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Hard Toothed Cylindrical Gearbox

Product Overview

The Hard Toothed Cylindrical Gearbox is a heavy-duty industrial power transmission unit engineered for high-torque mechanical drives. Featuring carburized, quenched, and precision-ground alloy steel gears, this unit delivers mechanical efficiency exceeding 98% per reduction stage, high load-carrying capacity, and stable continuous operation in demanding industrial environments. It functions as a primary speed reducer and torque multiplier for heavy machinery.

Key Features and Advantages

Carburized and Ground Gearing

Manufactured from high-grade alloy steel, carburized to a case depth of 0.8 mm to 2.5 mm, with surface hardness maintained at HRC 58 to 62 and tooth profiles finished to DIN Class 6 accuracy.

Thermal Management

Optimized housing geometry featuring external ribbing for natural convection, supplemented by optional internal cooling coils or auxiliary cooling fans to stabilize oil bath temperatures under continuous heavy loads.

Rigid Housing Structure

Premium cast iron or ductile iron housings, stress-relieved via high-temperature annealing to prevent structural deformation under combined radial and axial loads.

Positive Lubrication Circuitry

Integrated splash lubrication combined with engineered internal oil distribution channels to ensure reliable oil delivery to high-load bearing assemblies, eliminating boundary friction.

Modular Integration

Standardized parallel shaft configurations, hollow output options with shrink discs, and rigid mounting footprints designed for direct plant integration.

Technical Specifications

Technical Parameter	Specification Standard / Range
Gear Geometry	Involute cylindrical spur and helical gear configurations
Center Distance	100 mm to 1000 mm
Transmission Ratio	i = 1.25 to 450 (Single to multi-stage configurations)
Input Power	Up to 5000 kW
Output Torque	Up to 900,000 Nm
Mechanical Efficiency	Greater than or equal to 98 percent per reduction stage
Gear Precision Grade	DIN 3962 Class 6
Bearing Selection	Heavy-duty cylindrical roller and tapered roller bearings conforming to international ISO standards
Lubrication Standard	ISO VG 220 to 460 industrial synthetic or mineral gear oils

Models and Configurations

ZLY Series

Two-stage hard-toothed cylindrical gear reducer (medium-to-high reduction ratios)

ZSY Series

Three-stage hard-toothed cylindrical gear reducer (high reduction ratios)

DBY / DCY Series

Bevel-cylindrical gear reducer (orthogonal shaft layout)

Mounting Options

Foot-mounted, shaft-mounted with torque arm, or flange-mounted variations

Industrial Applications

Bulk Material Handling: Heavy-duty belt conveyors, stacker-reclaimers, and apron feeders.

Mining & Mineral Processing: Jaw crushers, ball mills, rod mills, and industrial flotation cells.

Cement & Construction Materials: Vertical roller mills, rotary kilns, and cement separators.

Metallurgy & Metal Working: Continuous casting roller tables, cooling beds, and rolling mill primary drives.

Manufacturing and Quality Control

Forging & Metallurgical Inspection: Raw steel forgings undergo ultrasonic testing (UT) per ASTM standards to screen for internal inclusions before machining.

Machining Operations: CNC gear hobbing and shaping followed by CNC profile grinding to strictly control tooth pitch and lead deviations.

Heat Treatment Processing: Automated multi-purpose chamber furnace lines execute controlled atmosphere carburizing, quenching, and tempering with continuous process logging.

Metrological Verification: Analytical gear inspection centers measure tooth profile, helix angle error, and total runout.

Factory Run-Testing: 100 percent no-load running test for a minimum of 2 hours to verify vibration velocity, bearing temperature rise, and acoustic output levels prior to packaging.

Customization Options

01/

Housing Materials: Cast steel or welded structural steel variants engineered for extreme impact load conditions.

02/

Shaft Configurations: Special spline shafts, double-extended input/output shafts, or custom hollow bore diameters with fitted shrink discs.

03/

Sealing Solutions: Labyrinth seals with oil flingers, or heavy-duty taconite seals designed for abrasive, high-dust operating environments.

04/

Condition Monitoring Provisions: Tapped ports and mounting pads for vibration accelerometers, RTD oil temperature sensors, and flow switches.

Frequently Asked Questions

Q: What is the standard design life (L10h) of the bearings and gears under continuous full-load operation?

A: The calculated fatigue life (L10h) of the rolling element bearings is greater than or equal to 80,000 hours under rated load and proper lubrication. Carburized gear teeth possess a designed contact fatigue life exceeding 100,000 hours within specified thermal limits.

Q: How is thermal equilibrium maintained in high ambient temperature environments?

A: Thermal ratings are evaluated per DIN 3993 standards. When generated operational heat surpasses natural housing convection capacity, auxiliary cooling loops—such as external oil-to-water heat exchangers, shaft-mounted cooling fans, or internal cooling water coils—are integrated.

Q: Can these units be dimensionally matched to interchange with legacy gearboxes on-site?

A: Yes. Critical interface parameters—including center height, footprint mounting dimensions, shaft diameters, and overall envelope constraints—can be engineered to match legacy installations, minimizing downtime during brownfield replacements.

Q: What quality documentation is included with each shipment?

A: Each unit ships with a Technical Data Sheet, Quality Inspection Report (including gear metrology charts, material mill test certificates, and UT test logs), Installation and Maintenance Manual, and a recommended spare parts list (BOM).

Q: What is the standard factory lead time for custom gear ratio configurations?

A: Catalog standard models require 8 to 12 weeks. Fully customized designs involving non-standard housing dimensions or specialized ratios require 14 to 20 weeks, depending on raw material forging availability and heat treatment scheduling.

Q: What is the required lubrication maintenance schedule for optimal performance?

A: For mineral gear oils, initial oil replacement is mandatory after the first 500 operating hours (break-in period), followed by subsequent changes every 5,000 operating hours or 12 months. Synthetic oils extend replacement intervals up to 12,000 to 15,000 operating hours, verified via regular oil condition monitoring (viscosity and acid number analysis).

We are one of the most professional hard toothed cylindrical gearbox manufacturers and suppliers in China, specialized in providing high quality products and efficient solutions to global clients. Welcome to buy durable hard toothed cylindrical gearbox for sale here from our factory. For price consultation, contact us.

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