Crane Reducer Worm Gear Motor Cast
2 month ago
Product details
1. Product Definition & Core Functions
TheCrane Reducer Worm Gear Motor (Cast)is a critical transmission device for crane equipment, enabling low-speed, high-torque output. It integrates a worm gear reducer with an electric motor, featuring a cast housing (typically cast iron or aluminum alloy). Its core functions include:
• Speed Reduction & Torque Amplification: Converts high-speed motor rotation into low-speed, high-torque output via worm gear meshing, meeting load demands for crane hoisting, slewing, or luffing mechanisms.
• Self-Locking Capability: When the worm’s lead angle is smaller than the friction angle, reverse self-locking prevents load drops, enhancing safety.
• Compact Structure: The cast housing provides rigid support, adapting to space-constrained crane installations.
2. Casting Materials & Processes
2.1 Common Casting Materials
【表格】
Material Type Grade Examples Characteristics Applications
Gray Cast Iron (HT) HT200, HT250 Low cost, excellent damping, superior castability, but low tensile strength (200–250 MPa). Small/medium crane reducer housings.
Ductile Iron (QT) QT400-15, QT500-7 High strength (400–500 MPa), good toughness, cost-effective alternative to steel castings. Large crane reducers or high-load components.
Aluminum Alloy (ZL) ZL102, ZL104 Low density (~2.7 g/cm³), corrosion-resistant, but low strength (150–200 MPa). Lightweight crane or port equipment housings.
2.2 Casting Process Selection
• Sand Casting: Low cost, suitable for mass production, but lower surface precision (Ra ≥ 12.5 μm).
• Die Casting: Ideal for aluminum alloy housings, high dimensional accuracy (Ra ≤ 3.2 μm), but high equipment investment.
• Lost Foam Casting: Enables complex structures, reduces machining, and suits customized reducers.
3. Worm Gear Transmission Design
3.1 Key Parameters
• Module (m): Determines gear size; cranes typically use modules of 2–8 mm.
• Number of Starts (z₁): Worm starts range from 1–4; fewer starts enhance self-locking but reduce efficiency.
• Gear Ratio (i): Common range: 10–80, selected based on crane load requirements.
• Center Distance (a): Affects reducer size; must match motor power.
3.2 Material Pairing
• Worm: Typically 20CrMnTi carburized steel, surface hardness HRC58-62, high wear resistance.
• Worm Gear: Often tin bronze (ZQSn6-6-3) or aluminum-iron bronze (ZQAl9-4), excellent friction reduction but costly.
• Alternative: Nylon or engineering plastic worm gears (lower cost, limited load capacity, suitable for light cranes).
4. Performance Metrics & Testing
4.1 Core Performance Parameters
【表格】
Parameter Test Standard Typical Value
Efficiency GB/T 16444 70%–85% (depends on starts and lubrication)
Noise ISO 8579 ≤75 dB (at 1 m distance)
Temperature Rise GB/T 10069 ≤60 K (continuous operation)
Lifespan ISO 10823 ≥10,000 hours (under rated load)
4.2 Testing Procedures
• No-Load Test: Verifies noise, vibration, and temperature rise compliance.
• Load Test: Simulates crane rated load to assess efficiency and leakage.
• Destructive Test: Operates at 1.5× overload to validate structural strength.
5. Applications & Selection Criteria
5.1 Typical Applications
• Bridge Cranes: Hoisting mechanism reducers, withstanding frequent start/stop shocks.
• Gantry Cranes: Travel mechanism reducers, requiring low-speed stability.
• Tower Cranes: Slewing mechanism reducers, needing self-locking to resist wind loads.
5.2 Selection Factors
• Load Type: Static loads (e.g., hovering) prioritize self-locking; dynamic loads (e.g., hoisting) focus on efficiency.
• Environment: Aluminum housings for humid conditions (rust resistance); ductile iron for high-temperature settings.
• Installation Space: Cast housing dimensions must align with crane structures to avoid interference.
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Ningbo Hengnuo Hydraulic Drive Co.,Ltd
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