XLD-serien cyklo-gearreduktion – Vertikal flangemonteret cykloidal gearkasse

Produktoversigt

De XLD cyclo gear reducer is a flange-mounted variant designed for vertical or angular mounting configurations where a traditional foot-mounted base is either impractical or unnecessary. While the BWD/BW series sits on a flat surface and bolts down through feet, the XLD attaches through a circular flange pattern and hangs from or bolts onto a machine frame, vessel wall, or structural platform. This gives mechanical designers more freedom in positioning the drive assembly relative to the driven equipment.

The XLD product line covers frame sizes 1 through 11. On the smaller end, Frame 1 has a 160 mm flange diameter with a 28 mm output shaft, weighing just 8 kg and suitable for light conveyor drives or small agitator systems. At the upper end, Frame 11 reaches an 880 mm flange diameter with a 130 mm output shaft, weighing 210 kg and capable of driving heavy industrial mixers, kiln rotation systems, and aggregate processing equipment. This range makes the XLD flange-mounted cycloidal gearbox a popular choice across a wide spectrum of Korean industrial applications from semiconductor cooling tower drives in Gyeonggi-do to cement plant rotary systems in Gangwon-do.

 

De XLD cycloidal speed reducer is dimensionally equivalent to corresponding Sumitomo CHHJ and SM-Cyclo flange-mounted models, allowing direct bolt-in replacement. This information is provided purely for customer cross-referencing purposes and does not indicate any affiliation with or endorsement by the referenced manufacturer. Korea Ever-Power manufactures these units independently under our own quality control system. The XLD is one of over 20 models in the cyklo gear reducer series.

All XLD units feature GCr15 chromium bearing steel cycloidal discs hardened to HRC 58-62, precision-ground alloy steel pin rings, and HT200 cast iron housings machined to tight concentricity tolerances. Output shaft tolerance is held to h6 standard. Both single-shaft and double-shaft (through-drive) output configurations are available across most frame sizes.

Tekniske specifikationer og dimensioner

The following tables present the installation and shaft-end dimensions for the XLD cyclo gear reducer series. The flange bolt circle diameter (D1) and number of bolt holes determine how the reducer attaches to your equipment frame. The output shaft diameter (d1) and keyway width (b1) determine coupling compatibility. All output shaft tolerances are h6 unless otherwise noted.

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

Bemærk: Matchende tolerance for aksel d₁/d₂ is h6.

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

Single Stage vs Double Stage Cyclo Reducer: How to Choose the Right Configuration

De XLD flange-mounted cyclo gear reducer is offered in both single-stage (XL) and double-stage (XLD) versions. Deciding between them comes down to one primary question: what output speed and reduction ratio does your application require? Both share the same housing footprint and flange bolt pattern for each frame size, so the external mounting interface remains unchanged regardless of whether you select single or double stage.

A single-stage XL cycloidal gearbox is the better choice when your target output speed falls between roughly 17 and 167 rpm (assuming a standard 4-pole 1500 rpm motor). Single-stage units cost less, weigh less, and run at higher efficiency because the power passes through only one cycloidal disc-and-pin set. Most belt conveyor drives, ventilation fan drives, and general-purpose machine drives operate in this speed range and are well-served by single-stage reduction.

A double-stage XLD cycloidal speed reducer becomes necessary when the target output speed drops below approximately 15 rpm or when the required ratio exceeds 87:1. In a double-stage arrangement, the output of the first cycloidal set feeds into the input of the second cycloidal set within the same housing, compounding the ratios. This means a first stage at 29:1 followed by a second stage at 29:1 yields an overall ratio of 841:1, producing an output speed of about 1.8 rpm from a 1500 rpm motor. Double-stage units are commonly found on rotary kiln drives, sludge digester stirrers, and ultra-slow-speed turntable applications.

Energy Efficiency and Operating Cost Impact

The efficiency of a speed reducer directly affects electricity bills and motor sizing. A reducer running at 90% efficiency converts 90% of motor input power into useful output torque, while the remaining 10% becomes waste heat. A less efficient reducer, such as a worm type at 60% efficiency, wastes 40% of motor power as heat. For facilities running multiple drives around the clock, this difference adds up quickly.

Consider a real calculation: a single 11 kW motor running a cykloid hastighedsreducer at 88% efficiency for two shifts per day (16 hours), 300 days per year. The annual energy wasted as heat is: 11 kW x 0.12 x 16 h x 300 d = 6,336 kWh. If that same drive used a worm reducer at 62% efficiency instead, the waste energy climbs to: 11 kW x 0.38 x 16 h x 300 d = 20,064 kWh. At a Korean industrial electricity rate of approximately 120 KRW per kWh, the annual saving per drive is roughly 1,647,360 KRW (about 1,250 USD). Across ten drives in a typical production facility, the combined annual saving exceeds 12,000 USD purely from reduced electricity waste.

Beyond electricity savings, higher efficiency also means smaller motors can be specified for the same output torque requirement. This reduces motor purchase cost, starter/VFD sizing, and cable cross-section requirements. The XLD flange-mounted cyclo gearbox maintains its efficiency advantage across the entire ratio range, unlike snekkegearreduktionsgear where efficiency degrades sharply at higher ratios.

Installation and Commissioning Steps

Proper installation is critical for reaching the rated service life of any cykloidal pinhjulsreducer. Follow this sequence when installing the XLD cyclo gear reducer for the first time or when reinstalling after maintenance.

1. Inspect the mounting flange surface on both the reducer and the receiving frame. Remove any burrs, paint buildup, or debris. The flange faces must be flat and parallel to within 0.1 mm across the full bolt circle.
2. Lift the reducer into position using appropriately rated rigging attached to the lifting eyebolts (provided on Frames 5 and above). For smaller frames, manual handling is acceptable with two workers.
3. Insert mounting bolts through the flange holes and tighten in a star pattern to the torque values specified in the installation manual for each bolt size (M8 through M20 depending on frame).
4. Connect the motor to the input shaft using a flexible coupling. Align radial offset to within 0.05 mm and angular misalignment to within 0.5 degrees. Use dial indicators or laser alignment tools for accuracy. If a drivaksel is used between the reducer output and driven equipment, verify the universal joint working angles are within specification.
5. Fill with lubricating oil through the breather cap opening. Use 40# or 50# mechanical oil for standard conditions, or 70#/90# EP gear oil for extended service intervals. Fill to the center of the sight glass.
6. Run the unit unloaded for 30 minutes. Check for abnormal noise, vibration, oil leaks at shaft seals, and housing temperature. The housing surface should not exceed 70 degrees C during this break-in run.
7. Connect the load and run under partial load (50-75%) for the first 4 hours. Monitor temperature and vibration. After confirming stable operation, increase to full rated load.
8. Drain and replace oil after 100 hours of initial operation. This first oil change removes metal particles generated during the break-in period.

Relaterede og kompatible produkter

De XLD cycloidal gear reducer integrates into complete drive systems alongside these companion products, all available from Korea Ever-Power:

• Electric motors: IEC standard flange and foot-mounted, three-phase induction, 0.12 kW to 315 kW
• Flexible couplings: Jaw type, pin-and-bush, and disc couplings for vibration isolation
• Drive shafts and universal joints for angular torque transmission
• Sprockets and roller chains for chain-driven output connections
• Planetary gearboxes for series connection to achieve ultra-high ratios beyond 7,569:1
• Worm gear reducers for applications requiring self-locking holding capability

Ofte stillede spørgsmål

What is the difference between the XLD and XL flange-mounted cyclo gear reducer models?

XL denotes the single-stage flange-mounted model with ratios from 9:1 to 87:1. XLD denotes the double-stage version with ratios from 99:1 to 7,569:1. Both mount using the same flange bolt pattern for a given frame size.

Can I replace a foot-mounted BWD with a flange-mounted XLD on existing equipment?

Yes, but the mounting interface is different. You would need to fabricate a mounting bracket or adapter plate that converts from foot mounting to flange mounting. The internal cycloidal mechanism and performance are equivalent between BWD and XLD at the same frame size.

Should I choose single stage or double stage for a belt conveyor running at 25 rpm?

At 25 rpm output from a 1500 rpm motor, the required ratio is 60:1, which falls within the single-stage XL range (9:1 to 87:1). A single-stage unit will be lighter, more efficient, and less expensive than a double-stage unit for this application.

Can the XLD output connect to a chain drive system?

Yes. The keyed output shaft pairs directly with standard tandhjul og kæder for conveyor, elevator, and material handling applications. Size the sprocket bore to match the XLD output shaft diameter from the table above.

What is the maximum axial load the XLD output shaft can handle?

Axial load limits vary by frame size. In flange-mounted vertical installations where the output shaft supports a hanging load (such as an agitator impeller), the shaft bearings handle both torque and impeller weight. For loads exceeding the standard bearing capacity, we supply an external thrust bearing support kit. Contact our engineering team with your specific load figures for proper sizing.

How often should I change the oil in the XLD series cyclo gear reducer?

First oil change at 100 running hours, then every 6 months for standard 8-hour daily operation or every 3 to 4 months for continuous 24-hour duty. Use 40# or 50# mechanical oil at standard temperatures, or 70#/90# EP gear oil for better protection and longer intervals.

Does the XLD produce less noise than a helical gearbox at the same ratio?

At equivalent ratios and loads, cycloidal reducers and helical gearboxes produce similar noise levels (60-75 dB(A) range). The cycloidal unit tends to have a smoother, less tonal noise character because it lacks the periodic gear tooth meshing frequency that helical units produce. In practice, the noise difference is minor and unlikely to be the deciding factor between the two types.

Customer Feedback

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Han Ji-hoon, Project Engineer, Seoul Automation Systems (February 2025)

"We specified XLD Frame 6 units for a packaging line retrofit. The flange mount bolted directly onto the existing machine frame without any adapter plates. Saved us fabrication time and cost. Units have been running 16 hours a day for five months with no problems."

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Suzuki Takeshi, Maintenance Coordinator, Fukuoka Port Logistics (January 2025)

"We use XLD-8 on our container stacking crane travel drives. The shock loading from sudden starts and stops has not caused any issues after 7 months. Previously we were replacing worm gear bronze wheels every 12-14 months on the same equipment. Expecting the cyclo units to last significantly longer based on current condition."

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Yoon So-ra, Purchasing Manager, Busan Marine Equipment (March 2025)

"Bestilte fem XLD-enheder og modtog dem inden for en uge i Busan. Emballagen var fremragende. En ting jeg sætter pris på er, at navneskiltet tydeligt viser forholdet, serienummeret og olietypen, hvilket gør vedligeholdelsesregistreringer enkle."

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Kato Emi, Fabrikschef, Shizuoka Textile Manufacturing (december 2024)

"XLD-3- og XLD-4-enhederne på vores farvemaskines drev kører ekstremt problemfrit. Vibrationsniveauerne ligger inden for de originale udstyrsspecifikationer. Prisen er meget konkurrencedygtig i forhold til japanske indenlandske mærker, og kvaliteten har været tilsvarende i vores erfaring i det seneste år."

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Tran Minh DucDriftsingeniør, Binh Duong Industrizone, Vietnam (november 2024)

"Købte XLD-9 dobbelttrinsenheder til vores langsomtgående rotationstørrer. Udgangshastigheden er 2,8 o/min, og momenttilførslen har været ensartet under varierende belastningsforhold. Ever-Power-teamet hjalp os med at beregne det korrekte forhold og servicefaktor under tilbudsprocessen, hvilket forhindrede en dimensioneringsfejl, vi selv ville have lavet."

Vores produktionsanlæg

Hver XLD flange-mounted cyclo gear reducer Enheden fremstilles i vores produktionsbase udstyret med CNC-bearbejdningscentre, varmebehandlingsovne, koordinatmålemaskiner og dedikerede renrum til montering. Vores ISO 9001-certificerede kvalitetssystem dækker inspektion af råmaterialer, tolerancekontrol under bearbejdning, verifikation af gearhårdhed, støj- og vibrationstest af den samlede enhed samt endelig inspektion af maling og emballage før forsendelse.

Den årlige produktionskapacitet overstiger 50.000 enheder på tværs af hele cyklo-drevreducer modellinjer. Standard XLD-rammer (størrelser 1 til 8 med populære udvekslingsforhold) opbevares på lager af færdigvarer for hurtig forsendelse, typisk inden for 3 til 5 hverdage efter ordrebekræftelse. Større rammer og ikke-standardkonfigurationer har leveringstider på 2 til 4 uger. Vores koreanske forbindelseskontor i Incheon håndterer lokal logistikkoordinering for kunder i Korea. Produktoplysninger og tekniske downloads er tilgængelige på cyclogearreducer.top.

Pakning og forsendelse