Weigao HD-Series Spiral Bevel Gear Commutator: Precision Meshing & Quick-Maintenance Solution
I. Product Overview
Weigao HD-Series Spiral Bevel Gear Commutator is a high-precision transmission device integrating Gleason tooth system spiral bevel gears and split-type quick-maintenance structure. Tailored for equipment requiring high-precision direction switching and efficient maintenance such as precision machine tools, automation production lines, and new energy equipment, it overcomes the shortcomings of traditional commutators such as poor meshing precision, cumbersome maintenance, and insufficient protection. Compliant with GB/T 10095-2018 and ISO 6336 precision standards, with IP67/IP69K graded protection, it features 20CrNi2Mo alloy spiral bevel gears, split-type cast iron housing, and high-pressure resistant sealing system. Boasting advantages of ultra-precise meshing, quick disassembly maintenance, extreme environment adaptation, and low-noise operation, it operates stably at -40℃ to +120℃, serving as a core precision transmission component for high-end industrial systems worldwide.
II. Core Advantages
1. Gleason Tooth System Design, Ultra-Precise Meshing Transmission
Adopting Gleason involute spiral bevel gear design with optimized contact spot distribution, the HD series realizes high-efficiency power transmission and ultra-precise direction switching. Gears are crafted from 20CrNi2Mo alloy steel, undergoing deep carburizing quenching, five-axis precision grinding, and tooth surface polishing treatment, with tooth surface hardness up to HRC 60-64 and roughness ≤Ra 0.02μm. The tooth profile design ensures contact spot coverage over 80% of the tooth surface, increasing contact strength by 50% compared with standard bevel gears and reducing meshing vibration significantly. Transmission efficiency reaches 96%-98%, with torque density up to 19Nm/cm³, and gear backlash controlled within ≤3arcmin for precision grade, ≤1.5arcmin for ultra-precision grade. It can withstand 3.5 times rated load instantaneous impact, ensuring stable operation in high-frequency start-stop precision scenarios.
2. Split-Type Quick-Maintenance Structure, Efficient Operation
The HD series adopts split-type housing design with quick-release fasteners, realizing efficient maintenance and reducing downtime significantly. It covers transmission ratio 1:1-15:1, power range 0.75kW-110kW, and rated torque 500Nm-28000Nm, with 90° vertical steering as standard and 45°/60° optional precision steering angles. The split-type cast iron housing with reinforced flange connection ensures structural rigidity while enabling quick disassembly, reducing maintenance time by 50% compared with integral housing models. It supports multi-mode precision installation including foot-mounted, flange-mounted, and hollow shaft-mounted, with positioning pin holes ensuring repeated installation accuracy ≤0.01mm. The compact structure with optimized layout saves installation space, facilitating integration into high-density automation equipment.
3. IP69K Grade Protection, Extreme Environment Adaptation
Targeting high-end industrial scenarios, the series adopts multi-layer composite sealing design to achieve extreme protection performance. Standard models adopt IP67 protection, combining double-end mechanical seal, labyrinth structure, and high-performance fluorine rubber seals to resist dust, water immersion, and chemical corrosion. Enhanced models upgrade to IP69K protection, withstanding high-pressure steam cleaning and adapting to harsh environments such as food processing and chemical cleaning workshops. The housing surface adopts nano-ceramic anti-corrosion coating, passing 3000-hour salt spray test. The optimized gear meshing design controls operating noise to ≤48dB at 1m, meeting precision workshop noise standards. It maintains stable performance at -40℃ low temperature and +120℃ high temperature, adapting to extreme climate and working conditions.
4. Precision Lubrication System, Long Service Life
The lubrication system is optimized for precision transmission and long-term operation: small-medium power models use fully synthetic precision gear oil (ISO VG 150) for oil bath lubrication, realizing maintenance-free operation within 25000 hours; large-power models adopt micro-pump forced lubrication with oil cooler, controlling operating temperature below 70℃. The system is equipped with online oil quality sensor, temperature monitor, and automatic oil replenishment interface, facilitating real-time monitoring and remote maintenance. The first oil change is recommended after 1000 hours of initial operation, and subsequent oil changes every 15000 hours under rated load. The split-type structure allows quick replacement of gear sets and seals without disassembling the whole device, with standardized precision accessories ensuring consistent meshing accuracy after maintenance.
III. Typical Application Fields
- Precision Machine Tools: CNC machining center feed mechanisms, HD series with ultra-precise meshing ensuring movement accuracy
- Automation Lines: Robotic arm transmission units, split-type design and low noise adapting to high-density workshop layout
- New Energy Equipment: Wind power generator steering mechanisms, IP69K protection and wide temperature range matching outdoor operation
- Food Processing: Automatic packaging machine transmission systems, high-pressure cleaning resistance and corrosion protection
- Aerospace: Precision testing equipment steering modules, ultra-low backlash and stable transmission ensuring test accuracy
IV. Key Technical Parameters
| Model Series | Transmission Ratio Range | Rated Torque | Lubrication Mode | Protection Grade |
| HD-Small (0.75kW-15kW) | 1:1-8:1 | 500Nm-3500Nm | Oil Bath Lubrication | IP67 (Optional IP69K) |
| HD-Medium (11kW-55kW) | 1:1-12:1 | 3000Nm-15000Nm | Oil Bath Lubrication | IP67 (Optional IP69K) |
| HD-Large (55kW-110kW) | 1:1-15:1 | 12000Nm-28000Nm | Forced Lubrication | IP67 (Optional IP69K) |
V. Installation & Maintenance
Select models based on precision requirement, speed ratio demand, and working environment (refer to the specification table). Use high-precision laser alignment tools to ensure coaxiality error ≤0.008mm during installation, fasten split housing bolts with specified torque (40-120N·m for small models, 120-220N·m for large models) in diagonal sequence. Check gear contact spots with coloring method after installation to ensure optimal meshing. Regularly inspect oil quality, sealing performance, and gear meshing status, clean the oil cooler and filter semi-annually. Avoid overload operation exceeding 3.5 times rated torque, and use dedicated fully synthetic precision gear oil. Entrust maintenance to professional technicians familiar with precision commutator systems.
Weigao HD-Series Spiral Bevel Gear Commutator adheres to the philosophy of "precision first, efficient maintenance, and extreme adaptation". Its Gleason tooth system and split-type structure break through traditional commutators' precision and maintenance limitations, ensuring reliable operation in high-end industrial scenarios. Backed by strict quality control and professional after-sales service, it provides high-precision transmission solutions for machine tool, automation, and new energy industries, establishing itself as a trusted global partner in precision industrial transmission.
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