Планетарный редуктор с высоким крутящим моментом для тяжелой промышленности — серия PF (60/90/120/150PF)

The PF series high-torque planetary gearbox is designed for continuous operation under high sustained loads where conventional inline helical reducers overheat and worm gearboxes sacrifice unacceptable efficiency losses. Engineered around a reinforced ring-gear housing with oversized output-shaft bearings, the PF series absorbs radial loads up to 14,000 N (150PF) and axial loads up to 5,200 N (90PF) — load ratings that reflect real-world conveyor belt tensions and hoist sheave forces, not laboratory-ideal conditions.

The 3× instantaneous peak torque rating protects motor shafts during abrupt starts under full load, emergency stops, and shock-load events common in mining crushers, cement mixers, and ship-loader conveyor drives. IP65 protection keeps process water, cement slurry, and mine dust out of the gear cavity indefinitely.

Where precision-grade gearboxes minimise backlash at the cost of load capacity, the PF series reverses the engineering priority: every structural choice maximises load capacity and service life under sustained heavy duty, while still holding noise within acceptable factory-floor limits through precision-ground helical tooth profiles.

Key Design Features

1. 1

   Ductile Iron Housing with Ribbed Reinforcement

   GJS-500 ductile iron housing with external rib geometry distributes bending loads from output shaft cantilevered sprockets, preventing housing distortion that causes gear misalignment and premature wear.

2. 2

   Oversized Tapered Roller Output Bearings

   Output shafts run in paired tapered roller bearings, not ball bearings, enabling the 14,000 N radial load rating on 150PF without bearing deflection that would offset planet gear mesh geometry.

3. 3

   Helical Planet Gears — Reduced Noise, Higher Overlap

   Helical tooth profiles provide 1.6× contact ratio versus spur gears, smoothing torque pulsation under fluctuating loads and holding noise to ≤68 dB(A) at rated speed — 8–10 dB quieter than comparable spur-planet designs.

4. 4

   Double-Lip IP65 Output Shaft Sealing

   Spring-energised double-lip radial shaft seals with dust exclusion lips prevent ingress of cement dust, coal dust, mine water, and spray cleaning in harsh production environments without requiring protective covers or sleeve guards.

5. 5

   Lifetime High-Viscosity Grease Fill

   High-viscosity lithium complex grease engineered for sustained temperatures to +90°C eliminates the oil-level inspection windows and drain plugs that corrode and leak in outdoor industrial installations.

Steel Mill Roll Tables

Hot-mill runout table drives experience extreme thermal radiation, mill scale ingestion, and water-cooling spray. PF IP65 units require no additional protection enclosures and tolerate 60°C ambient without derating.

Port & Ship-Loader Drives

Marine salt-spray environments accelerate corrosion on exposed gearboxes. The PF sealed housing with epoxy-primer paint system withstands ISO 12944 C4 salt-fog classification without additional galvanic protection.

Winch & Anchor Capstans

Marine deck winches and offshore anchor capstans require intermittent peak torque 2–3× rated during rope-jamming events. The 3× peak torque tolerance of PF series prevents costly gearbox failures during anchor chain retrieval operations.

Every PF unit undergoes 110% overload testing, radial load deflection measurement, and IP65 pressure differential leak testing before shipment. For mining applications requiring ATEX zone classification, contact our engineering team for explosion-proof input motor coupling options.

Factory Acceptance Tests — Every Unit

• ✔ Full-load torque test at 110% rated for 30 min continuous
• ✔ IP65 ingress test — pressure differential method
• ✔ Output shaft radial load deflection ≤0.05 mm
• ✔ Peak torque 3× rated — 5-cycle shock test
• ✔ Noise measurement at rated speed in anechoic chamber

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→ Heavy-Duty CV Drive Shafts

Constant-velocity drive shafts rated for high radial and axial misalignment — ideal for connecting PF output flanges to conveyor head drums or hoist drums with structural deflection under load, without transmitting bending forces into the gearbox output bearing.

• ▸ Torque capacity to 2,500 N·m
• ▸ Angular misalignment ±8°
• ▸ Full-float spline for axial compensation

→ Right-Angle Worm Gearbox Stage

For 90° output direction and inherent self-locking holding torque, mount a worm stage downstream of the PF output shaft. Combined ratios to 5,000:1 achieve ultra-low output speeds for kiln drives and slow-feed granule conveyors without VFD over-frequency operation.

• ▸ Self-locking ratios ≥40:1
• ▸ Right-angle output for constrained machine layouts
• ▸ Bronze worm for quiet, corrosion-resistant operation

→ Agricultural & Outdoor Bevel Gearboxes

For split-shaft conveyor drives and outdoor bulk-handling applications, bevel gear stages provide right-angle power splitting without the efficiency loss of worm stages. Combines with PF series for grain elevator and fertiliser conveyor installations.

• ▸ Bevel efficiency 96–98%
• ▸ IP67 rated for outdoor, rain-exposed installations
• ▸ PTO-compatible input flanges available

Installed 12× 120PF units on our coal preparation plant belt conveyors 18 months ago. Zero failures, zero oil leaks, and noise levels noticeably lower than the old worm gearboxes we replaced. Sealed grease eliminated the quarterly oil top-up that was our biggest maintenance task on those conveyors.

We specified 150PF units for our cement plant clinker conveyor — the high radial shaft load from the heavy-gauge chain sprockets was killing our previous reducers in 6–8 months. The 14,000 N radial rating on 150PF solved that entirely. 14 months running, no bearing issues.

Used 90PF units for a harbour ship-loader travel drive. IP65 handling of salt spray was exactly as specified — no corrosion or seal weep after 10 months outdoor coastal operation. Slight comment: delivery documentation should show IP test certificate number, not just the IP rating — our customer audit requires traceability.

Fourth order from our company. 60PF units on rice mill paddy conveyors — compact enough to fit in tight chain-drive pits, quiet enough that operators nearby don't need hearing protection. Very competitive pricing on OEM volumes. Would not consider switching suppliers at this point.

QWhy does the PF series have a 3× peak torque rating and when does it apply?

The 3× rating covers the instantaneous torque spike during direct-on-line motor start under full load, emergency e-stop braking, and jam-clearing reversal events. It does not mean the gearbox can sustain 3× rated torque continuously — sustained overloads beyond rated torque accelerate bearing and gear wear. Size the gearbox at rated torque matching expected continuous load, and let the 3× rating handle transient events.

QCan PF series operate in ATEX classified hazardous areas?

The standard PF gearbox housing and grease fill are not ATEX certified. For coal mine faces, grain dust silos, or chemical plant drives in Zone 1/Zone 2 classified areas, ATEX-rated motor and coupling must be used. Contact our engineering team for ATEX-compatible coupling adapter plates that maintain the equipment-level classification of the motor while connecting to the PF input flange.

QHow do I calculate the correct frame size when a sprocket or pulley is mounted on the output shaft?

Calculate radial shaft load as: F = (2 × Torque_output) ÷ Sprocket_pitch_radius × Load_factor. Compare this against the max radial load in the spec table. If calculated radial load exceeds spec, move to the next larger frame size or add an external plummer block to share the radial load. Never exceed the published radial load figure — doing so will accelerate output bearing failure regardless of torque loading.

QWhat is the difference between PF and PL series for general industrial use?

PL series targets standard-duty automation with servo motors — 10–20 arcmin backlash, IP54, 30,000-hour life. PF series targets heavy continuous industrial duty — IP65, 3× peak torque, 14,000 N radial shaft load, higher grease viscosity. If your application uses AC induction motors, runs continuously at high torque, and operates in dusty or wet environments, PF is the correct series. If you use servo motors for positioning, the PL or PLE/PLF series is more appropriate.

QCan I use a VFD (variable frequency drive) with PF series gearboxes?

Yes. VFD operation is fully compatible with PF gearboxes. When operating below base speed (e.g., below 25 Hz), reduce the continuous torque rating proportionally to account for reduced motor cooling. Do not operate above rated input speed — the maximum input speed (3,000–3,500 rpm depending on frame) is an absolute limit regardless of VFD frequency setting.

QWhat maintenance is required in the first year of operation?

Sealed lifetime grease eliminates oil changes. In the first year: inspect output shaft seal condition at 3 months (look for grease weep at the shaft exit); check housing paint condition at 6 months for facilities with aggressive chemical wash-down; and verify input coupling condition at 12 months. If the unit operates in ambient temperatures above 70°C continuously, reduce the first inspection interval to 6 weeks.