Weigao T-Series Spiral Bevel Gear Commutator: Heavy-Duty Rigidity & Universal Adaptation Solution
I. Product Overview
Weigao T-Series Spiral Bevel Gear Commutator is a heavy-duty universal transmission device integrating high-rigidity spiral bevel gear structure and wide-range speed ratio adjustment function. As a versatile commutator for industrial general-purpose scenarios, it is tailored for equipment requiring stable direction switching and heavy-load transmission such as construction machinery, mining conveyors, and agricultural machinery. It overcomes the shortcomings of traditional commutators such as poor load-bearing rigidity, narrow speed ratio range, and frequent maintenance needs. Compliant with GB/T 10095-2018 and ISO 6336 industrial standards, with IP65/IP67 graded protection, it features 42CrMo alloy spiral bevel gears, integral forged cast iron housing, and maintenance-free sealing system. Boasting advantages of strong load-bearing capacity, wide speed ratio adaptation, long-term maintenance-free operation, and rugged durability, it operates stably at -40℃ to +120℃, serving as a core universal transmission component for industrial systems worldwide.
II. Core Advantages
1. High-Rigidity Gear Structure, Stable Heavy-Load Transmission
Adopting reinforced spiral bevel gear design with tooth root thickening optimization, the T series realizes reliable power transmission and stable direction switching under heavy load. Gears are crafted from 42CrMo alloy steel, undergoing deep carburizing quenching, precision grinding, and tooth surface strengthening treatment, with tooth surface hardness up to HRC 62-66 and roughness ≤Ra 0.03μm. The spiral tooth structure with optimized helix angle ensures uniform force distribution, increasing tooth root bearing capacity by 40% compared with standard spiral bevel gears. Transmission efficiency reaches 94%-96%, with torque density up to 20Nm/cm³, and gear backlash controlled within ≤8arcmin for standard grade, ≤4arcmin for heavy-duty grade. It can withstand 4 times rated load instantaneous impact, effectively resisting vibration and impact from frequent start-stop, suitable for harsh heavy-load working conditions.
2. Model-Graded Design, Scenario-Specific Adaptation
The T series adopts graded design with multiple models covering ultra-wide speed ratio range, supporting universal adaptation to various industrial equipment. It covers transmission ratio 1:1-20:1, power range 1.5kW-160kW, and rated torque 800Nm-35000Nm, with 90° vertical steering as standard and 30°/45°/60° optional steering angles. The housing adopts integral forged cast iron structure with cross-shaped reinforced rib layout, enhancing torsional rigidity by 45% and avoiding gear misalignment under extreme load. It supports multi-mode installation including foot-mounted, flange-mounted, and hollow shaft-mounted, with standardized connection interfaces adapting to different motor and working machine configurations. The rugged structure with enlarged installation base reduces vibration amplitude by 30%, facilitating integration into harsh outdoor and heavy-industry scenarios.
3. Maintenance-Free Sealing System, Harsh Environment Durability
Targeting harsh industrial environments, the series adopts maintenance-free composite sealing design to extend service life. Standard models adopt IP65 protection, combining double-lip skeleton oil seal, labyrinth structure, and high-performance sealing gasket to effectively resist dust, sand, and industrial sewage intrusion. Enhanced models upgrade to IP67 with fluorine rubber seals and anti-corrosion coating, adapting to humid, corrosive, and dusty working conditions such as mining sites and construction sites. The housing surface adopts anti-rust and anti-corrosion treatment passing 2000-hour salt spray test. The optimized gear meshing design controls operating noise to ≤56dB at 1m, meeting industrial operation standards. It maintains stable performance at -40℃ low temperature and +120℃ high temperature, adapting to extreme climate conditions.
4. Heavy-Duty Lubrication System, Low Operation Cost
The lubrication system is optimized for heavy-duty long-term operation: small-medium power models use high-grade extreme pressure gear oil (ISO VG 220) for oil bath lubrication, realizing maintenance-free operation within 20000 hours; large-power models adopt forced circulation lubrication with oil cooler, controlling operating temperature below 75℃. The system is equipped with oil sight glass, temperature sensor, and anti-clogging filter, facilitating real-time monitoring and reducing maintenance workload. The first oil change is recommended after 800 hours of initial operation, and subsequent oil changes every 12000 hours under rated load. The modular structure allows quick replacement of wearing parts, with standardized accessories ensuring maintenance efficiency, reducing downtime by 45%.
III. Typical Application Fields
- Construction Machinery: Excavator rotating mechanisms, T series with high torque and strong impact resistance adapting to construction site vibration
- Mining Industry: Mine conveyor steering units, dust-proof sealing and rugged structure adapting to underground harsh environment
- Agricultural Machinery: Large tractor transmission systems, wide speed ratio range and low-temperature resistance matching outdoor operation
- Port Machinery: Cargo crane steering mechanisms, high rigidity and stable transmission ensuring heavy-load handling safety
- Metallurgical Auxiliary: Steel mill slag conveyor units, high-temperature resistance and corrosion protection adapting to metallurgical environment
IV. Key Technical Parameters
| Model Series | Transmission Ratio Range | Rated Torque | Lubrication Mode | Protection Grade |
| T-Small (1.5kW-22kW) | 1:1-8:1 | 800Nm-4500Nm | Oil Bath Lubrication | IP65 (Optional IP67) |
| T-Medium (18kW-75kW) | 1:1-15:1 | 4000Nm-18000Nm | Oil Bath Lubrication | IP65 (Optional IP67) |
| T-Large (75kW-160kW) | 1:1-20:1 | 15000Nm-35000Nm | Forced Circulation Lubrication | IP65 (Optional IP67) |
V. Installation & Maintenance
Select models based on load capacity, speed ratio demand, and working environment (refer to the specification table). Use laser alignment tools to ensure coaxiality error ≤0.015mm during installation, fasten bolts with specified torque (50-150N·m for small models, 150-280N·m for large models) in diagonal sequence. Avoid knocking shaft parts during installation to prevent bearing or gear damage. Regularly inspect oil level, sealing performance, and gear meshing status, clean the oil cooler and filter quarterly. Avoid overload operation exceeding 4 times rated torque, and use dedicated extreme pressure gear oil. Entrust maintenance to professional technicians familiar with heavy-duty commutator systems.
Weigao T-Series Spiral Bevel Gear Commutator adheres to the philosophy of "heavy-duty durability, universal adaptation, and low-cost operation". Its reinforced spiral bevel gear structure and maintenance-free design break through traditional commutators' load and durability limitations, ensuring reliable operation in harsh industrial scenarios. Backed by strict quality control and professional after-sales service, it provides cost-effective transmission solutions for construction, mining, and agricultural industries, establishing itself as a trusted global partner in universal heavy-duty transmission.
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