The ZLYJ series reducer is a specialized gear transmission device meticulously designed for use in plastic and rubber screw extruders. This highly functional machine boasts a hard tooth surface and thrust package, enabling it to function optimally. The device is styled to adhere to the technical specifications stipulated in JB/T8853-2001 “Cylindrical Gear Reducer.” Its gears and shaft parts are constructed from high-strength alloy steel, with extra hardening using carburizing, quenching, and equipment grinding. The gear precision is rated at GB10095-8&6 grade, with a tooth surface hardness HRC54-62.
Applications:
This specialized reducer is suitable for plastic and rubber screw extruders and carefully designed to meet industry standards. It is ideally suited for plastic film extrusion, pipe extrusion, sheet extrusion, wire and cable extrusion, and other extrusion equipment. The ZLYJ series reducer is highly functional in different environments and can be customized to fit unique production scenarios. It is an advanced machine that guarantees optimal performance, is easy to maintain, and will last very long.
Scope of application:
- The input speed of the gearbox is generally not greater than 1500 rpm.
- The peripheral speed of the gear drive is not more than 20 m/s.
- The working environment temperature is -40 °C – 45 °C. If it is lower than (TC), the lubricating oil should be preheated to above 0 °C before starting. This reducer can be used in both forward and reverse directions, but in some models, The speed shaft and one-way oil pump, the default direction is: facing the output shaft, and the output shaft rotates clockwise. If the law is changed, please specify when ordering.
The model of the reducer:
The reducer model’s code includes the model, the center distance of the output stage, the nominal transmission ratio, and the assembly type.
Marking example:
Selection of reducer(6 Steps)
The mechanical power, axial thrust, and thermal power of the ZLYJ reducer core, the detailed steps are as follows:
First Step: Selected speed ratio (Table 1)
Input speed nl=1000rpm, output speed n2=70rpm,
i=nl/n2=1000/70=14.28, Choose a speed ratio 14.
Second Step: Select the specifications of the reducer
Select the model according to the input power and output speed the user provides.
Input power P=26KW.
Check the meter, 29KW>26KW, and the most economical, choose ZLYJ200.
Third Step: Select the assembly form of the reducer
Select the assembly type of the reducer according to the customer’s installation method
Fourth Step: Calculate Axial Thrust
Fa=n x ds2 x PS/(4 x 1000)
Fifth Step: Determining the connection size
- Check the hole diameter, critical width or spline parameters, and shaft hole depth of the hollow output shaft.
- Check the size of the foundation’s installation hole and the threaded hole of the thrust.
Sixth Step: Determine the cooling method
Small-size reducers generally adopt splash lubrication and natural cooling. The large-size reducer adopts forced lubrication and more excellent cooling. If the user requires configuration beyond the attached table, it must be declared when ordering.
The load capacity of the reducer
model ZLYJ | ZSYJ | ZSYJ | ZSYJ | |||||||||||||||
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Specification | 112-8 | 133-8 | 146-10 | 173-10 | 200-12.5 | 225-12.5 | 250-16 | 280-16 | 315-16 | 330-16 | 375-16 | 420-16 | 450-20 | 560-20 | 630-20 | 450-32 | 560-57 | 630-44 |
Nominal input power (KW) nA=1500r/min | ||||||||||||||||||
generally reliable | 15 | 22 | 30.8 | 39 | 55 | 82.5 | 75 | 116 | 171 | 260 | 315 | 303 | 600 | 825 | 240 | 240 | 370 | |
high reliable | 10 | 15 | 18.3 | 30.8 | 45 | 67 | 60 | 75 | 75 | 207 | 207 | 250 | 266 | 550 | 675 | 200 | 220 | 315 |
Allowable output torque (N.M) | ||||||||||||||||||
generally reliable | 800 | 1165 | 1962 | 2484 | 4379 | 6568 | 7643 | 11822 | 17427 | 26497 | 32102 | 38599 | 76433 | 105095 | 48917 | 87134 | 103694 | |
high reliable | 825 | 764 | 1165 | 1962 | 3583 | 5334 | 6306 | 7643 | 11822 | 21000 | 21096 | 25478 | 33885 | 70063 | 85978 | 40765 | 79873 | 88280 |
Allowable output shaft axial thrust (KN) | ||||||||||||||||||
axial thrust | 35 | 39 | 54 | 110 | 155 | 180 | 192 | 258 | 287 | 390 | 390 | 430 | 500 | 700 | 770 | 500 | 700 | 770 |
Recommended configuration | ||||||||||||||||||
mm Screw diameter | 35 | 45 /50 | 55 | 65 | 75 | 90 | 100 | 105/ 110 | 120 | 130/ 150 | 150 /160 | 165 | 165 | 190 | 200 | 165 | 190 | 200 |
(kw)input power | 5.5 | 8 | 11 | 18.5 | 26 | 45 | 45 | 55 | 75 | 132 | 132 | 160 | 213 | 440 | 540 | 200 | 220 | 315 |
n(rpm) input | 800 | 800 | 900 | 900 | 1000 | 1000 | 1120 | 960 | 960 | 960 | 960 | 960 | 1200 | 1200 | 1200 | 1500 | 1500 | 1500 |
n(rpm) output | 100 | 100 | 90 | 90 | 80 | 80 | 70 | 60 | 60 | 60 | 60 | 60 | 60 | 60 | 60 | 47 | 26 | 34 |
Note:
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One area of cooling must be equipped with cooling and forced oil circulation. 112, 133, 146, and 173 do not need to be fitted with cooling when selected according to high reliability.
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The input power and output torque listed in the table have considered the series of working conditions and can be directly selected.
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The output torque listed in the table is the primary basis for selection. The transmission ratio can be adjusted according to user needs. The I of ZLYJ is 6.3-20, and the I of ZSYJ is 22.4-100.
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When the bearing load factor fd=1.5 is calculated according to the allowable axial thrust and the given speed of the output shaft in the table, the theoretical calculation life of the thrust bearing is about 12,000 hours except for the 133 and 146 types, and the other types are all in About 25,000 hours.
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In the following situations, check the cooling design parameters of the reducer:
5.1.Select according to the high-reliability data, but when the output speed exceeds the table (2)n (that is, the input power is increased).
5.2. According to the available reliable selection, when the input power is increased.
5.3. When the heat dissipation area of the internal cooling method is insufficient, an external oil cooler with an oil pump is used. When using an external cooler, additional sketches should be provided when ordering. -
Users can make a preliminary selection according to the data listed in the table. When ordering, our factory will check each case in detail to improve the reliability of choice.
Dimensions and installation form:
Remark:
- The power and torque in the above table have considered the working condition and safety factors and can be directly selected.
- The power and torque in the above table are mainly for the plastic extruder reducer. When the user uses it in rubber machinery, the power and torque in the above table are multiplied by a factor of 0.9.
- When the error between the input or output speed and the above table is greater than 4%, the power conversion should be carried out concerning the nearest gear speed.