ZFY Four-Stage Cylindrical Gear Reducer: Ultra-Wide Ratio & Extreme Heavy-Duty Transmission Solution
I. Product Overview
Weigao ZFY Four-Stage Cylindrical Gear Reducer is a high-end core transmission device tailored for extreme heavy-duty industrial scenarios that demand ultra-large reduction ratio, ultra-high torque output, and long-term stable operation under severe working conditions. Compliant with GB19004—88 national standards and certified by ISO 6336 (Gear Strength Level 2), IP56 protection, and ISO 9001 quality management system, this product is specifically designed to address pain points such as narrow ratio range, insufficient torque margin, and poor impact resistance of traditional reducers in extreme environments. Integrating optimized four-stage parallel shaft transmission structure, high-rigidity integral casting housing, and enhanced heavy-load bearing system, it realizes precise speed reduction with ultra-wide ratio, strong load-bearing capacity, and excellent environmental adaptability. It can stably operate in complex conditions involving continuous ultra-heavy load, frequent strong impact, and temperature fluctuations from -40℃ to +120℃, providing reliable power support for key equipment in global mining, metallurgy, ports, and building materials industries.
II. Core Advantages
1. Optimized Four-Stage Transmission Structure, Ultra-Wide Ratio & High Precision
Adopting an optimized four-stage parallel shaft transmission design, the reducer achieves a reduction ratio range of 40-400 (stepless selection), and can be customized to 500-5000 through multi-stage combination, fully covering the low-speed and high-torque needs of extreme heavy-duty equipment. The transmission system adopts a symmetrical split-flow layout, with high-speed stage, intermediate I stage, intermediate II stage, and low-speed stage gears evenly distributed relative to bearings, reducing load concentration by 70% compared with traditional four-stage structures. Gears are made of high-quality 20CrNiMo alloy steel, processed by integral forging, carburizing and quenching, and super-precision grinding, with tooth surface hardness reaching HRC 60-64 and roughness ≤Ra 0.16μm. Precision tooth profile modification and crowning technology ensure a meshing contact area of over 97%, realizing smooth and efficient transmission with efficiency up to 90%-94%.
2. High-Rigidity Integral Casting Housing, Super Strong Impact Resistance
The housing is made of high-strength HT350 cast iron, formed by one-time integral casting and precision machining. Finite element simulation optimization is applied to internal structure, and key stress-bearing parts such as bearing seats and gear installation positions are equipped with dense reinforced rib networks, enhancing overall rigidity and impact resistance. With a maximum wall thickness of 45mm and radial load-bearing capacity of 75kN (60% higher than ordinary four-stage reducers), the integral structure eliminates assembly gaps, ensures coaxiality of input, intermediate, and output shafts, and effectively reduces vibration and noise caused by shaft deflection under strong impact. The surface is treated with anti-rust, anti-corrosion, and high-temperature resistant painting, adapting to dusty, humid, and high/low temperature harsh environments.
3. Enhanced Heavy-Load Bearing System, Stable & Durable
Equipped with an enhanced five-shaft heavy-load bearing system, the input and intermediate shafts adopt high-precision cylindrical roller bearings with enhanced load capacity, while the output shaft uses extra-large-capacity self-aligning roller bearings with double-sided sealing and dust-proof design, effectively bearing ultra-large radial and axial loads and compensating for slight shaft deflection. High-precision preloading during assembly improves shaft system rigidity and stability by 80% compared with ordinary models. Forced circulating oil lubrication with independent oil pump, combined with built-in oil guide grooves and multi-point oil spray nozzles, ensures sufficient lubrication and heat dissipation of bearings, with service life exceeding 30,000 hours.
4. Efficient Composite Heat Dissipation, Adapt to Extreme Temperature
The composite heat dissipation system includes dense spiral heat dissipation fins on the housing surface (increasing heat dissipation area by 70%), and high-power models are equipped with forced cooling fans and intelligent temperature-controlled oil coolers, quickly dissipating heat generated during extreme heavy-duty operation. Built-in high-precision oil filters (filtration accuracy up to 5μm) and oil temperature sensors monitor lubricating oil status in real time. High-quality extreme pressure anti-wear gear oil with high viscosity index is adopted, supporting preheating to above 0℃ when working at low temperature below 0℃, fully adapting to complex temperature environments.
III. Typical Application Fields
- Mining Industry: Large mining hoist main drives, ultra-heavy-duty belt conveyor transmissions
- Metallurgical Industry: Heavy plate rolling mill main transmissions, continuous casting machine main drives
- Port Machinery: Gantry crane main drives, bulk cargo ship unloader transmissions
- Building Materials Industry: Large cement mill main drives, rotary kiln main transmissions
- Heavy-Duty Machinery: Large forging press main drives, shield machine transmissions
IV. Key Technical Parameters
| Power Range | 22kW - 500kW |
| Reduction Ratio | 40 - 400 (four-stage); 500 - 5000 (customized) |
| Output Torque | 3000N·m - 100000N·m |
| Operating Noise | ≤68dB - ≤75dB (1m distance) |
| Operating Temperature | -40℃ - +120℃ |
V. Installation & Maintenance
Support horizontal foot-mounted, flange-mounted, and vertical flange-mounted installation, with multi-directional positioning holes and standard IEC interfaces for flexible adaptation. Ensure coaxiality error ≤0.1mm during installation, and fix with high-strength anti-loosening bolts. Select 320#/460#/680# extreme pressure anti-wear gear oil according to working conditions. Replace oil after first 2000 hours of operation, and conduct comprehensive maintenance every 3000 hours. Stop immediately for inspection if abnormal noise, vibration, or overheating occurs.
VI. Conclusion
Weigao ZFY Four-Stage Cylindrical Gear Reducer, with its design philosophy of "ultra-wide ratio precision, extreme heavy-duty durability", breaks through the performance limitations of traditional reducers in extreme scenarios. It provides high-reliability transmission solutions for key industries, supported by customized services and global after-sales support. Compliant with international standards and national regulations, it is committed to becoming a trusted partner in the global extreme heavy-duty transmission field.
Download
