WE12 Worm Gear Drive Torque Revolution in Heavy Rotation

WE12 Worm Gear Drive Torque Revolution in Heavy Rotation

What is Worm Gear Drive WE12

Worm Gear Drive WE12 is an ultra-heavy-duty integrated slewing drive engineered for extreme-load scenarios. It integrates a precision-ground alloy steel worm, high-strength bronze worm wheel with ZA/ZK tooth profiles, and a reinforced slewing ring bearing within a single rigid housing. Designed to withstand colossal multi-directional forces – static axial loads up to 760 kN, static radial loads of 280 kN, dynamic axial loads of 190 kN, and dynamic radial loads of 148 kN – the WE12 generates 9.5 kN.m output torque, resists tilting moments up to 57 kN.m, and provides critical holding torque of 43 kN.m. Its IP65-sealed architecture ensures reliable operation in abrasive environments while offering inherent mechanical self-locking upon power disengagement.

Enhancing Torque in Worm Gear Slewing Drives

Maximizing torque output in worm gear systems requires strategic engineering optimizations:

Gear Ratio Optimization: WE12’s 79:1 ratio significantly multiplies input torque (T_out = T_in × η × i), where high efficiency (η) is maintained through ZA/ZK profiles

Advanced Tooth Geometry: Precision-ground ZA/ZK profiles achieve >90% contact ratio, distributing load across 40% more tooth surface versus standard worms

Material Strength Synergy: Case-hardened 18CrNiMo7-6 steel worms (62 HRC) paired with centrifugal-cast CuSn12Ni bronze wheels withstand 980 MPa contact stress

Friction Reduction: Ultra-low viscosity synthetic lubricants with EP additives maintain μ<0.04 under 760 kN loads

Thermal Management: Ribbed housing design increases heat dissipation by 35%, preventing viscosity breakdown at sustained 9.5 kN.m output

Bearing Preload Control: Tapered roller bearings with 0.08mm preload minimize system deflection, preserving torque transfer efficiency

WE12 implements these principles to achieve 22% higher torque density than comparable drives while maintaining ≤0.15° precision.

Key Features of Worm Gear Drive WE12

Mega-Load Capability: Engineered for industrial giga-applications, WE12 withstands 760 kN static axial loads – equivalent to supporting 77 metric tons vertically – plus 280 kN radial loads and 57 kN.m tilting moments.

Fail-Safe Self-Locking: The shallow 4° lead angle creates irreversible drive geometry, mechanically locking loads up to 43 kN.m without auxiliary brakes. Critical for crane boom safety.

Extreme Environment Protection: Triple-lip seals, hardened bearing races (60 HRC), and IP65 rating defend against quarry dust, mining slurry, and high-pressure washdown. WEA12/WEB12 variants offer enhanced sealing.

Precision Motion Control: ≤0.15° tracking accuracy achieved through CNC-ground tooth profiles and preloaded bearing systems. Maintains positioning under full 9.5 kN.m torque.

Efficiency-Optimized Drive: ZK-profile worms achieve 82-88% efficiency at operational loads – best-in-class for high-ratio worm gears.

Drive Flexibility: Direct integration with hydraulic motors (up to 500 bar continuous) or IEC 200mm frame electric motors (servo/vector compatible).

Power-Dense Architecture: Generates 9.5 kN.m torque from 68 kg mass – 140 Nm/kg torque-to-weight ratio outperforms planetary alternatives in slow-speed applications.

Worm Gear Drive WE12 Applications

Mining Mega-Machines: Rotating excavator platforms (50+ ton buckets), stacker-reclaimer booms, and SAG mill feed systems. Handles shock loads from rock impact.

Tunnel Boring Systems: Main cutterhead drives in >12m diameter TBMs. 760 kN axial capacity absorbs thrust forces; sealed design resists abrasive slurry.

Offshore Cranes: Slewing drives for 300+ ton deck cranes. 43 kN.m holding torque secures loads in marine conditions; corrosion-resistant coatings prevent salt degradation.

Steel Mill Handling: Ladle turret rotation and bloom transfer cars. Withstands 800°C radiant heat; bronze wheel resists seizure under thermal cycling.

Heavy Press Manufacturing: Ejection systems for 50,000+ kN presses. Maintains precision alignment under cyclic loading.

Dam Gate Mechanisms: Hydraulic gate positioning in spillways. Self-locking prevents unintended movement during flood events.

Aerospace Fixturing: Satellite antenna positioners and rocket assembly jigs. ≤0.15° accuracy meets aerospace tolerances.

Factors Influencing Worm Gear Drive WE12 Price

Material Premium: Aircraft-grade steel worms (+25% cost) and marine-grade bronze wheels (+18%) extend service life 3x in abrasive environments.

Precision Manufacturing: CNC profile grinding (DIN Class 9 accuracy) and induction hardening add 30% cost but ensure ≤0.15° precision.

Sealing Tier: Standard IP65 costs 15% less than IP69K (WEB12) with triple-labyrinth seals for acidic environments.

Bearing Configuration: Crossed-roller bearings (+22%) versus standard tapered rollers for higher moment rigidity.

Custom Ratios: Non-standard ratios (e.g., 100:1) require new hob cutters, increasing cost 20-25%.

Certifications: API 8C (+12%), DNV-GL (+8%), or CE explosion-proof (+15%) certification for regulated sectors.

Input Options: Hydraulic motor flanges (+10%), IEC C-face adapters (+7%), or integrated servo motors (+35-60%).

Volume Economics: 50+ unit orders reduce per-unit cost by 28% via batch production optimization.

Global Supplier of Worm Gear Drive WE12

LYRADRIVE engineers mission-critical slewing solutions worldwide, with the WE12 series as its flagship heavy-load drive. Their ISO 9001-certified manufacturing delivers application-optimized configurations including WE12, WEA12 (single-seal), and WEB12 (double-seal) variants. Technical support covers FEA load analysis, CAD integration, and lifecycle optimization. With global logistics hubs and 24/7 technical support, LYRADRIVE ensures operational continuity for critical infrastructure projects.