The WPEA houses two independent worm-and-wheel pairs in a single cast iron body, arranged in series. The first-stage worm shaft receives motor power; its worm wheel drives the second-stage worm shaft; the second-stage worm wheel delivers the ultra-reduced output torque. The two gear sets are separated by an intermediate shaft and bearing arrangement that maintains precise alignment under full load.

Ultra-High Reduction Ratios — 1/200 to 1/900

The WPEA achieves ratios from 1/200 to 1/900 in a single housing — ratios that would require two separate single-stage gearboxes in series with an intermediate shaft arrangement occupying far more floor space. For mineral processing, winch drives, and slow-turning kilns, this is the compact solution to extreme speed reduction. Keywords: ultra-high ratio double speed worm gearbox, two-stage worm reducer 1/900.

Two-Stage Precision Worm Pairs

Both worm-and-wheel pairs are ground to ISO 1328 Grade 7 tolerances. Despite the two gear meshes, the WPEA delivers noise levels ≤75 dB(A) at rated load — impressive for a two-stage drive. Transmission efficiency of 40–70% depending on combined ratio (two-stage efficiency is the product of individual stage efficiencies).

Rugged FC25 Cast Iron Housing

The elongated FC25 cast iron housing is designed to handle the higher internal forces inherent in two-stage drives. Ribbed reinforcements at the intermediate bearing positions resist deflection under the high-torque loads typical of 1/600+ ratio applications. Keywords: heavy-duty double speed worm drive, cast iron two-stage gearbox.

Five Shaft-Direction Options

Five standard positions (A–E) maintain the installation flexibility expected of the WPE series, allowing the WPEA to integrate into mining, chemical, and materials handling machine layouts without angle-drive accessories.

Strong Self-Locking at High Combined Ratios

At combined ratios of 1/400 and above, the WPEA provides robust self-locking behaviour under static conditions — preventing back-driving of connected loads. This is particularly valuable for hoisting and vertical conveying applications where gravity-induced reversal must be contained.

Compact vs Two Single-Stage Units in Series

The WPEA two-stage housing is typically 30–40% shorter and lighter than the equivalent two-gearbox-in-series arrangement. This space and weight saving is significant in cramped mine drives, ship deck machinery, and elevated machine structures where every kilogram and millimetre matters.

Mining Conveyors & HoistsUnderground and surface mine belt conveyor drives, mine hoist auxiliary drives, and ore transfer conveyor systems requiring 1/400–1/900 reduction ratios for ultra-slow, ultra-high-torque operation.

Cement & Lime KilnsRotary kiln auxiliary (slow) drives, clinker cooler conveyor drives, and raw mill table feeder systems where 1/600–1/900 ratio drives prevent thermal damage to kiln bricks during start-up and maintenance.

Heavy Mixing & AgitationLarge-volume industrial stirrer drives for bitumen, ceramic slurry, and heavy chemical mixing vessels requiring very low RPM and very high torque output continuously.

Marine & Port EquipmentHarbour crane slewing drives, ship deck winch auxiliaries, and port container spreader drives where compact high-ratio gearboxes save valuable deck and crane boom space.

Grain & Bulk HandlingLarge silo discharge auger drives, grain warehouse drag conveyor drives, and bulk material reclaimer slewing mechanisms requiring reliable ultra-low-speed high-torque drives.

Heavy Machinery AuxiliariesRolling mill pinch roll drives, heavy press flywheel deceleration drives, and large lathe slow-feed drives where the WPEA’s extreme ratio range provides precise ultra-low-speed control.

ISO 9001:2015 & CE

Full ISO 9001:2015 QMS with CE Declaration of Conformity per shipment. Two-stage units are subject to enhanced gear-mesh dimensional checks covering both worm pairs — not only final output shaft geometry.

Two-Stage Run Test

Each WPEA undergoes a two-stage loaded run test verifying: (1) noise ≤75 dB(A) across both gear meshes, (2) oil seal integrity under full torque, (3) output torque within ±5% of rated specification. Test duration: 45 minutes at rated input speed.

️ Material Traceability

Housing: FC25 cast iron (≥250 MPa). Both worm shafts: 20CrMnTi (≥58 HRC). Both wheel rims: ZCuSn10Pb1 tin-bronze. Full material mill certificates available for mining and marine sector compliance requirements.

We have been manufacturing WPE series two-stage worm gearboxes for over two decades, supplying mining equipment OEMs, cement plant machinery builders, and heavy marine equipment manufacturers in Australia, Germany, South Africa, the USA, and over 60 countries worldwide. Our two-stage housing production uses dedicated CNC boring lines that hold intermediate shaft bore-to-bore alignment to ≤0.02 mm — critical for correct gear mesh geometry across both stages.

• ✅ 20+ years WPE double-speed gearbox manufacturing experience
• ✅ Dedicated two-stage boring lines — intermediate shaft alignment ≤0.02 mm
• ✅ Full OEM capability — custom ratios within 1/200–1/900, special shaft lengths
• ✅ Mining & marine documentation packages including material certs and test reports
• ✅ 60+ country export record — established logistics to all major mining regions

“We replaced two tandem single-stage gearboxes on our ore conveyor with WPEA-100/155 units. The footprint reduction alone saved us 600 mm per drive point in a very tight underground heading — but the reliability improvement has been the real win. 22 months of continuous operation, zero unplanned stops. Impressive build quality.”

Mitchell P., Mining Engineer
Gold Mine, Western Australia, Australia

“We use WPEA-120/175 (1/900 ratio) as the kiln slow drive on our 4.5 m diameter rotary kiln. The ultra-low output speed is critical for controlled brick heating during start-up. The unit has performed flawlessly for 3 years, handling the very high intermittent shock loads of kiln start-up reliably.”

Friedrich K., Drive Systems Engineer
Cement Plant, Saxony, Germany

“WPEA units on our ship loader slewing drives have handled the demanding 24/7 port environment without issue. The self-locking at high ratios provides a useful passive brake on the slewing mechanism when the drive is de-energised. Quality and lead time were both excellent from Ever-power.”

John N., Port Machinery Manager
Bulk Cargo Terminal, Durban, South Africa

“Solid two-stage worm reducers for our heavy mixer drive application. The WPEA-80/135 units have been running at 1/600 ratio for 18 months on our thickener drives. Dimensional consistency is excellent — our maintenance team can swap units without shimming. Would prefer slightly faster documentation turnaround but product quality is first-rate.”

Robert H., Chief Engineer
Mineral Processing Plant, Nevada, USA