy-duty scenarios, this product integrates optimized two-stage parallel shaft cylindrical gear transmission design, high-rigidity integral casting housing, precision hard tooth surface technology, and enhanced load-bearing system. It realizes a perfect combination of large-ratio precision speed reduction, strong heavy-duty bearing capacity, excellent impact resistance, and long-term stable operation, and can reliably operate in complex working conditions involving continuous heavy load, frequent impact load, and long-term continuous operation. As a core transmission component for key heavy-duty industrial equipment, the ZLY Two-Stage Cylindrical Gear Reducer is widely applied in plastic extruders, heavy-duty belt conveyors, metallurgical continuous casting machines, and mining auxiliary hoists, providing high-precision, high-reliability power support for global heavy-duty industrial production projects. The product has passed international certifications such as ISO 6336 gear strength certification, IP55 protection certification, and ISO 9001 quality management system certification, and is trusted by more than 50 countries and regions for its excellent heavy-duty impact-resistant scenario adaptation performance.
II. Core Advantages: Five Heavy-Duty Transmission Strengths, Defining High-Ratio Stability Standards
1. Optimized Two-Stage Transmission Structure, Wide Ratio & High Precision
The product adopts an optimized two-stage parallel shaft cylindrical gear transmission structure, which effectively expands the reduction ratio range to 8-40 (stepless selection), covering the speed reduction needs of most heavy-duty industrial equipment. The transmission system adopts a split-flow type layout design, where the high-speed stage and low-speed stage gears are symmetrically arranged relative to the bearings, ensuring uniform force distribution on the gears and shafts, and reducing load concentration . The gears are made of high-quality 20CrMnTi alloy steel, 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. Precision tooth profile modification technology is adopted to optimize the meshing angle, making the meshing contact area reach more than 96%, realizing smooth and precise power transmission. The two-stage transmission efficiency is as high as 94%-96%, which is 4%-6% higher than that of ordinary two-stage soft tooth surface reducers, ensuring efficient energy conversion while meeting high-ratio speed reduction needs.
2. High-Rigidity Integral Casting Housing, Strong Impact Resistance
The housing is made of high-strength HT300 cast iron, formed by one-time integral casting and precision machining. The internal structure is optimized by finite element simulation analysis, and the key stress-bearing parts (such as bearing seats and gear installation positions) are equipped with reinforced rib networks, which significantly improves the overall rigidity and impact resistance of the housing. The maximum wall thickness of the housing reaches 30mm, and the maximum radial load bearing capacity is 42kN, which is 45% higher than that of ordinary two-stage cylindrical gear reducer housings. The integral casting structure eliminates assembly gaps, ensures the coaxiality of the input, intermediate and output shafts, and effectively reduces vibration and noise caused by shaft deflection during impact load operation. The housing surface is treated with anti-rust and anti-corrosion painting, which can adapt to dusty, humid and other harsh industrial environments.
3. Enhanced Load-Bearing Bearing System, Stable & Durable
The product is equipped with an enhanced three-shaft bearing system. The input shaft and intermediate shaft adopt high-precision cylindrical roller bearings, and the output shaft adopts large-capacity self-aligning roller bearings with double-sided sealing, which can effectively bear large radial and axial loads and automatically compensate for slight shaft deflection. All bearings are preloaded during assembly, which improves the rigidity and stability of the shaft system, and ensures stable operation even under frequent impact load conditions. The bearing lubrication adopts forced circulating oil lubrication, and the built-in oil guide grooves and oil spray nozzles ensure sufficient lubrication and heat dissipation of the bearings. The bearing service life reaches more than 20,000 hours under normal working conditions, which lays a solid foundation for the long-term reliable operation of the reducer. The shaft extension is processed by precision grinding, with high dimensional accuracy and surface finish, facilitating reliable connection with driven equipment.
4. Efficient Heat Dissipation System, Adapt to Continuous Heavy-Load Operation
The heat dissipation system adopts a composite efficient heat dissipation design: the outer surface of the housing is distributed with dense spiral heat dissipation fins, which increase the heat dissipation area by 50% compared with ordinary models; the high-power models are equipped with an integral forced cooling fan and an independent oil cooler, which can quickly take away the heat generated during heavy-load operation. The built-in high-precision oil filter (filtration accuracy up to 10μm) and oil temperature sensor monitor the lubricating oil status in real time, ensuring the cleanliness and temperature stability of the lubricating oil. The product uses high-quality extreme pressure anti-wear industrial gear oil, which has excellent thermal stability and load-bearing capacity. It can work normally in the operating temperature range of -15℃ to +110℃, fully adapting to the high-temperature environment generated by continuous heavy-load operation of industrial equipment.
5. Flexible Installation & Convenient Maintenance, Cost-Effective Operation
The product supports multiple 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 IEC flange interfaces, which are compatible with most heavy-duty industrial equipment and can be flexibly adjusted according to the equipment layout. The installation positioning accuracy error is ≤0.1mm, ensuring the reliability of the transmission system connection. The housing is designed with a centralized large-diameter oil filling port, a quick-opening oil drain port, and a transparent high-temperature resistant oil level observation window, which facilitates daily lubrication management and maintenance operations. The key components are standardized and serialized, and the vulnerable parts can be quickly replaced without disassembling the whole machine, reducing equipment downtime. The rated service life reaches more than 18 years under normal maintenance conditions, and the maintenance cycle is extended by 60% compared with ordinary models. The overall maintenance cost is reduced by 40% compared with similar products, significantly saving the user's operation and maintenance costs.
III. Typical Application Fields: Focus on Heavy-Duty Industry, Empowering Stable Production
With its exclusive optimized two-stage transmission structure, high-rigidity impact-resistant housing, enhanced load-bearing system and efficient heat dissipation design advantages, Weigao ZLY Two-Stage Cylindrical Gear Reducer has become the core transmission choice for heavy-duty industrial equipment, and its typical application fields include:
- Plastic Extrusion Industry: Single-screw plastic extruder main drives, film blowing machine transmission systems, adapting to large torque transmission, continuous operation and high temperature resistance requirements;
- Mining Auxiliary Industry: Heavy-duty mining belt conveyor drives, ore hoist auxiliary transmission systems, adapting to heavy load impact, dusty environment and long-term continuous operation needs;
- Metallurgical Industry: Metallurgical continuous casting machine transmission systems, steel rolling mill auxiliary drives, adapting to heavy load, high temperature and frequent impact load conditions;
- Building Materials Industry: Large cement rotary kiln auxiliary drives, concrete mixer main transmission systems, adapting to heavy load, dusty environment and high-temperature operation requirements;
IV. Technical Parameters: Precise Matching, Meeting Diverse Needs
- Heavy-Duty Conveying Industry: Port bulk cargo conveyor drives, coal handling system transmission systems, adapting to ultra-heavy load, long-distance continuous operation and harsh environment needs;
| Item | Specification Range |
| 3kW - 160kW | 1.5kW - 75kW |
| 8 - 40 (Two-stage, Stepless Selection); 50 - 2000 (Customized Multi-stage) | 10 - 80 (Single-stage); 100 - 1500 (Customized Double-stage) |
| 500N·m - 25000N·m (Graded by Model) | 800N·m - 12000N·m (Graded by Model) |
| 94% - 96% (Depending on Reduction Ratio) | 85% - 93% (Depending on Model and Reduction Ratio) |
| ≤62dB - ≤70dB (Measured at 1m Distance) | ≤58dB - ≤65dB (Measured at 1m Distance) |
| Protection Level | IP55, ISO 6336 Gear Strength Certification, ISO 9001 Quality Management System Certification |
| -15℃ - +110℃ | -30℃ - +120℃ |
| Horizontal Foot-mounted, Horizontal Flange-mounted, Vertical Flange-mounted, ZLY (Two-Stage Cylindrical Gear Heavy-Duty 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, Anti-Wear Coating), Hollow Shaft Output (Locking Disk Connection), Flange Output (Standard IEC Interface), Reinforced Shaft Extension (For Ultra-High Power Matching) | 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, load characteristics and transmission requirements, and ensure that the coaxiality error between the reducer and the motor/driven equipment is ≤0.1mm. Use high-strength alloy steel bolts to fix the reducer firmly on the reinforced mounting base to avoid vibration and displacement during impact load operation. Strictly follow the installation specifications to check the cleanliness of the connection parts and ensure reliable connection. Select the appropriate extreme pressure anti-wear industrial gear oil according to the working conditions: use 220# for normal temperature and general load, 320# for high temperature and heavy load, and 460# for ultra-heavy load. Regularly check the oil level, oil quality, sealing performance and heat dissipation system status; replace the lubricating oil after the first 2000 hours of operation, and perform comprehensive maintenance every 4000 hours thereafter, including checking gear meshing status, bearing temperature, fastener tightness, heat dissipation fin cleanliness and housing integrity. If abnormal phenomena such as excessive noise, vibration, oil leakage, overheating or abnormal oil pressure occur during operation, stop the machine immediately in a safe manner for inspection and troubleshooting.
VI. Conclusion: Heavy-Duty High-Ratio Transmission Leader, Empowering Industrial Production Upgrade
Adhering to the design philosophy of "High-Ratio Precision, Heavy-Duty Durability, Stable Operation & Efficient Adaptation", Weigao ZLY Two-Stage Cylindrical Gear Reducer focuses on the core transmission needs of heavy-duty industrial equipment, integrating multiple exclusive technologies such as optimized two-stage parallel shaft transmission design, high-rigidity integral casting housing, and enhanced load-bearing bearing system. It breaks through the performance limitations of traditional two-stage cylindrical gear reducers in heavy-duty impact multi-scenario applications, providing high-precision, high-reliability power transmission solutions for plastic extrusion, mining auxiliary, metallurgical, and building materials key industries. We will continue to rely on advanced high-ratio transmission technology, deeply explore the personalized needs of different heavy-duty industrial scenarios, provide customized product solutions and global after-sales service support, and work with customers to promote the upgrade of heavy-duty industrial production technology. The ZLY Two-Stage Cylindrical Gear Reducer has passed strict international certifications, fully complying with the technical standards and safety requirements of global heavy-duty industrial fields, and is committed to becoming a trusted partner in the global heavy-duty high-ratio transmission field.
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