WPEA Double Speed Cast Iron Worm Gearbox — WP Series

When your process demands output shaft speeds as low as 1.67 RPM from a standard 1,500 RPM motor — without a gearbox cascade, without planetary stages — single-stage worm reduction reaches its 1/60 limit. The WPEA Double Speed Cast Iron Worm Gearbox breaks through this barrier with two worm stages in one precision-machined cast iron body, delivering ratios from 1/200 to 1/900 (overall 1/100–1/3600 range). Whether you’re driving a pharmaceutical crystalliser at 1 RPM, a concrete mixer at 5 RPM, or a tunnel dryer conveyor at 3 RPM, the WPEA delivers ultra-low output speeds with output torques up to 6,050 Nm — without any additional gearbox stages.

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■ Two Worm Stages in One Housing — 60% Shorter Than Cascade

Two worm gear stages coaxially housed in a single cast iron body eliminate the intermediate shaft, coupling, and second housing required by a two-gearbox cascade arrangement — reducing total drive train length by up to 60%.

■ Matched-Pair Bronze Wheels — Consistent Noise Below 72 dB(A)

Both worm wheels are manufactured as a matched pair in the same production batch, ensuring tooth profile consistency. Noise below 72 dB(A) across the full 1/200–1/900 ratio range — impossible to achieve with two separately-sourced single-stage gearboxes.

■ Dual Independent Oil Chambers — Stage-Optimised Lubrication

Two separate oil chambers allow each stage to be independently filled and optimised. This is a critical advantage over two-gearbox cascade arrangements where both stages are forced to use identical oil specification.

■ Self-Locking at High Ratios — Static Load Security

At ratios above 1/200, both worm stages contribute to static self-locking, providing holding torque for inclined and vertical loads without an independent brake in many applications.

■ Output Torques up to 6,050 Nm from Standard Motor

WPEA size 155–250 delivers 6,050 Nm from an 11.71 kW input at 1/900 ratio — matching many hydraulic drives at a fraction of installation complexity.

■ 12 Standard Size Combinations — Full Application Coverage

Nine size combinations (40–70 through 155–250 mm combined centre distance) cover output torques from 250 Nm to 6,050 Nm for the complete spectrum of ultra-slow industrial drive applications.

☵ Pharmaceutical Crystallisers

Crystallisers require precise low-speed agitation (1–10 RPM) with high torque consistency. WPEA 1/900 ratio from 1,500 RPM input delivers 1.67 RPM — ideal for API crystal growth where speed deviation affects crystal size distribution.

⚒ Concrete & Construction Mixing

Transit mixer drums and concrete batching plant drives require 3–8 RPM with very high torque. WPEA size 250 delivers 6,050 Nm output from 11.71 kW — handling the heaviest concrete mixing loads.

⚊ Tunnel Dryer & Curing Oven Conveyors

Drying conveyors requiring belt speeds below 0.5 m/min need ratios far beyond 1/60. The WPEA’s extreme double-stage reduction enables standard motors to drive ultra-slow curing process conveyors.

⚔ Rotary Kiln Drives

Industrial kilns typically rotate at 1–5 RPM. WPEA achieves this output speed range from a standard 4-pole motor with the high torque capacity needed for the large rotating mass.

⚛ Precision Positioning — Slow Rotation

Scientific equipment, antenna systems, and heavy machinery requiring ultra-precise slow rotation (below 5 RPM) use WPEA’s dual-stage for extreme reduction accuracy and self-locking at high ratios.

✎ ISO 9001:2000 Certified

Every WPEA is manufactured, assembled, and tested under the ISO 9001:2000 quality management framework. We were among the first in our industry category to achieve this certification.

✎ CE Marking

Full CE marking confirms compliance with EU Machinery Directive 2006/42/EC — covering safety, design standards, and manufacturing quality for mechanical power transmission equipment including double-stage worm gearboxes.

✎ Pre-Shipment Testing (Every Unit)

Noise test (below 72 dB(A) at rated load), oil leak test (30-minute pressurisation, both chambers), torque transmission test (output torque within ±5% of rated). Failed units are reworked — not shipped.

✎ Matched-Pair Manufacturing

Both worm wheel sets for each double-stage unit are manufactured in the same production batch, ensuring tooth profile consistency between primary and secondary stages. This matched-pair quality assurance is unique to our double-stage production process.

“WPEA-80/135 drives our crystalliser agitators at 3 RPM. Dual-stage in one housing gave us the ratio we needed in a footprint we could fit. After 30 months continuous pharmaceutical production, zero gearbox failures. Speed consistency within 0.5% of setpoint.”

“Replaced a two-gearbox cascade with WPEA on our reactor drive. Saved 380mm shaft length and eliminated one coupling. Matched-pair worm wheels run significantly quieter than our previous arrangement.”

“WPEA-135/200 on our rotary kiln drives. High output torque at extreme ratios is exactly what kiln drives need. Cast iron handles the dusty high-temperature environment far better than aluminium alternatives.”

“WPEA drives our rotary dryer conveyor at 2 RPM. Compact housing fits our existing plant layout. Recommendation: the dual oil fill ports should be more clearly labelled for maintenance teams. Otherwise excellent product.”