Heavy duty gearboxes with high torque capacity and excellent efficiency are critical for powering demanding applications in mining, steel production, cement plants, and large material handling systems. These units deliver maximum torque while minimizing energy losses, helping operations reduce costs and improve overall equipment effectiveness.
Product Overview
These gearboxes serve primary crushers, grinding mills, large conveyors, and heavy presses where both high torque and energy efficiency are essential. Core strengths include exceptional torque density, optimized gear geometry for reduced losses, robust construction for continuous duty, and the ability to operate reliably under heavy shock loads.
Technical Parameters
| Parameter | Specification Range |
|---|---|
| Input Power | Up to 5500 kW |
| Output Torque | Up to 1350000 Nm |
| Ratio Range | 7:1 to 450:1 |
| Input Speed | Up to 1800 rpm |
| Efficiency | Up to 97 percent |
| Mounting Options | Foot, flange, shaft-mounted |
| Protection Rating | IP65 or higher |
Working Principle
Power from the motor is transmitted through multiple stages of precision-cut helical or bevel-helical gears. Each stage multiplies torque while reducing speed. Optimized tooth profiles and high-quality bearings minimize friction losses, allowing the gearbox to deliver high torque with excellent overall efficiency even under continuous heavy loading.
Core Advantages
Handles very high output torques required by large crushers, mills, and heavy conveyors without compromising reliability.
Precision gear geometry and quality bearings reduce power losses, lowering energy consumption in continuous operations.
Reinforced housing and optimized tooth design withstand sudden overloads common in mining and heavy industry.
Delivers high torque from a relatively compact and robust package, simplifying installation on large equipment.
Higher efficiency directly translates into lower electricity usage over the long service life of the equipment.
Designed for 24/7 operation with stable temperatures and minimal maintenance requirements.
Structure and Material Craftsmanship
Housings are manufactured from high-strength cast iron or fabricated steel with internal ribbing for maximum rigidity. Gears are precision ground from case-hardened alloy steel with optimized tooth profiles for efficiency. Large-diameter shafts and heavy-duty bearings handle combined radial and axial loads. Advanced sealing and lubrication systems maintain performance and protect components under continuous heavy operation.
Typical Application Scenarios
Primary and Secondary Crushers: Delivers the massive starting and running torque required while maintaining high efficiency during continuous crushing operations.
Large Overland Conveyors: Provides high torque at the head pulley with excellent efficiency, reducing power consumption on long-distance material transport.
Grinding Mills in Mineral Processing: Handles heavy shock loads from grinding media while operating efficiently under constant high torque demand.
Selection Guide
Calculate required output torque including starting torque and apply an appropriate service factor. Determine the exact ratio needed for the desired output speed. Consider mounting position, available space, and ambient conditions. Review efficiency curves at the expected operating load to ensure optimal energy performance. Evaluate thermal capacity for continuous duty and confirm adequate lubrication and cooling provisions for the application.
Comparison with Other Brands
The table below shows common equivalent models for reference. EVER POWER is an independent Dutch company and does not produce or sell counterfeit products of any brand. This information assists with cross-brand selection only.
| EVER POWER Model | SEW Equivalent | Flender Equivalent | Sumitomo Equivalent | Key Selection Note |
|---|---|---|---|---|
| EP-HT-950 | X4K 315 | B4SH 11 | Paramax 11000 | High torque crusher drive |
| EP-HT-1400 | X5K 355 | B5SH 13 | Paramax 13000 | Large conveyor head pulley |
| EP-HT-2100 | X6K 400 | B6SH 14 | Paramax 15000 | Grinding mill primary drive |
Quality Certification and Service Commitment
All gearboxes are produced under ISO 9001:2015 quality management and carry CE marking. A minimum two-year warranty covers materials and workmanship. Global technical support, spare parts, and on-site service are available from the Dutch headquarters and authorized partners.
Frequently Asked Questions
Q: How is efficiency measured and what typical values can be expected?
A: Efficiency is measured at rated load and speed. Well-designed heavy duty helical and bevel-helical gearboxes typically achieve 95 to 97 percent efficiency.
Q: What service factor should be used for applications with frequent shock loads?
A: A service factor of 2.0 or higher is recommended for crushers and other equipment subject to frequent heavy shock loads.
Q: Can these gearboxes operate efficiently at partial loads?
A: Yes. Modern designs maintain good efficiency across a wide load range, although peak efficiency occurs near rated load.
Q: What maintenance practices help maintain high efficiency over time?
A: Regular oil analysis, proper lubrication levels, and timely oil changes help preserve gear and bearing condition, maintaining efficiency throughout the service life.
Q: Are condition monitoring options available?
A: Yes. Vibration, temperature, and oil condition sensors can be factory-fitted for integration with plant monitoring systems.
Case Studies – Engineer Field Notes
Chile – Large copper mine in the Atacama Desert. A high torque gearbox was installed on a primary crusher. After 20 months of operation the maintenance team reported excellent efficiency, stable temperatures, and no unplanned stops despite continuous heavy loading.
Canada – Oil sands operation in Alberta. The unit drives a large overland conveyor. Operations data confirmed measurable energy savings compared with the previous gearbox and reliable performance through extreme winter conditions.
Australia – Iron ore processing plant in Western Australia. Installed on a grinding mill drive. Site records show high efficiency maintained over the first major service interval with no loss of performance under continuous duty.
Call to Cooperation
EVER POWER, a Dutch company with extensive experience in high torque and high efficiency heavy duty gearboxes, welcomes the opportunity to support your next mining, steel, or material handling project. Our engineering team can review your torque and efficiency requirements and recommend the most suitable configuration.
Visit the main site for more product information. For detailed specifications or a project review, please use the contact form. We are prepared to deliver reliable, efficient solutions tailored to your heavy duty applications.