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WPEX Dual Output Shaft Double Speed Worm Gear Reducer — Synchronised Ultra-High Ratio Bilateral Drive from a Single Unit
When a paper machine requires both left and right rollers driven at precisely 1/600 of motor speed, or a wide mining conveyor needs both drive drums synchronised at 1/400 ratio from a single motor, no standard single-output gearbox can meet the requirement. The WPEX dual output shaft double speed worm gear reducer is the engineered solution — combining two-stage reduction (ratios 1/200 to 1/900) with dual synchronised output shafts, delivering mechanically perfect bilateral synchronisation at the extreme low speeds that only a two-stage drive can achieve.
The E, E₁, and E₂ output shaft dimensions in the specification table define the two equal-length output shaft extensions on each side of the worm wheel bore. Because both shafts are keyed to the same second-stage worm wheel, speed equality is a mechanical certainty — no synchronisation electronics, no differential drives, no chain backlash. Available in 9 size groups, ratios 1/200–1/900, shaft directions A–E. About Ever-power | Request a Quotation
Technical Specifications
WPEX shares the WPEO housing body. E₁ and E₂ = equal output shaft extensions each side of the second-stage worm wheel. Reference input speed 1500 r/min. All dimensions in mm.
| Size | Ratio | A | AA | AB | BA | BB | BC | BE | HB | CA | M | N | E | E₁ | E₂ | G | Z | HS | U | T×V | LS | S | W×Y | Wt(kg) |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 40-70 | 1/200–1/900 | 286 | 195 | 153 | 40 | 131 | 65 | 87 | 50 | 157 | 156 | 295 | 120 | 120 | 135 | 20 | 15 | 25 | 12 | 4×2.5 | 60 | 28 | 8×4 | 19 |
| 50-80 | 297 | 197 | 144 | 50 | 142 | 70 | 108 | 65 | 188 | 175 | 320 | 140 | 130 | 150 | 20 | 15 | 30 | 12 | 4×2.5 | 65 | 32 | 10×4.5 | 27 | |
| 60-100 | 363 | 231 | 175 | 60 | 169 | 90 | 120 | 75 | 222 | 224 | 410 | 190 | 165 | 215 | 22 | 15 | 40 | 15 | 5×3 | 75 | 38 | 10×4.5 | 44 | |
| 70-120 | 408 | 256 | 193 | 70 | 190 | 100 | 140 | 90 | 260 | 266 | 450 | 220 | 185 | 215 | 30 | 18 | 40 | 18 | 5×3 | 85 | 45 | 12×4.5 | 63 | |
| 80-135 | 471 | 298 | 226 | 80 | 210 | 110 | 160 | 105 | 295 | 306 | 495 | 260 | 210 | 235 | 30 | 18 | 50 | 22 | 7×4 | 95 | 55 | 16×6 | 96 | |
| 100-155 | 555 | 354 | 269 | 100 | 252 | 140 | 190 | 130 | 345 | 350 | 590 | 290 | 245 | 295 | 35 | 21 | 50 | 25 | 7×4 | 110 | 60 | 18×7 | 149 | |
| 120-175 | 598 | 379 | 287 | 120 | 255 | 150 | 219 | 155 | 394 | 640 | 320 | 267 | 323 | 40 | 21 | 65 | 30 | 7×4 | 110 | 65 | 18×7 | 191 | ||
| 135-200 | 662 | 425 | 318 | 135 | 319 | 175 | 256 | 185 | 456 | 440 | 710 | 370 | 290 | 360 | 40 | 24 | 75 | 35 | 10×4.5 | 125 | 70 | 20×7.5 | 278 | |
| 155-250 | 795 | 510 | 380 | 155 | 385 | 200 | 295 | 203 | 545 | 510 | 860 | 440 | 350 | 440 | 45 | 28 | 85 | 40 | 12×5 | 155 | 90 | 25×9 | 442 |
* E = total second-stage worm wheel shaft length; E₁ and E₂ = individual output shaft extension lengths (equal by default). CA = overall output shaft span between outer bearing faces. Shaft directions A–E (5 positions). Shared specification drawing with WPEO.
Product Structure — Two-Stage Cascade with Dual Output Shaft
The WPEX extends the two-stage WPEO housing by boring the second-stage worm wheel shaft through both sides of the housing, creating equal-length output shaft extensions at both ends. The wider housing body provides two additional bearing bores flanking the worm wheel, supporting the extended shaft under asymmetric loading while maintaining the full torque capacity of the selected size and ratio combination.
| Drive Stages | Two worm-and-wheel pairs in series; ratio 1/200–1/900 |
| Output Shafts | Two equal-length shafts, both keyed to second-stage worm wheel — zero speed differential |
| Synchronisation | Mechanical lock — mathematically exact speed equality, no electronic control required |
| Housing | FC25 cast iron; wider body than WPEO for dual output bearing bores |
| Bearings | Six bearings total: two on each worm shaft (both stages) + two on output shaft ends |
| Shaft Directions | 5 positions (A–E); dual output protrudes symmetrically from both sides |
✅ Key Features & Benefits
Ultra-High Ratio + Perfect Bilateral Synchronisation
The WPEX uniquely delivers ratios of 1/200–1/900 AND mechanically exact dual-output synchronisation in a single unit. No other product type simultaneously achieves such extreme speed reduction while guaranteeing zero bilateral speed differential. Ideal for paper machines, wide mining conveyors, and precision industrial drives requiring both extreme ratio and symmetrical twin-point drive. Keywords: dual output double speed worm gearbox, synchronised two-stage worm reducer.
Eliminates Synchronisation System Complexity
Replacing a two-stage single-output gearbox plus synchronisation chain (or electronic servo synchronisation) with a single WPEX eliminates multiple components, alignment requirements, and maintenance points. For paper machines and wide conveyors operating at very low speeds, chain synchronisation at these speeds introduces backlash; the WPEX eliminates it mechanically.
Two-Stage Precision for Extreme-Low-Speed Applications
Both worm pairs are ground to ISO 1328 Grade 7 tolerances. The resulting output is smooth, consistent, and free from the cyclical velocity variations that characterise poorly meshed gears — important for paper web stability, film processing uniformity, and bulk material conveying where speed variation causes product quality issues.
Single-Unit BOM Efficiency
One WPEX replaces: (1) a two-stage gearbox, (2) a synchronisation drive system (chain, belt, or servo), (3) all associated mounting hardware. For OEM machine builders, this single-product BOM simplification reduces cost, procurement complexity, and assembly time across a production programme.
Full 9-Size Range for Heavy Bilateral Drives
From size 40-70 (output torque ~250 Nm per shaft end at 1/200) to size 155-250 (~6,050 Nm combined at 1/900), the WPEX covers the full range of bilateral heavy industrial drive requirements within the WPE two-stage product family.
Strong Self-Locking at High Combined Ratios
At combined ratios of 1/400 and above, the WPEX provides self-locking on both output shaft ends simultaneously — preventing bilateral back-driving of connected loads under gravity or residual drive forces when the motor is de-energised.
Industry Applications
The WPEX is specified wherever bilateral synchronised drive at ultra-high reduction ratios is required in a single unit:
Paper Machine DrivesWide paper machine press section roll drives and coating section roller drives requiring both left and right ends driven at precisely equal ultra-low speeds (1/400–1/900 ratio) for even web tension.
Wide Mining ConveyorsWide belt conveyor head drum bilateral drives in open-cast mines and ore processing plants where both drum ends must be driven synchronously at low speeds under high torque.
Film & Foil ProcessingBiaxial stretching machine drive rolls, metal foil rolling mill work roll drives, and plastic film extrusion haul-off drives requiring precise bilateral synchronisation at very low output speeds.
Textile Finishing LinesWide fabric tentering machine drive systems and heavy calender roll bilateral drives in textile finishing where bilateral speed matching across the full web width prevents fabric distortion.
Heavy Packaging LinesWide-format industrial strapping machine drives, heavy wrapping line bilateral conveyors, and pallet wrapping turntable drives requiring synchronised bilateral low-speed drive.
Test & Calibration EquipmentIndustrial dynamometer loading drives, material testing machine bilateral loading systems, and precision rotary table drives where mechanically exact bilateral synchronisation at very low speeds is a fundamental measurement requirement.
Quality Control & Certification
ISO 9001:2015 & CE
Full ISO 9001:2015 QMS. CE Declaration of Conformity per shipment. WPEX output shaft run-out is verified at both shaft ends (≤0.05 mm TIR each) in addition to standard two-stage gear mesh checks, ensuring both output ends contribute equal and symmetrical torque.
Bilateral Synchronisation Test
Each WPEX undergoes a bilateral symmetry verification: output shaft run-out measured at both ends; keyway position symmetry checked; torque balance verified during the 45-minute loaded run test. Both shaft ends must produce equal speed and torque within instrument measurement accuracy.
️ Material Standards
Housing: FC25 cast iron (≥250 MPa). Both worm shafts: 20CrMnTi (≥58 HRC). Both output shaft extensions machined from the same billet and heat-treated together for matched mechanical properties. Full material certs on request for paper and film industry quality documentation.
Why Choose Ever-power for WPEX Double Speed Gearboxes
We supply WPEX dual-output two-stage worm gearboxes to paper machine OEMs, wide conveyor builders, and film processing equipment manufacturers in Japan, the Netherlands, Brazil, Australia, and over 60 countries worldwide. Our bilateral symmetry test — verifying both output shaft ends, not just the overall unit — is the quality assurance standard that paper and film industry customers rely on for consistent bilateral synchronisation across an entire machine.
- ✅ Bilateral symmetry test as standard — both output ends verified, not spot-check
- ✅ Same-billet output shaft machining — matched properties guaranteed on both sides
- ✅ Paper & film industry supply expertise — we understand bilateral synchronisation requirements
- ✅ Custom output shaft extensions for asymmetric machine configurations on OEM request
- ✅ 20+ years export record — Japan, Netherlands, Brazil, Australia and beyond
⭐ Customer Reviews
“We use WPEX-100/155 units on our press section felt roll bilateral drives. The 1/600 ratio achieves the ultra-low roll speed our process needs, and the bilateral synchronisation is mechanically exact — no differential across the felt width after 18 months of continuous operation. The chain synchronisation system on our old machine was a constant maintenance headache; the WPEX has eliminated it entirely.”
Brian W., Paper Machine Engineer
Paper Mill, Tasmania, Australia
“We integrate WPEX gearboxes into our wide paper machine auxiliary drive systems. The combination of two-stage reduction ratio and dual output synchronisation is unique in the market at this product price point. Build quality from Ever-power is consistent batch to batch — essential for our production line supply chain requirements.”
Kenji M., Drive Systems Manager
Paper Equipment Manufacturer, Shizuoka, Japan
“We specified WPEX-120/175 for a wide mining conveyor bilateral head drum drive. The 1/800 ratio gives us the very low drum speed needed for controlled ore loading, and the bilateral symmetry means both drum ends pull at equal torque. Excellent product engineering and reliable delivery from Ever-power.”
Marco V., Machine Design Engineer
Wide Conveyor Systems, Rotterdam, Netherlands
“WPEX gearboxes on our metal foil rolling mill work roll bilateral drives. The dual-output two-stage design replaced a single gearbox plus synchronisation chain — simpler, lower maintenance, and the synchronisation is better. Good quality and competitive pricing. Some flexibility on delivery scheduling would be appreciated.”
Carlos F., Applications Engineer
Film Processing Equipment, São Paulo, Brazil
❓ Frequently Asked Questions
How does the WPEX differ from the single-stage WPX?
The WPX (single-stage) achieves ratios of 1/5–1/60 with dual output shafts. The WPEX (two-stage) achieves 1/200–1/900 — far higher ratios — with dual synchronised output shafts. Both provide mechanically exact bilateral synchronisation, but the WPEX is for applications requiring extreme speed reduction that the single-stage WPX cannot achieve. Housing dimensions are larger for the WPEX due to the two-stage internal arrangement.
Can different loads be applied to each output shaft of the WPEX?
Yes — both output shafts rotate at identical speed, but they can carry different torque loads. The combined torque from both shaft ends must not exceed the rated output torque for the selected WPEX size and ratio. For significantly asymmetric loading (one side much heavier than the other), contact our engineers for a bearing life assessment — asymmetric loading affects the second-stage output shaft bearing life calculation.
What is the maximum combined output torque of the WPEX?
At 1500 r/min input, the maximum combined output torque depends on size and ratio. For size 155-250 at ratio 1/900, the combined output torque is approximately 6,050 Nm (from the WPE power and torque table). This is split between both output shaft ends — each shaft end provides approximately 3,025 Nm under symmetric loading. Contact our engineers with your specific input power and required ratio for a precise torque calculation.
Are the two WPEX output shaft extensions the same length?
Standard supply provides equal extensions (E₁ = E₂) per the specification table. Asymmetric extensions — different E₁ and E₂ lengths — are available as a custom option for OEM customers whose machine geometry requires the gearbox to be positioned off-centre between the two drive points. Contact us with your required E₁ and E₂ dimensions for a custom quotation.
What is the noise level of the WPEX compared to a single-stage WPX?
The WPEX produces slightly higher noise than the single-stage WPX due to two gear meshes. However, at the ultra-low output speeds of 1/200–1/900 ratio operation, absolute output shaft RPM is so low that gear-mesh noise at the output is inaudible. The main noise source is the first-stage worm mesh — typically ≤75 dB(A) at rated load — which is similar to a single-stage unit of equivalent input power.
Perfect Bilateral Synchronisation at Ultra-High Ratios — Get WPEX Quote
Whether you need 1/400 for a wide paper roll drive or 1/900 for a precision bilateral test rig, the WPEX delivers mechanically exact synchronisation at ratios no single-stage product can match. Request a free selection calculation from our engineers.
