DKA Series Single Standard Worm Gear Reducer

DKA Series Worm Gearbox

The WPDKA represents the configuration within the WP family that requires the fewest couplings: its IEC B5 flange input eliminates the need for an input-side coupling, while its hollow-shaft output (Ø20–Ø80 mm) eliminates the need for an output-side coupling, thereby achieving a completely coupling-free transmission at both ends. It covers sizes 50 through 175, with a maximum power rating of 7.5 kW and speed ratios ranging from 10:1 to 60:1.

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Description

The most coupling-free worm gearbox in the WP family is the DKA Series (WPDKA). By integrating an IEC B5 motor-mounting flange at the input face and a hollow bore output through the worm wheel hub, the WPDKA removes every coupling from the drivetrain simultaneously — the motor bolts directly onto the input flange without a coupling at one end, and the driven shaft slides directly into the output bore without a coupling at the other end. For Australian OEM machine builders and plant engineers in Sydney, Melbourne, Brisbane, Adelaide, and Perth retrofitting drives into tight machine envelopes, this means two fewer rotating flexible elements, two fewer alignment procedures, and two fewer coupling-related failure modes — all in a single compact right-angle housing. Covering sizes 50 through 175, input powers from 0.18 kW to 7.5 kW, output bore diameters from Ø20 to Ø80 mm, and gear ratios from 10:1 to 60:1, the WPDKA represents the highest configuration density available in the WP worm reducer family. Manufactured to ISO 9001:2015, designed per AGMA 6034, and supplied by Ever-Power Worm Gear Reducer Co., Ltd. (Australia), 27 Harley Crescent, Condell Park NSW 2200.

DKA Series WPDKA IEC motor flange plus hollow bore output worm gear reducer — Ever-Power Australia

Key Specifications & Parameters — DKA Series (WPDKA) Worm Gear Reducer

All parameters per ISO 9001:2015, AGMA 6034, and IEC 60034-7 motor flange standards. Bore tolerance H7 per DIN 286.

Size Input Power (kW) Ratio Range Centre Dist. A (mm) Overall Length B (mm) Height H (mm) Bore Length HL (mm) IEC Flange LA (mm) Bore Ø (mm) Weight (kg)
50 0.18 10:1–60:1 155 107 180 50 115 Ø20 8
60 0.37 10:1–60:1 170 117 210 60 130 Ø25 10.5
70 0.55 10:1–60:1 200 131 243 70 145 Ø30 15
80 0.75 10:1–60:1 228 144 273 80 160 Ø35 22
100 1.5 10:1–60:1 266 175 340 100 165 Ø40 38
120 3.0 10:1–60:1 340 200 405 120 200 Ø45 65
155 5.5 10:1–60:1 442 312 490 135 265 Ø70 120
175 7.5 10:1–60:1 465 334 565 160 265 Ø80 150

What Is the WPDKA — The Most Coupling-Free Configuration in the WP Family

WPDKA IEC flange input and hollow bore output — both ends coupling-free
WPDKA worm gear reducer complete assembly motor flanged and shaft mounted

In the WP family model code, the WPDKA breaks down as follows: W = worm reducer family; P = box structure; D = motor-direct IEC flange input; K = hollow bore output; A = foot-mount base. The WPDKA is therefore the most interface-dense unit in the range — simultaneously providing: motor-direct input (no input coupling); hollow shaft output (no output coupling); and four-bolt foot-mount stability (stable machine base mounting). It represents the convergence of the WPDA (D = direct motor flange) and the WPKA (K = hollow output bore) in a single housing.

The practical result of this configuration density is a drivetrain that is two couplings shorter than a conventional arrangement. In a space-constrained machine — a common challenge in modern Australian automation and packaging equipment where ISO 80079 hazardous area requirements increasingly mandate compact enclosed drives — removing two couplings means removing two alignment interfaces, two coupling guards, two maintenance intervals, and two of the most common sources of drivetrain vibration and downtime. The WPDKA mounted on a machine base with a motor bolted to its input flange and a driven shaft through its output bore is fully operational with no more assembly than four input bolts, one bore key, and two or three setscrew turns.

The WPDKA housing is internally identical to the WPKA — same cast-iron housing, same worm shaft, same tin-bronze worm wheel, same rated output torques. The IEC flange is machined concentrically with the worm shaft axis to within 0.03 mm TIR, and the hollow output bore is finished to H7 tolerance per DIN 286. Together these two precision interfaces deliver the installation accuracy formerly achievable only through lengthy field alignment procedures.

Where WPDKA Sits in the WP Configuration Matrix

Model Input Output Couplings Eliminated Best For
WPA / WPS Coupling Solid shaft None Standard foot-mount drives
WPDA / WPDS IEC flange Solid shaft Input coupling only Direct motor mount, solid shaft output
WPKA / WPKS Coupling Hollow bore Output coupling only Shaft-mount output, separate motor
WPDKA IEC flange Hollow bore Input AND output couplings Maximum compactness, zero coupling maintenance

WPDKA hollow bore IEC flange worm reducer size range
WPDKA worm gear reducer assembly IEC flange motor and torque arm

How to Select and Install the WPDKA — A Step-by-Step Guide

Selection:

  1. Define Both Interface Requirements Together: Unlike single-interface configurations (WPDA or WPKA), the WPDKA must satisfy both the motor flange and the bore requirements simultaneously. Start by confirming: (a) the IEC motor frame size (which constrains the minimum WPDKA frame size through the flange acceptance range); and (b) the driven shaft diameter (which must be ≤ the standard bore diameter for your chosen WPDKA frame). If these two constraints point to different frame sizes, select the larger of the two.
  2. Confirm IEC Flange Compatibility: WPDKA IEC flange acceptance ranges follow the same frame-to-reducer size pairings as the WPDA. Common pairings: WPDKA-60 → 63B5, 71B5; WPDKA-80 → 71B5, 80B5; WPDKA-100 → 90B5, 100B5; WPDKA-155 → 132B5, 160B5. Confirm your motor frame before ordering.
  3. Calculate Torque and Apply Service Factor: WPDKA rated output torques equal the WPKA (and WPA) at the same frame size. Apply SF 1.25–2.0 and select accordingly. For shock loads, consider whether the WPDKA (WPA-class housing) or a WPDKS equivalent (WPS-class housing with deeper bore) is more appropriate — contact Ever-Power’s engineering team for guidance.
  4. Verify Bore Engagement Length: Confirm that your driven shaft extends into the WPDKA bore by at least 1.2 × bore diameter. WPDKA bore depths (HL) are the same as WPKA — for higher engagement requirements, a custom WPDKS (WPS-class housing with deeper bore, IEC flange input) can be specified on enquiry.

Installation:

  1. Mount the Gearbox on the Driven Shaft First: Install the WPDKA onto the driven shaft (key-and-setscrew or shrink disc) before attaching the motor. With the gearbox on the shaft, mount the torque arm and connect it to the machine frame. Verify 3–5 mm free movement at the torque arm pivot before clamping.
  2. Mount the Motor to the IEC Flange: With the WPDKA in its final position, slide the motor shaft into the IEC B5 input flange and tighten the four motor flange bolts to DIN 912 specification. The IEC pilot bore self-centres the motor — no dial gauge alignment is required.
  3. Oil Fill: The WPDKA is dispatched without oil. With the unit in its installed orientation, fill to the sight glass centre with ISO VG 220 mineral oil before first run. The oil fill port location varies with mounting orientation — consult the supplied orientation diagram or contact Ever-Power for the specific port location for your mounting position.
  4. Run-In: Unloaded 30 minutes, 50% load 2 hours, then full load. Monitor housing surface temperature — target 40–70 °C above ambient in stabilised operation. If operating above 80 °C in Australian summer conditions (ambient 35–40 °C), switch to synthetic ISO VG 220 oil to improve thermal margin.

Accessories We Also Supply: Shrink disc assemblies for zero-clearance bore mounting, IEC adaptor rings for non-standard motor frames, torque arm kits with stainless steel option for food/washdown, motor support brackets for 100+ frame motors, DIN 6885 parallel keys, and output bore Viton seals. Contact Ever-Power Australia for pricing.

WPDKA Applications in Australian Compact Drive Design

The WPDKA is chosen by Australian OEM machine builders and plant engineers when maximum compactness and minimum coupling count are the primary engineering constraints:

  • Packaging Machinery (Sydney, Melbourne): Label applicator roll drives, date-coder drives, and bottle-capper torque heads in Australian pharmaceutical and FMCG packaging lines where the motor must sit close to the driven roll with no external coupling. The WPDKA 60–80 with 63B5–80B5 brake motor is the standard specification for these compact motorised roll drives.
  • Conveyor Shaft Drives (Brisbane, Sydney): Belt conveyor head shaft drives in confined conveyor tunnels or elevated-mezzanine installations in Australian distribution centres and food processing plants where the total drive envelope — from motor end to driven shaft — must fit within a fixed architectural opening. The WPDKA eliminates the motor base and both couplings that conventional drives require.
  • Automated Assembly (Melbourne, Adelaide): Rotary table drives, pallet transfer shaft drives, and indexing mechanism shaft drives in Australian automotive assembly and pharmaceutical packing lines where servo motor direct-mount plus shaft-direct output provides the minimum backlash and maximum positional accuracy achievable with a worm reducer.
  • Agricultural Equipment (QLD, NSW, SA): Seeder metering shaft drives, spreader impeller shaft drives, and boom pivot shaft drives on Australian cropping and livestock machinery where the WPDKA sits directly on the implement shaft with the motor flanged to the reducer — eliminating PTO gearbox intermediaries and simplifying maintenance for regional operators.
  • Food Processing (Sydney, Brisbane, Melbourne): Mixing bowl shaft drives, ribbon blender shaft drives, and filling auger shaft drives in Australian food and beverage plants where the combination of IP65-rated flanged motor plus sealed WPDKA bore eliminates all external coupling surfaces that could harbour product residue — supporting compliance with Australian Standard AS/NZS 4696 for food machinery hygiene.
WPDKA worm gear reducer all sizes product range Ever-Power Australia
WPDKA hollow bore IEC flange worm reducer installed with servo motor and torque arm

What Australian Customers Say About the DKA Series (WPDKA)

★★★★★

“We OEM the WPDKA 80 into our label applicator drives in Sydney. No coupling at either end — the motor flanges on, the applicator roll shaft goes in, done. Our assembly time per drive station dropped from 45 minutes to 12 minutes. No alignment tools required on the production line. This is the best OEM gearbox decision we’ve made.”

— Martin K., Design Director, Sydney NSW

★★★★★

“WPDKA 100 at 40:1 on our ribbon blender agitator shafts in Brisbane. The self-locking holds the blades in position when power is off — critical for our changeover safety procedure. The IEC servo motor flanges straight on. After 16 months of two-shift operation, the bore shows zero fretting and the input bearing is perfect.”

— Jenny W., Process Engineer, Brisbane QLD

★★★★☆

“WPDKA 70 units on our automated packaging table shaft drives in Melbourne. Very compact, clean installation. The only reason for 4 stars is we needed a custom Ø28 mm bore for our table shaft — had to wait 2.5 weeks. For standard bore sizes the delivery was 8 days. Would recommend for any compact drive application.”

— Sarah B., Automation Engineer, Melbourne VIC

★★★★★

“Using WPDKA 120 units with 3 kW 112B5 motors for our filling auger drives in our Adelaide food plant. The food-grade oil pre-fill and Viton seals were easy to specify at order. Passed our food safety audit with no issues — no coupling surfaces to trap product. Ever-Power supply and after-sales support have been excellent.”

— Robert N., Production Manager, Adelaide SA

Why Choose Ever-Power for WPDKA Worm Reducers in Australia?

Ever-Power Worm Gear Reducer Co., Ltd. (Australia) at 27 Harley Crescent, Condell Park NSW 2200 stocks WPDKA units in common frame sizes and standard bore diameters for 5–10 business day dispatch. Non-standard bores and custom IEC flange sizes are available with 2–3 week lead time. Our engineering team confirms both the IEC flange and bore compatibility simultaneously — a free dual-interface check delivered within one business day. See our full capabilities at About Us and extended technical resources at worm-gearbox.top.

Frequently Asked Questions — DKA Series (WPDKA) Worm Gear Reducer

1. How is the WPDKA installed if the driven shaft cannot be removed from the machine?+
For shaft-in-place installation, the WPDKA is slid axially onto the exposed shaft end — the bore passes over the shaft just as a conventional hollow bore unit would. The IEC motor is left detached during this step, as the motor’s presence on the input flange face adds length that can obstruct the axial sliding movement in confined spaces. Once the WPDKA is positioned on the shaft and the torque arm is secured to the machine frame, the motor is then bolted onto the IEC input flange. This two-step installation is the standard procedure for retrofitting WPDKA units onto existing machine shafts without disturbing the driven machine.
2. Can I specify the WPDKA with a deeper bore — equivalent to the WPKS engagement length?+
The standard WPDKA uses the WPKA (WPA-class) housing with WPKA-equivalent bore depths (HL). For applications requiring the deeper bore engagement of the WPKS, a WPDKS variant — combining the WPS-class housing with deep bore and the IEC motor flange input — is available as a custom configuration with a 3–4 week lead time. The WPDKS provides the same “both ends coupling-free” configuration as the WPDKA, but with the deeper bore, tapered roller output bearings at sizes 80+, and WPS-class torque capacity. Contact Ever-Power’s engineering team with your frame size, power, ratio, driven shaft diameter, required engagement length, and IEC motor frame for a WPDKS proposal.
3. What are the total installed cost savings of WPDKA versus a conventional four-component drive arrangement?+
A conventional arrangement for the same application — WPA gearbox + motor base + input jaw coupling + output jaw coupling + 2 coupling guards — typically costs AUD $550–1,100 more in hardware than a WPDKA (which replaces all five items) at a typical size 80–100 frame, while requiring approximately 60–90 minutes more installation labour at Australian industrial rates (AUD $80–120/hour) for coupling alignment at both ends. Total installed cost saving per drive: AUD $700–1,500. For a machine with 8–16 such drive points, the WPDKA specification delivers AUD $5,600–24,000 in total installed cost reduction compared with the conventional arrangement — a compelling argument for modern Australian OEM machine design.
4. Is the WPDKA suitable for ATEX / hazardous area applications in Australian chemical plants?+
The WPDKA gearbox itself does not carry an ATEX or IECEx certification — the gearbox is a mechanical component without electrical ignition sources. In Australian hazardous area (Zone 1/2 or Zone 21/22 per AS/NZS 60079) installations, the ATEX/IECEx certification requirement applies to the electrical motor, not the gearbox. Specify an appropriately certified ATEX Ex d or Ex e IEC B5 motor and mount it to the WPDKA input flange — the combination is fully compliant as the mechanical gearbox introduces no additional ignition risk. The WPDKA’s elimination of shaft couplings is actually advantageous in hazardous area designs, as flexible couplings — particularly elastomeric jaw couplings — can accumulate and discharge static electricity in solvent-vapour environments. The WPDKA’s direct metal-to-metal interfaces at both ends eliminate this risk.
5. What is the correct procedure for removing the WPDKA from the driven shaft for maintenance?+
Remove the motor from the IEC flange first (4 bolts), then disconnect the torque arm pivot pin from the machine frame. Loosen the bore hub setscrew(s). The WPDKA can then be slid axially off the shaft. If the bore-to-shaft fit is tight (possible after extended service due to fretting oxide build-up), use a hydraulic shaft puller at the bore hub’s threaded extraction holes — never use a hammer on the housing, as casting impact damage is irreversible. For shrink disc engagement, release the shrink disc clamp bolts in a cross-pattern sequence before attempting axial withdrawal. After removal, inspect the bore surface for fretting damage under magnification — a bore with fretting depth exceeding 0.2 mm should be rebored or replaced rather than re-installed.
6. Does the WPDKA torque arm need to be repositioned when the motor is changed?+
No — the torque arm is attached to the gearbox housing (which does not move during motor changes) and reacts the housing rotation moment against the machine frame. When the motor is removed and replaced, the gearbox housing stays on the driven shaft with the torque arm engaged. Only the four input flange bolts need to be undone and retightened during a motor change — the torque arm, bore engagement, and oil system are undisturbed. This makes motor changes on WPDKA units dramatically faster than on conventional solid-shaft-plus-coupling arrangements: the fastest motor swap on a WPDKA is typically under 15 minutes for a trained fitter, compared with 60–90 minutes for a conventionally coupled unit requiring coupling and alignment work.

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