ZSY Three-Stage Cylindrical Gear Reducer: Ultra-High Ratio Precision Transmission, Leading Ultra-Heavy-Duty Industrial Applications
I. Product Overview: Three-Stage Ultra-High Ratio Configuration, Meeting Ultra-Heavy-Duty Precision Transmission Needs
Weigao’s ZSY Three-Stage Cylindrical Gear Reducer is a top-tier power transmission device specially developed for ultra-heavy-duty industrial scenarios requiring ultra-large reduction ratio, ultra-high torque output, and long-term stable operation under severe impact conditions, such as large-scale mining hoists, metallurgical rolling mills, port heavy-duty cranes, and large cement rotary kilns. Targeting the pain points of traditional reducers such as insufficient reduction ratio, weak torque-bearing capacity, and poor stability in ultra-heavy-duty high-demand scenarios, this product integrates optimized three-stage parallel shaft cylindrical gear transmission design, ultra-high-rigidity integral casting housing, precision hard tooth surface strengthening technology, and enhanced heavy-load bearing system. It realizes a perfect combination of ultra-high-ratio precision speed reduction, ultra-strong heavy-duty bearing capacity, excellent impact resistance, and long-term reliable operation, and can stably operate in complex working conditions involving continuous ultra-heavy load, frequent strong impact load, and 24-hour continuous operation. As a core transmission component for key ultra-heavy-duty industrial equipment, the ZSY Three-Stage Cylindrical Gear Reducer is widely applied in large mining hoists, metallurgical hot rolling mills, port container cranes, and large cement rotary kilns, providing high-precision, high-reliability power support for global ultra-heavy-duty industrial production projects. The product has passed international certifications such as ISO 6336 gear strength certification (level 2), IP56 protection certification, and ISO 9001 quality management system certification, and is trusted by more than 50 countries and regions for its excellent ultra-heavy-duty scenario adaptation performance.
II. Core Advantages: Five Ultra-Heavy-Duty Transmission Strengths, Defining Ultra-High Ratio Stability Standards
1. Optimized Three-Stage Transmission Structure, Ultra-Wide Ratio & High Precision
The product adopts an optimized three-stage parallel shaft cylindrical gear transmission structure, which effectively expands the reduction ratio range to 20-200 (stepless selection), and can be customized to 250-4000 for multi-stage combination, fully covering the speed reduction needs of ultra-heavy-duty industrial equipment. The transmission system adopts a symmetrical split-flow layout design, where the high-speed stage, intermediate stage and low-speed stage gears are evenly arranged relative to the bearings, ensuring uniform force distribution on the gears and shafts, and reducing load concentration by 60% compared with traditional three-stage structures. The gears are made of high-quality 20CrNiMo alloy steel, processed by integral forging, carburizing and quenching, and super-precision grinding. The surface hardness reaches HRC 60-64, and the tooth surface roughness is ≤Ra 0.16μm. Precision tooth profile modification and crowning technology are adopted to optimize the meshing angle, making the meshing contact area reach more than 97%, realizing smooth and precise power transmission. The three-stage transmission efficiency is as high as 92%-95%, which is 5%-8% higher than that of ordinary three-stage soft tooth surface reducers, ensuring efficient energy conversion while meeting ultra-high-ratio speed reduction needs.
2. Ultra-High-Rigidity Integral Casting Housing, Strong Impact Resistance
The housing is made of high-strength HT350 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, gear installation positions and flange connections) 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 40mm, and the maximum radial load bearing capacity is 65kN, which is 55% higher than that of ordinary three-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 strong impact load operation. The housing surface is treated with anti-rust, anti-corrosion and anti-high-temperature painting, which can adapt to dusty, humid, high-temperature and other harsh industrial environments.
3. Enhanced Heavy-Load Bearing System, Stable & Durable
The product is equipped with an enhanced four-shaft heavy-load bearing system. The input shaft and intermediate shafts adopt high-precision cylindrical roller bearings with enhanced load capacity, and the output shaft adopts extra-large-capacity self-aligning roller bearings with double-sided sealing and dust-proof design, which can effectively bear ultra-large radial and axial loads and automatically compensate for slight shaft deflection. All bearings are preloaded with high precision during assembly, which improves the rigidity and stability of the shaft system by 70% compared with ordinary models, and ensures stable operation even under frequent strong impact load conditions. The bearing lubrication adopts forced circulating oil lubrication with independent oil pump, and the built-in oil guide grooves and multi-point oil spray nozzles ensure sufficient lubrication and heat dissipation of the bearings. The bearing service life reaches more than 25,000 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 and surface hardening treatment, with high dimensional accuracy and surface finish, facilitating reliable connection with driven equipment.
4. Efficient Composite Heat Dissipation System, Adapt to Continuous Ultra-Heavy-Load Operation
The heat dissipation system adopts a high-efficiency composite heat dissipation design: the outer surface of the housing is distributed with dense spiral heat dissipation fins, which increase the heat dissipation area by 60% compared with ordinary models; the high-power models are equipped with an integral forced cooling fan and an independent oil cooler with temperature control function, which can quickly take away the large amount of heat generated during ultra-heavy-load operation. The built-in high-precision oil filter (filtration accuracy up to 5μm) 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 with high viscosity index, which has excellent thermal stability and load-bearing capacity. It can work normally in the operating temperature range of -20℃ to +120℃, fully adapting to the high-temperature environment generated by continuous ultra-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 ultra-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 20 years under normal maintenance conditions, and the maintenance cycle is extended by 70% compared with ordinary models. The overall maintenance cost is reduced by 45% compared with similar products, significantly saving the user's operation and maintenance costs.
III. Typical Application Fields: Focus on Ultra-Heavy-Duty Industry, Empowering Stable Production
With its exclusive optimized three-stage transmission structure, ultra-high-rigidity impact-resistant housing, enhanced heavy-load bearing system and efficient composite heat dissipation design advantages, Weigao ZSY Three-Stage Cylindrical Gear Reducer has become the core transmission choice for ultra-heavy-duty industrial equipment, and its typical application fields include:
- Mining Industry: Large mining hoist main drives, ultra-heavy-duty mining belt conveyor drives, adapting to ultra-large torque transmission, frequent impact load and long-term continuous operation needs;
- Metallurgical Industry: Metallurgical hot rolling mill main transmission systems, continuous casting machine main drives, adapting to ultra-heavy load, high temperature and frequent strong impact load conditions;
- Port Machinery Industry: Port container crane main drives, bulk cargo ship unloader transmission systems, adapting to ultra-heavy load, variable load operation and harsh marine environment requirements;
- Building Materials Industry: Large cement rotary kiln main drives, cement mill main transmission systems, adapting to ultra-heavy load, dusty environment and high-temperature continuous operation requirements;
IV. Technical Parameters: Precise Matching, Meeting Diverse Needs
- Heavy-Duty Machinery Industry: Large forging press auxiliary drives, heavy-duty shield machine transmission systems, adapting to ultra-high torque, strong impact and complex working condition needs;
| Item | Specification Range |
| Power Range | 15kW - 400kW |
| Reduction Ratio | 20 - 200 (Three-stage, Stepless Selection); 250 - 4000 (Customized Multi-stage) |
| Output Torque | 2000N·m - 80000N·m (Graded by Model) |
| Transmission Efficiency | 92% - 95% (Depending on Reduction Ratio) |
| Operating Noise | ≤65dB - ≤72dB (Measured at 1m Distance) |
| Protection Level & Certification | IP56, ISO 6336 Gear Strength Certification (Level 2), ISO 9001 Quality Management System Certification |
| Operating Temperature Range | -20℃ - +120℃ |
| Installation Mode | Horizontal Foot-mounted, Horizontal Flange-mounted, Vertical Flange-mounted, ZSY (Three-Stage Cylindrical Gear Ultra-Heavy-Duty Type) |
| Output Shaft Type | Solid Shaft Output (Flat Key/Spline, Anti-Wear & Anti-Corrosion Coating), Hollow Shaft Output (Locking Disk Connection), Flange Output (Standard IEC Interface), Reinforced Shaft Extension (For Ultra-High Power Matching) |
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 with anti-loosening devices to fix the reducer firmly on the reinforced mounting base to avoid vibration and displacement during strong 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 320# for normal temperature and general load, 460# for high temperature and heavy load, and 680# 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 3000 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: Ultra-Heavy-Duty High-Ratio Transmission Leader, Empowering Industrial Production Upgrade
Adhering to the design philosophy of "Ultra-High-Ratio Precision, Ultra-Heavy-Duty Durability, Stable Operation & Efficient Adaptation", Weigao ZSY Three-Stage Cylindrical Gear Reducer focuses on the core transmission needs of ultra-heavy-duty industrial equipment, integrating multiple exclusive technologies such as optimized three-stage parallel shaft transmission design, ultra-high-rigidity integral casting housing, and enhanced heavy-load bearing system. It breaks through the performance limitations of traditional three-stage cylindrical gear reducers in ultra-heavy-duty strong impact multi-scenario applications, providing high-precision, high-reliability power transmission solutions for mining, metallurgical, port, and building materials key industries. We will continue to rely on advanced ultra-high-ratio transmission technology, deeply explore the personalized needs of different ultra-heavy-duty industrial scenarios, provide customized product solutions and global after-sales service support, and work with customers to promote the upgrade of ultra-heavy-duty industrial production technology. The ZSY Three-Stage Cylindrical Gear Reducer has passed strict international certifications, fully complying with the technical standards and safety requirements of global ultra-heavy-duty industrial fields, and is committed to becoming a trusted partner in the global ultra-heavy-duty high-ratio transmission field.
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