XWED dvostepeni cikloidni reduktor – cikloidni mjenjač s prirubnicom

Pregled proizvoda

The XWED cyclo gear reducer is the double-stage, flange-mounted counterpart to the foot-mounted BWED series. Where the BWED sits on a horizontal base and connects through floor-level bolting, the XWED double stage flange-mounted cycloidal gearbox attaches through a circular flange pattern directly to the driven machine frame, vessel bracket, or structural steel platform. Both models share the same internal cycloidal disc-and-pin mechanism and achieve the same compound ratio range of 99:1 to 7,569:1, but the flange interface eliminates the need for a separate foundation or baseplate at the installation site.

The XWED series spans frame sizes 31 through 184, covering center heights from 140 mm to 420 mm and output shaft diameters from 35 mm to 140 mm. Weight ranges from 82 kg at the smallest frame to 1,270 kg at the largest. These dimensions are cross-compatible with Sumitomo CHHJ double-stage and equivalent flange-type cycloidal models, allowing direct bolt-pattern replacement. This cross-reference is stated solely for customer convenience during selection and does not suggest the sale of counterfeit products or brand affiliation.

The XWED flange-mounted cyclo drive reducer is specified in applications where the reducer must mount directly onto equipment without a separate foundation: top-of-vessel agitator drives, wall-mounted crane travel mechanisms, overhead conveyor drives, and integrated machine tool feed systems. As part of the ciklo reduktor family, the XWED shares the same GCr15 bearing steel internals and cast iron housing construction as all other models in the Ever-Power cycloidal lineup.

Technical Specifications

The XWED cycloidal speed reducer dimensional table below presents installation dimensions, shaft-end geometry, and the frame-specific data required for accurate selection. When replacing an existing flange-mounted double-stage reducer, match the flange bolt circle, shaft diameter, and center height to ensure physical compatibility. All output shafts are machined to h6 tolerance.

XWED Installation and Shaft-End Dimensions (mm) - Representative Frames

Note: Shaft d₁/d₂ tolerance is h6. Full frame data (31 through 184) available upon request. Contact our engineering team for the complete dimensional drawing set.

Total Cost of Ownership: XWED Cycloidal vs Conventional Gearbox

Purchasing price alone rarely tells the full story of what a ciklo reduktor costs over its operational lifetime. The total cost of ownership (TCO) includes the initial purchase, energy consumption over years of service, scheduled maintenance labor and materials, unplanned downtime costs, and the eventual cost of replacement. Here is how the XWED flange-mounted cycloidal gearbox stacks up against a conventional multi-stage helical or pužni reduktor at an equivalent 500:1 ratio over a 5-year operating period.

The worm reducer starts with the lowest purchase price, but its poor efficiency at high ratios creates an energy penalty that accumulates relentlessly. Over 5 years on a 15 kW motor running two shifts, the worm option wastes approximately 99,000 kWh more electricity than the XWED. At Korean industrial rates of around 120 KRW per kWh, that energy gap alone amounts to roughly 11,880,000 KRW (about 9,000 USD). Add the cost of one or two bronze worm wheel replacements, and the initially cheap worm reducer becomes the most expensive option over its lifetime.

The 4-stage helical gearbox matches or slightly exceeds the XWED in raw efficiency, but its purchase price is substantially higher due to the precision manufacturing of four gear stages. The XWED double stage cyclo gear reducer sits in the middle on purchase price and energy cost, while offering the longest expected service life and the best shock load resilience. For most industrial buyers making a 5-year or longer investment decision, the XWED delivers the strongest total value proposition among the three options.

Torque and Speed Calculation for the XWED

Accurate torque calculation prevents both undersizing (premature failure from overload) and oversizing (unnecessary cost and wasted space). The following formulas apply to the XWED flange-mounted cyclo gear reducer and all double-stage cycloidal models in the Ever-Power range.

Worked example: A 7.5 kW motor at 1500 rpm drives an XWED with an overall ratio of 473:1. The output torque is: (7.5 x 9550 x 473 x 0.78) / 1500 = 17,616 N.m, and the output speed is 1500 / 473 = 3.17 rpm. This would suit a slow-speed digester stirrer or a turntable drive where the load requires approximately 15,000 N.m at the shaft with a 1.15 safety factor margin.

When selecting an XWED frame for your application, always calculate the required output torque first, then select a frame whose rated torque exceeds your calculated value by a service factor of at least 1.25 for uniform loads and 1.5 or higher for shock or impact loads. The output shaft must also be checked against the radial load from the driven equipment. For applications where a pogonsko vratilo with universal joints connects the reducer to the driven machine, the angular misalignment of the joint introduces additional radial force on the output bearing that must be accounted for in the frame selection.

Lubrication System and Oil Specification

Correct lubrication is the single most important maintenance factor for any cikloidni reduktor sa zupčastim kotačem. The XWED double stage cyclo gear reducer uses an oil bath lubrication system for horizontal and near-horizontal mounting orientations. For vertical or steeply inclined flange-mount positions, an internal oil pump circulates lubricant to the upper-stage bearings that would otherwise sit above the oil bath level.

● Standard Oil: 40# or 50# mechanical oil for ambient temperatures between -10°C and +40°C.

● Recommended Upgrade: 70# or 90# extreme pressure (EP) gear oil for better film strength at the rolling contact surfaces and longer drain intervals.

● Cold Climate: Synthetic PAO-based gear oil (ISO VG 150 or VG 220) for environments below -10°C.

● Food-Grade: NSF H1 certified synthetic gear oil for food and pharmaceutical processing equipment.

First oil change at 100 running hours. Subsequent changes every 6 months (8-hour daily duty) or every 3 months (continuous 24-hour duty). Drain through the plug at the housing base, refill through the breather cap until oil reaches the center of the sight glass. The XWED ships without oil; fill before first operation.

Safety Considerations and Compliance

Installing and operating a XWED cyclo gear reducer in an industrial environment requires attention to several safety factors that protect both personnel and equipment.

The rotating output shaft must be enclosed within a guard that complies with Korean Occupational Safety and Health Act requirements and international ISO 14120 machine guarding standards. All XWED units are supplied with protective plugs on unused shaft openings, but the operating shaft end must have a separate guard installed by the end user as part of the machine integration.

The XWED flange-mounted cycloidal gearbox does not self-lock. If power is removed while the output shaft is under load (such as a suspended weight or a vertical conveyor), the load can backdrive the reducer and cause uncontrolled motion. For such applications, an electromagnetic brake on the motor shaft or a mechanical backstop device must be installed. This is particularly critical for overhead crane travel drives, inclined conveyors, and any lifting mechanism.

All Ever-Power ciklo reduktor pogona products carry CE marking and are manufactured under ISO 9001:2015 certified quality management. For applications in ATEX-classified hazardous areas, enhanced shaft sealing and explosion-proof motor couplings are available upon request. Documentation packages including declaration of conformity, test certificates, and material traceability reports can be supplied for projects requiring formal compliance records.

Povezani i kompatibilni proizvodi

The XWED cyclo gear reducer integrates into complete drive assemblies alongside these complementary products from Korea Ever-Power:

Motor-side components include IEC standard three-phase induction motors and flexible couplings. For the XWED series, motor power typically ranges from 0.75 kW to 55 kW. Coupling selection should account for the cycloidal mechanism's pulsation damping characteristics, meaning a standard jaw coupling is sufficient for most installations without the need for highly flexible disc-type couplings.

Output-side connections vary by application. Chain-driven systems use matched lančanici i lanci rated for the XWED output torque. Direct-coupled systems use keyed shaft connections or rigid flange couplings. Angular offset applications use universal joint assemblies.

For ratios beyond 7,569:1, the XWED can be connected in tandem with a planetarni mjenjač pre-stage. This combined arrangement is used in specialized ultra-slow-speed applications such as astronomical telescope tracking drives and continuous casting machine oscillators.

Često postavljana pitanja

What is the difference between the XWED and the BWED cyclo gear reducer?

Both are double-stage cycloidal models with the same internal mechanism and ratio range. The BWED is horizontal foot-mounted (bolts to a flat base), while the XWED is flange-mounted (bolts through a circular flange to a machine frame or platform). Choose based on your mounting arrangement.

How do I calculate the correct XWED frame size for my flange-mounted application?

Calculate your required output torque using T = (P x 9550 x i x 0.78) / n_in. Then select a frame whose rated torque exceeds your result by a service factor of at least 1.25 for steady loads or 1.5 for impact/shock loads. Also verify the output shaft diameter fits your coupling or driven equipment bore. Our engineering team offers free sizing assistance.

Can the XWED double stage cycloidal gearbox be mounted at any angle?

The flange-mounted design allows mounting in any orientation: horizontal, vertical shaft-up, vertical shaft-down, or angled. For orientations beyond 15 degrees from horizontal, verify that the internal oil pump (included on vertical-rated models) properly circulates lubricant to all bearings. Specify your intended mounting orientation when ordering.

Does the XWED cyclo gear reducer require a separate brake for vertical lifting applications?

Yes. The cycloidal mechanism does not self-lock. If the output shaft supports a hanging load that could backdrive the unit when power is removed, a motor-mounted electromagnetic brake or a mechanical backstop must be installed. This is a mandatory safety requirement, not optional.

What lubricant viscosity grade is correct for outdoor installations in Korean winters?

Korean winter temperatures in northern regions (Gangwon-do, Gyeonggi-do) can drop below -15°C. Standard mineral gear oil may become too viscous to circulate properly at these temperatures. Specify synthetic PAO-based gear oil (ISO VG 150) for outdoor installations exposed to temperatures below -10°C. This maintains adequate flow even at -25°C.

Recenzije kupaca

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Hwang Jae-sung, Mechanical Design Lead, Pohang Steel Fabrication (February 2025)

"We use XWED-85 on a turntable positioner for heavy steel plate welding. The flange mount bolted directly to our existing frame without any adapter plate. Output speed is 0.8 rpm at 1500 rpm input, and the torque delivery has been rock-solid through 9 months of daily production. The compact length of the double-stage cycloidal compared to the 4-stage helical box we replaced saved about 350 mm in our cramped work cell."

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Nakamura Sota, Plant Engineering, Tokyo Environmental Services (January 2025)

"Running XWED-53 on sludge scraper bridge drives. The flange-mounted configuration was necessary because there is no flat surface available near the tank perimeter. These units operate 24/7 and the energy savings over the old worm units were measurable on our facility power monitoring system within the first billing cycle."

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Shin Yoo-jin, Procurement Coordinator, Daegu Industrial Automation (March 2025)

"Ordered six XWED units in mixed frame sizes for a packaging line retrofit project. The pricing was competitive, delivery to Daegu took 6 days, and the dimensional accuracy was confirmed by our installation team on first fitting. No alignment issues, no surprises. We have added Ever-Power to our approved supplier list based on this experience."

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Bui Thanh Long, Facilities Manager, Haiphong Cement Group, Vietnam (December 2024)

"We replaced three aging imported double-stage reducers with XWED-96 units on our clinker cooler drives. The cross-reference from the Ever-Power team was accurate, and the physical swap was straightforward. After four months of continuous operation, oil analysis shows clean results with no abnormal metal content. We found the product information and full specifications at cyclogearreducer.top, which made the initial evaluation much easier."

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Park Ji-won, Equipment Engineer, Jeju Water Authority (November 2024)

"Good product at a fair price. The XWED-42 drives on our flocculator paddles have been trouble-free for seven months. The only feedback I have is that the operation manual could use a Korean language version for our maintenance staff. Otherwise, the units perform exactly as specified."

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