Beskrivning
WPDS Flange-Mounted Single Speed Worm Gear Reducer with Cooling Fins — Motor-Direct Drive with Superior Thermal Management
Motor-direct drives generate heat from two sources simultaneously: the motor and the gearbox. In high-duty-cycle applications — continuous process lines, chemical plant drives, multi-shift production — this combined thermal load can quickly push a standard flanged gearbox beyond its safe operating temperature. The WPDS motor-direct worm gear reducer addresses this challenge by combining the installation simplicity of an IEC flange-mount with the thermal performance of an integral cooling fin array.
The WPDS delivers up to 15°C lower sustained operating temperature compared to the equivalent WPDA smooth-body unit — extending lubricant service life, protecting seals, and reducing the risk of overtemperature tripping in enclosed machine cabinets or hot plant rooms. Available in 12 frame sizes (40–250 mm), motor powers from 0.12 to 15 kW, and ratios from 1/5 to 1/60. Om Ever-power | Request a Free Thermal Assessment
Technical Specifications
WPDS shares the WPDA base footprint but with increased housing height (H) due to the integral fin array. Note the higher HL values vs WPDA. Reference input speed 1500 r/min. All dimensions in mm.
| Size | Power(kW) | Ratio | A | AB | BB | CC | H | HL | M | N | E | F | G | Z | LA | LB | LC | LE | LZ | Q | U | T×V | LS | S | W×Y | Wt(kg) |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 40 | 0.12 | 1/5–1/60 | 135 | 75 | 74 | 40 | 141 | 60 | 90 | 100 | 70 | 80 | 13 | 10 | 115 | 95 | 140 | 4 | M8 | 31 | 11 | 4×12.8 | 28 | 14 | 5×3 | 5 |
| 50 | 0.18 | 151 | 83 | 97 | 50 | 180 | 80 | 120 | 140 | 95 | 110 | 15 | 12 | 115 | 95 | 140 | 4 | M8 | 31 | 11 | 4×12.8 | 40 | 17 | 5×3 | 8 | |
| 60 | 0.37 | 167 | 91 | 112 | 60 | 202 | 90 | 130 | 150 | 105 | 120 | 20 | 12 | 130 | 110 | 160 | 4 | M8 | 33 | 14 | 5×16.3 | 50 | 22 | 7×4 | 11 | |
| 70 | 0.37/0.75 | 200/202 | 109/111 | 131 | 70 | 238 | 105 | 150 | 190 | 115 | 150 | 20 | 15 | 130/165 | 110/130 | 160/200 | 4 | M8/M10 | 40/42 | 14/19 | 5×16.3/6×21.8 | 60 | 28 | 7×4 | 17 | |
| 80 | 0.75/1.5 | 225 | 125 | 142 | 80 | 273 | 120 | 170 | 220 | 135 | 180 | 20 | 15 | 165 | 130 | 200 | 4.5 | M10 | 48/52 | 19/24 | 6×21.8/8×27.3 | 65 | 32 | 10×4.5 | 22 | |
| 100 | 1.5/2.2/3.0 | 280 | 148 | 169 | 100 | 334 | 150 | 190 | 270 | 155 | 220 | 25 | 15 | 165 | 130 | 200 | 4.5 | M10 | 52 | 24 | 8×27.3 | 75 | 38 | 10×4.5 | 38 | |
| 120 | 2.2/3.0 | 333 | 181 | 190 | 120 | 423 | 180 | 230 | 320 | 180 | 260 | 30 | 18 | 215 | 180 | 250 | 5 | M12 | 63 | 28 | 8×31.3 | 85 | 45 | 12×4.5 | 64 | |
| 135 | 3.0/4.0 | 375 | 202 | 210 | 135 | 482 | 215 | 250 | 350 | 200 | 290 | 30 | 18 | 215 | 180 | 250 | 5 | M12 | 63 | 28 | 8×31.3 | 95 | 55 | 16×6 | 85 | |
| 155 | 5.5 | 448 | 247 | 252 | 155 | 541 | 235 | 275 | 390 | 220 | 320 | 35 | 21 | 265 | 230 | 300 | 5 | M12 | 83 | 38 | 10×41.3 | 110 | 60 | 18×7 | 118 | |
| 175 | 7.5 | 481 | 262 | 255 | 175 | 600 | 260 | 310 | 430 | 250 | 350 | 40 | 21 | 265 | 230 | 300 | 5 | M12 | 83 | 38 | 10×41.3 | 110 | 65 | 18×7 | 165 | |
| 200 | 11.0 | 543 | 285 | 319 | 200 | 677 | 290 | 360 | 480 | 290 | 390 | 40 | 24 | 300 | 250 | 350 | 6 | M16 | 114 | 42 | 12×45.3 | 125 | 70 | 20×7.5 | 236 | |
| 250 | 11.0/15.0 | 615 | 330 | 385 | 250 | 824 | 350 | 460 | 560 | 380 | 480 | 45 | 28 | 300 | 250 | 350 | 6 | M16 | 114 | 42 | 12×45.3 | 155 | 90 | 25×9 | 396 |
* HL = total height including fin array. WPDS and WPDA share identical base footprint (A, B, CC dimensions) — WPDS is a direct thermal upgrade for existing WPDA installations where adequate vertical clearance exists.
Product Structure — Motor Flange + Cooling Fin System
The WPDS combines three engineering features in one unit: a precision IEC motor flange at the rear, a cast-integral longitudinal fin array on top and side faces, and the proven FC25 grey cast iron housing carrying the worm gear set. The fins are integral to the casting — not bolted or bonded on — ensuring permanent thermal contact and vibration resistance throughout the service life.
| Motor Flange | IEC 60034-7 standard; precision pilot register to 0.05 mm TIR |
| Cooling Fins | Cast-integral longitudinal fins; up to +40% external surface area vs WPDA |
| Housing | FC25 grey cast iron; same base footprint as WPDA |
| Thermal Gain | ~15°C lower steady-state oil temperature vs equivalent WPDA at rated load |
| Output Shaft | Solid shaft with keyway; 5 direction positions (A–E) |
| Compatibility | Drop-in thermal upgrade for existing WPDA installations (verify H clearance) |
✅ Key Features & Benefits
Combined Motor-Direct + Thermal Optimisation
The WPDS is the only unit in the WP series that simultaneously eliminates coupling components AND provides enhanced thermal capacity. This dual benefit makes it the highest-value choice for high-duty-cycle motor-direct applications where both installation simplicity and thermal stability are required. Keywords: motor-direct gearbox with cooling, flanged worm reducer for continuous operation.
~15°C Lower Operating Temperature vs WPDA
At equivalent rated load and ambient temperature, the WPDS fin array reduces oil sump temperature by approximately 15°C compared to the smooth-body WPDA. In a 40°C machine room, this keeps the WPDS comfortably below the 95°C maximum oil temperature limit where the WPDA might reach it under peak load.
Precision IEC Flange — Zero Coupling Alignment
The IEC 60034-7 compliant motor flange with precision pilot register accepts standard motors directly. Motor-to-worm shaft connection via keyed bore eliminates coupling selection, alignment checking, and re-alignment after motor replacement — reducing planned maintenance time significantly.
Cast-Integral Fins — Permanent Thermal Contact
Unlike bolt-on heat sink accessories, the WPDS fins are cast as part of the housing body. This ensures maximum thermal conductivity between the oil bath and the fin surface, with no risk of fin loosening due to vibration over the service life.
Extended Lubricant and Seal Service Life
The lower sustained operating temperature directly extends ISO VG 320 mineral oil service life, reduces oxidation and base oil degradation, and slows NBR seal hardening — cutting total lubrication and seal replacement costs in multi-shift operations.
Drop-In Upgrade from WPDA
The WPDS shares the identical base footprint and shaft dimensions with the WPDA. Where a WPDA installation is experiencing overtemperature issues, the WPDS is the most cost-effective upgrade path — no mounting plate modification, no shaft coupling changes, just verify the increased H dimension fits within the available clearance.
Industry Applications
The WPDS is the solution of choice when a motor-direct drive must operate at high duty cycles or elevated ambient temperatures:
Chemical & PharmaceuticalContinuous stirred-tank reactor drives, pump motor-gearbox units, and distillation column auxiliaries in high-ambient-temperature process plant environments.
Paper & Pulp IndustryConveyor drives, press roll auxiliaries, and winding/unwinding systems in paper mills where high ambient temperatures and continuous multi-shift duty demand thermal stability.
Rubber & PlasticsExtruder take-off conveyors, calendar roll drives, and pelletiser auxiliaries in factories where the combination of hot-ambient conditions and continuous running pushes standard gearboxes to their thermal limits.
Foundry & CeramicsConveyor and charging equipment drives in foundries and kiln operations where ambient temperatures regularly exceed 40°C and the gearbox must operate reliably without auxiliary cooling.
24/7 Automated LinesAutomotive body shop conveyors, tyre manufacturing drives, and any fully automated production line where the combined thermal load of motor and gearbox in an enclosed cabinet demands the WPDS’s enhanced dissipation capability.
Middle East & Hot Climate ApplicationsAny industrial application in geographic regions with high ambient temperatures (Gulf States, South Asia, North Africa) where a standard motor-direct gearbox would require supplemental cooling but the WPDS manages thermally without it.
Quality Control & Certification
ISO 9001:2015 & CE
Full ISO 9001:2015 QMS with CE Declaration of Conformity per shipment. IEC flange dimensions CMM verified at final inspection against IEC 60034-7 specification.
️ Thermal Stability Run Test
Each WPDS undergoes a 90-minute thermal stability run at 110% rated torque. Oil sump temperature must stabilise below 95°C before shipment approval — this is a stricter criterion than our standard WPS thermal test, reflecting the additional heat input from a directly coupled motor.
Material & Fin Quality
Fins are inspected for casting voids, incomplete fill, and dimensional accuracy at foundry stage. Fin pitch, height, and wall thickness are verified against the drawing spec before machining commences — ensuring consistent thermal performance batch-to-batch.
Why Choose Ever-power for WPDS Gearboxes
We supply WPDS motor-direct finned gearboxes to chemical plant OEMs, rubber and plastics machinery builders, and automation integrators in Germany, Canada, the UAE, and Australia. Our in-house foundry gives us unique control over fin casting quality — we do not purchase externally cast housings and machine them; every WPDS housing is cast and machined in our own facility.
- ✅ In-house foundry and CNC machining — complete control of casting quality and fin geometry
- ✅ Thermal simulation on request — we model your duty cycle before you commit to an order
- ✅ IEC flange CMM verification — every unit measured, not just spot-checked
- ✅ OEM thermal upgrade service — we can re-specify your existing WPDA line to WPDS
- ✅ Worldwide export logistics — 60+ countries, 7–15 day standard delivery
⭐ Customer Reviews
“We upgraded our WPDA units to WPDS on a continuous chemical line running in a 48°C plant room. The temperature difference is immediate and significant — the WPDS runs cool enough that we no longer need to throttle the motor duty cycle to prevent overtemperature trips. Excellent product.”
Craig B., Maintenance Engineer
Chemical Processing Plant, Queensland, Australia
“We specify WPDS as standard for all motor-direct drives on our extruder take-off conveyors. The thermal performance is consistently better than the WPDA — our customers in hot production environments have zero overheating complaints since we made the switch. Build quality from Ever-power is excellent.”
Hans G., Drive Systems Engineer
Rubber & Plastics Machinery Builder, Düsseldorf, Germany
“WPDS gearboxes are now our standard recommendation for motor-direct applications in the Gulf region. The combination of IEC flange mounting and cooling fins is exactly what our customers need for continuous outdoor or semi-outdoor duty in 45°C+ ambient. Very satisfied with quality and delivery.”
Khalid A., Technical Manager
Industrial Equipment Supplier, Dubai, UAE
“Good performance from WPDS-100 units on our automated warehouse conveyor drives. The motors are in enclosed enclosures and the gearboxes benefit clearly from the fins in that environment. One unit had a minor cosmetic casting mark but functioned perfectly. Would specify WPDS again.”
Brian M., Project Engineer
Automation Systems Integrator, Calgary, Canada
❓ Frequently Asked Questions
How much cooler does the WPDS run compared to the WPDA?
At 100% rated load and 40°C ambient, the WPDS oil sump temperature is approximately 12–15°C lower than an equivalent WPDA. At 110% overload in a 45°C ambient — conditions common in the Gulf region and Southeast Asia — this differential can reach 20°C, which may be the critical margin between continuous operation and an overtemperature shutdown.
Can I replace an existing WPDA with a WPDS without machine modification?
In most cases yes — the WPDS shares the identical base footprint (A, B, CC dimensions) and shaft dimensions with the WPDA. The only dimensional change is the increased housing height (H) due to the cooling fins. Before ordering a WPDS replacement, measure the available vertical clearance above your existing WPDA and compare it to the H value for the WPDS frame size you need. If clearance is sufficient, it is a direct swap. Contact us with your clearance measurement and we will confirm.
Does the WPDS need a forced-air cooling fan or any supplemental cooling?
No — for standard rated duty cycles and ambient temperatures up to approximately 45°C, the WPDS provides sufficient natural convection cooling without any supplemental measures. Ensure at least 50 mm of unobstructed air space around the fin array. In confined enclosures, a small ventilation opening is sufficient. No external fans, water circuits, or cooling coils are required.
Is the WPDS suitable for use in food-contact or washdown environments?
The standard WPDS with NBR seals and untreated cast iron housing is not rated for direct food-contact or high-pressure washdown. For food and beverage applications requiring hygiene, we recommend the standard WPDA (no fins to trap product residue) with food-grade lubricant. If thermal performance is also required, contact us about our epoxy-coated WPDS variant with stainless steel output shaft option.
What synthetic lubricant is recommended for the WPDS in high-temperature applications?
For ambient temperatures above 40°C or sustained oil sump temperatures expected to exceed 80°C, we recommend upgrading from standard ISO VG 320 mineral oil to synthetic polyalkylene glycol (PAG) ISO VG 460. PAG oils offer superior viscosity index and thermal stability, further extending the thermal margin and lubricant life. Combined with the WPDS fin array, PAG lubrication can deliver drain intervals of 5,000 hours or more in moderate-temperature environments.
Stay Cool Under Pressure — Specify WPDS Today
If your motor-direct drive is approaching its thermal limits, the WPDS offers the most cost-effective path to reliable continuous operation. Request a duty-cycle thermal assessment and quotation from our engineering team.
