BWED Double Stage Cyclo Gear Reducer – Horizontal Foot-Mounted Gearbox

Product Overview

The BWED cyclo gear reducer is a double-stage horizontal foot-mounted speed reduction unit that houses two cycloidal disc-and-pin sets within a single cast iron casing. Where the single-stage BWD series tops out at a 87:1 ratio, the BWED double stage cycloidal gearbox picks up from 99:1 and extends all the way to 7,569:1. This makes the BWED the go-to solution for applications that demand very slow output shaft rotation without requiring an external pre-reduction stage or a variable frequency drive running at impractically low motor speeds.

The BWED product line covers frame sizes 130 through 184. The first digit indicates the first-stage frame, the second digit indicates the second-stage frame, and the trailing digit identifies the specific ratio combination. Center heights range from 160 mm (Frame 130) to 420 mm (Frame 184), and output shaft diameters span from 55 mm to 140 mm. These units are dimensionally interchangeable with Sumitomo CHHM double-stage and SM-Cyclo equivalent models for direct bolt-in replacement. This cross-reference information is provided purely for selection convenience and does not imply any brand affiliation or the sale of counterfeit products.

 

The BWED horizontal foot-mounted cyclo drive reducer finds its primary demand in rotary kiln drives for cement and lime processing, sludge thickener and digester stirrers in wastewater treatment, sugar mill crystallizer drives, large-diameter turntable positioners in steel fabrication, and slow-speed chain conveyor systems in mining. Across Korea and the broader Asia-Pacific region, plant engineers specify this model when they need output speeds below 15 rpm from a standard 4-pole 1500 rpm motor. The cyclo gear reducer product family includes single-stage, double-stage, foot-mounted, and flange-mounted variants to cover virtually any industrial speed reduction requirement.

Technical Specifications and Mounting Dimensions

The BWED cycloidal speed reducer dimensional data below covers both the installation footprint and the shaft-end geometry. When replacing an existing double-stage unit, match the center height, the mounting bolt spacing (A1/A0 and B1/B0), the output shaft diameter d1 with its keyway width b1, and the input shaft diameter d2. All shaft tolerances are h6 standard.

Table 1: BWED Installation and Shaft-End Dimensions (mm)

Table 2: BWED Outer Contour Dimensions and Weight (mm / kg)

 

Operating Environment and Conditions

The BWED double stage cycloidal gearbox is designed for continuous industrial duty under the following standard operating parameters. When conditions fall outside these ranges, contact our engineering team for modified configurations.

✔ Ambient Temperature: -10°C to +40°C with standard mineral oil. For environments below -10°C (cold storage warehouses, Arctic installations), synthetic low-temperature gear oil must be specified. For ambient temperatures above +40°C (foundries, kiln proximity), an auxiliary cooling fan or circulating oil system is recommended.

✔ Duty Cycle: Rated for S1 continuous duty. Bidirectional rotation is permitted on all BWED frame sizes. For frequent start-stop applications (more than 20 starts per hour), apply a service factor of 1.3 to the calculated torque when selecting the frame size.

✔ Mounting Inclination: The BWED horizontal foot-mounted unit should be installed within 15 degrees of horizontal. Beyond this angle, the oil bath cannot reliably reach all internal bearings, and a pressurized circulating lubrication system must be added.

✔ Corrosive and Dusty Environments: Standard units feature IP54-equivalent sealing. For washdown environments (food processing, outdoor installations), enhanced IP65 sealing with stainless steel output shaft options is available. For chemically corrosive atmospheres, the housing can be specified with epoxy-based anti-corrosion coating.

✔ Altitude: Standard ratings apply up to 1,000 meters above sea level. Above this altitude, the reduced air density lowers natural convection cooling capacity. Derate by approximately 3% per additional 500 meters, or add forced-air cooling.

Customization and OEM Options

Korea Ever-Power manufactures the BWED cyclo gear reducer in both standard catalog configurations and custom-engineered variants. Our in-house machining and assembly capabilities allow us to modify units without the long lead times typically associated with custom gearbox orders.

Typical lead time for custom BWED cycloidal gear reducer configurations is 2 to 4 weeks from order confirmation. Standard catalog models in popular frame sizes ship within 3 to 5 business days from our Korean dispatch facility.

BWED Cyclo Gear Reducer vs Helical Gearbox: Why Choose Cycloidal for High-Ratio Applications?

When engineers need ratios above 100:1, the choice typically narrows to either a multi-stage helical gear reducer (three or four pairs of spur/helical gears stacked in series) or a double-stage cycloidal speed reducer like the BWED. Both approaches can produce the same output speed, but the internal mechanics create very different operating characteristics that matter in real plant conditions.

The BWED horizontal foot-mounted cyclo gear reducer has a clear advantage in compactness: two cycloidal stages within a single housing achieve ratios that would require four helical gear pairs spread across a much longer gear train. For plant layouts where floor space is limited near the driven machine, this size difference alone can determine the choice. The shock load capacity also favors the cycloidal design, particularly in applications like crusher drives and reciprocating feeder mechanisms where sudden torque spikes are routine rather than exceptional.

Where worm gear reducers suffer from high friction losses at high ratios, and helical gearboxes become physically unwieldy at ratios above 200:1, the BWED double-stage cycloidal unit occupies a practical middle ground: good efficiency, excellent shock tolerance, compact dimensions, and straightforward maintenance. For ratios below 60:1, a two-stage helical gearbox is typically the more efficient and cost-effective option. Above that threshold, the BWED cyclo drive begins to pull ahead on total installed cost and footprint.

Quality Certifications and Service Commitments

Every BWED horizontal foot-mounted cyclo gear reducer that leaves our factory passes through a multi-stage quality verification process before shipment. Our production facility holds ISO 9001:2015 certification, and the products carry CE marking for compliance with European machinery directives applicable to Korean export customers supplying equipment to EU markets.

► Incoming Material Inspection: GCr15 steel billets are batch-tested for chemical composition and hardness before machining. Cast iron housings are checked for porosity and dimensional conformity to pattern drawings.

► In-Process Checks: Cycloidal disc tooth profiles are measured on coordinate measuring machines (CMM) after grinding. Pin ring hole positions are verified to within 0.01 mm positional tolerance.

► Assembly Testing: Each completed unit undergoes a no-load run test to verify noise, vibration, and operating temperature. Units above Frame 152 also receive a loaded torque test at 75% rated capacity.

► Warranty: 12-month warranty from date of delivery covering manufacturing defects in materials and workmanship. Technical support is available throughout the product life via email and phone from our Korean liaison office.

Related and Compatible Products

The BWED is typically part of a larger power transmission assembly. These products pair with the BWED double stage cyclo gear reducer in common industrial configurations:

On the motor side, the BWED pairs with IEC standard induction motors from 0.75 kW to 55 kW. For inputs above 18.5 kW, 6-pole 960 rpm motors are preferred over 4-pole 1500 rpm models to reduce internal bearing stress. Flexible couplings absorb minor misalignment between motor and reducer input shafts.

On the output side, the BWED connects to driven equipment through keyed shaft couplings, drive shafts with universal joints for angular offset, or sprockets and chains for chain-driven conveyors and elevators.

For ratios beyond the BWED range or for applications needing both high ratio and precision positioning, the unit can be combined in series with a planetary gearbox pre-stage. Our engineering team provides complete drive system packages with motor, coupling, reducer, and output connection specified as a matched set.

Frequently Asked Questions

What makes the BWED different from the single-stage BWD cyclo gear reducer?

The BWD is a single-stage unit with ratios from 9:1 to 87:1. The BWED contains two cycloidal stages in series within one housing, extending the ratio range from 99:1 to 7,569:1. The mounting footprint is the same for a given frame, but the BWED housing is longer to accommodate the additional stage. Efficiency is slightly lower (75-82% vs 85-92%) due to the double conversion, but this is offset by the much higher achievable ratio without needing external pre-reduction.

Is a BWED cycloidal reducer better than a helical gearbox for a 300:1 ratio application?

At 300:1, a helical gearbox would need four stages, making it considerably longer and more expensive than a two-stage BWED. The cycloidal unit also handles shock loads far better, which matters in applications like crusher feeds and reciprocating mechanisms. For smooth, constant-load applications where noise is the primary concern, a multi-stage helical box may produce slightly lower sound levels at certain frequencies, but the difference is marginal in most plant environments.

Can the BWED handle bidirectional rotation for reversible conveyor drives?

Yes. All BWED frame sizes permit forward and reverse rotation without any internal modification. The cycloidal disc-and-pin contact geometry is symmetrical and operates identically in both directions.

What lubricant is recommended for the BWED double stage cyclo gear reducer?

Use 70# or 90# extreme pressure gear oil for best protection of the double-stage internal components. The first oil change should be performed after 100 running hours to flush break-in metal particles. Subsequent changes are every 6 months under standard 8-hour daily operation, or every 3 to 4 months for continuous 24-hour duty.

What is the typical lead time for standard BWED models shipped to Korea?

Popular frame sizes (130, 141, 152, 153) with standard ratios ship within 3 to 5 business days from our dispatch facility. Larger frames (163, 174, 184) and non-standard ratio combinations require 2 to 3 weeks. Custom modifications add 1 to 2 additional weeks depending on scope.

How does the frame numbering system work for the BWED series?

The first digit indicates the first-stage cycloidal frame size, the second digit indicates the second-stage frame size, and the trailing digit identifies the specific ratio within that combination. For example, Frame 153 uses a Frame 15 first stage paired with a Frame 3 second stage, configured for the third available ratio in that pairing. Contact us with your required ratio and we will identify the matching frame designation.

Customer Reviews

---

Oh Sung-min, Kiln Department Supervisor, Gangwon Cement Corp. (January 2025)

"We run BWED-174 units on two rotary kiln drives at 2.1 rpm output. These replaced helical gearboxes that were three times the physical length and needed gear tooth replacement every 18 months. The BWED units have been operating for 11 months now with no signs of internal wear based on oil analysis reports. The installation footprint savings alone justified the changeover."

---

Takahashi Ryo, Equipment Procurement, Chiba Waste Management (March 2025)

"Needed BWED-152 for our sludge thickener drives. The Ever-Power units bolt directly into the same position as our previous Sumitomo double-stage units. No base plate modifications needed. Price was noticeably lower and delivery took just 8 days to Chiba port."

---

Jeong Eun-bi, Maintenance Engineer, Cheonan Automotive Parts (February 2025)

"We use BWED-141 on a paint line turntable positioner. The slow and steady rotation at 4 rpm is exactly what we needed. No vibration issues at all, which is critical for our coating quality. The unit runs 20 hours a day, six days a week, and after five months the oil is still clean with no metallic contamination visible."

---

Le Thi Mai, Technical Purchasing, Binh Duong Sugar Mill, Vietnam (December 2024)

"Ordered three BWED-163 units for crystallizer drives. The double-stage ratio gives us 1.5 rpm output which is perfect for the slow stirring requirement. Packaging was excellent for ocean freight, and the units arrived in perfect condition. We found the product range we needed at cyclogearreducer.top and the ordering process was straightforward."

---

Kim Tae-hyung, Project Manager, Sejong Engineering Solutions (November 2024)

"As a system integrator, we need reliable OEM supply with consistent quality. Ever-Power has delivered 40+ BWED units to us over the past year for various conveyor and mixer projects. Quality has been consistent across batches. Their willingness to accommodate small-quantity custom shaft modifications is a real advantage for project-based work."

Packing and Shipping