WPDS Series Worm Gear Reducer_ Dual-Access Hollow Bore Motor Drive_0204_01

DS Series (WPDS) worm gear reducer

The WPDS combines the IEC B5 flange input of the WPDA series with the reinforced output shaft cross-section of the WPS series. It offers a cantilever load capacity that is 30–40% higher than that of the WPDA, making it ideal for chain and belt drive applications. The series covers sizes 50 through 155, with gear ratios ranging from 10:1 to 60:1. It serves as a direct replacement for SEW-Eurodrive WS-D, Bonfiglioli VF-DS, and Motovario TS-flange units.

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Description

When a motorised worm gearbox must simultaneously accept a direct-flanged IEC motor at the input and sustain substantial chain, belt, or sprocket radial loads at the output — a combination that neither the WPDA nor the WPS alone satisfies — the DS Series (WPDS) worm gear reducer is the purpose-built solution. The WPDS combines the IEC B5 motor-mounting flange of the WPDA with the extended output shaft geometry and reinforced bearing arrangement of the WPS, delivering both benefits in one housing. Covering sizes 50 through 155, input powers from 0.18 kW to 5.5 kW, and standard gear ratios from 10:1 to 60:1, the WPDS provides a rated overhung load capacity approximately 30–40% higher than the standard WPDA at equivalent frame size — making it the specification of choice for chain conveyor drives, sprocket-loaded auger drives, and gear-pinion output drives in Australian manufacturing, food processing, and material-handling applications across Sydney, Melbourne, Brisbane, Adelaide, and Perth. Designed per AGMA 6034, manufactured to ISO 9001:2015, and supplied with free engineering support from Ever-Power Worm Gear Reducer Co., Ltd. (Australia), 27 Harley Crescent, Condell Park NSW 2200.

DS Series WPDS flange mount worm gear reducer high overhung load — Ever-Power Australia

Key Specifications & Parameters — DS Series (WPDS) Worm Gear Reducer

All parameters per ISO 9001:2015, AGMA 6034, and IEC 60034-7 motor flange dimensional standards.

Size Input Power (kW) Ratio Range Centre Dist. A (mm) Length B (mm) Height H (mm) IEC Flange LA (mm) Output LS (mm) Weight (kg)
50 0.18 10:1 – 60:1 165 175 180 115 40 7
60 0.37 10:1 – 60:1 185 190 205 130 50 11
70 0.55 10:1 – 60:1 215 215 240 145 60 16
80 0.75 10:1 – 60:1 250 240 280 160 65 25
100 1.5 10:1 – 60:1 310 255 363 165 75 40
120 3.0 10:1 – 60:1 370 305 435 200 85 68
135 4.0 10:1 – 60:1 415 345 490 225 95 88
155 5.5 10:1 – 60:1 442 402 536 265 110 122

What Is the DS Series (WPDS) and How Does It Differ from WPDA and WPS?

WPDS worm gear reducer output shaft heavy section and IEC flange input detail
WPDS flange mount worm gearbox with motor mounted

To understand the WPDS, it helps to think of it as the intersection of the WPDA and the WPS in a Venn diagram of WP configurations:

  • From the WPDA: The IEC B5 motor-mounting flange machined concentrically into the input housing face — no coupling, no alignment, no motor base.
  • From the WPS: The larger output shaft diameter, extended bearing span, and higher overhung radial load capacity at each frame size compared with the WPA/WPDA output shaft geometry.

This combination is specifically required when a chain-sprocket or belt-pulley output load would exceed the WPDA output bearing rating — a common situation in Australian chain conveyor drives above 0.75 kW and screw auger drives above 1.1 kW where belt or chain tensile forces are significant. At WPDS size 100, the rated mid-shaft overhung load is approximately 3,200 N — compared with approximately 2,400 N for the WPDA at the same frame size, a 33% improvement that is the difference between bearing failure at 8,000 hours and reliable operation beyond 20,000 hours in chain-drive service.

The WPDS also inherits the foot-mount base of the WPS family, giving the gearbox stable four-point floor mounting even with the motor cantilevered on the input flange. For IEC motors above 90 frame size, an additional motor support bracket is recommended to prevent resonant vibration at the motor flange under heavy motor weight — this bracket is available as a stocked accessory from Ever-Power.

WPS vs WPDA vs WPDS — Three-Way Comparison for Australian Engineers

Feature WPS WPDA WPDS
Motor input Coupling (shaft input) IEC B5 flange (direct) IEC B5 flange (direct)
Output shaft section Extended (WPS-type) Standard (WPA-type) Extended (WPS-type)
Overhung load (size 100) ~3,200 N ~2,400 N ~3,200 N
Alignment requirement Yes (dial gauge) None None
Best application Heavy torque, non-IEC motor IEC motor, light overhung load IEC motor + high overhung load

How to Select the WPDS — Overhung Load Calculation and IEC Flange Matching

  1. Calculate Overhung Load: F_OH = (2 × T_output) / D_sprocket (N). For a WPDS 100 at 30:1 driving a 200 mm PCD chain sprocket from a 1.5 kW motor: T_output ≈ (1.5 × 9,550 / 48 rpm) × 0.85 efficiency ≈ 255 N·m; F_OH = (2 × 255) / 0.2 = 2,550 N. WPDS 100 rated overhung load of ~3,200 N — acceptable with service factor margin.
  2. Confirm IEC Motor Frame: Select your IEC motor frame size based on power and speed. Cross-reference against the WPDS flange acceptance table for your chosen frame size. If the motor frame is larger than the standard WPDS flange accepts, specify the next larger WPDS frame size or request a custom adaptor ring from Ever-Power.
  3. Apply Service Factor: Use SF 1.25 (smooth loads), SF 1.5 (moderate shock), SF 2.0 (heavy shock). For chain conveyors in Australian mining or grain handling, SF 1.5 is typically appropriate. Multiply the design torque by the service factor and confirm the WPDS frame’s rated output torque is adequate.
  4. Check Thermal Rating: For Queensland and Western Australian summer conditions, derate the thermal power limit by 10% per 10 °C above the 20 °C reference. If marginal, specify synthetic ISO VG 220 lubricant.

Accessories We Also Supply: Motor support brackets (for 112+ frame motors), IEC adaptor rings (for non-standard motor frames), finished-bore sprockets and hubs, output shaft seals (NBR and Viton), and foot-mount shim packs. Contact Ever-Power Australia for bundled pricing.

WPDS Applications in Australian Chain-Drive and Conveyor Systems

The WPDS is specifically valued in Australian industrial applications where both direct motor mounting and significant output shaft radial loading must be accommodated in a single unit:

  • Chain Conveyor Drives (Sydney, Melbourne, Brisbane): Light-to-medium duty chain conveyors where the drive sprocket on the gearbox output shaft creates a chain-tension radial force that exceeds the WPDA output bearing rating. The WPDS handles these loads at ratios 15:1–40:1 within the 0.37–3.0 kW power range, eliminating the need to step up to a larger WPDA frame just to accommodate the bearing load.
  • Screw Auger Drives (QLD, SA): Grain handling, fertiliser, and cement screw auger drives in rural and industrial Queensland and South Australia where the auger shaft reaction creates significant radial loading on the gearbox output stub. The WPDS 100 and 120 at 20:1–30:1 with 1.5–3.0 kW motors are the standard specification for this application.
  • Packaging Line Drives (Sydney, Melbourne): Label applicator rolls, date-coding stamp drives, and bottle-capping torque-head drives where a compact motorised unit with sprocket output is needed. The WPDS form factor — motor flanged directly to the reducer — occupies significantly less axial space than an equivalent WPS with separate motor and coupling.
  • Roller Table Drives (Perth, Adelaide): Powered roller conveyors and roller-hearth furnace tables in metal processing and ceramics plants, where V-belt pulley outputs on gearbox stubs create sustained overhung loads during continuous production runs. The WPDS extended output shaft supports these loads without requiring an external pillow-block bearing arrangement.
WPDS worm gear reducer chain drive conveyor and auger applications Australia
DS Series WPDS worm gear reducer product range all sizes

What Australian Customers Say About the DS Series (WPDS)

★★★★★

“We had constant WPDA output bearing failures on our Brisbane chain conveyor line — the sprocket overhung load was just beyond the WPDA rating. Switched to WPDS 100 at 30:1 and the issue disappeared entirely. 18 months in with zero bearing failures. The Ever-Power engineering team identified the problem before we even ordered.”

— Trevor M., Maintenance Supervisor, Brisbane QLD

★★★★★

“Specified WPDS 80 with 0.75 kW 80B5 motor for our Melbourne packaging line roller drives. The direct flange mount saves about 200 mm of machine length per drive — on an 8-station line that adds up to significant space. Running 12 months without issue and noise levels are excellent.”

— Fiona P., Machine Design Engineer, Melbourne VIC

★★★★☆

“WPDS 120 on our Adelaide grain auger drives with 3 kW motors. The extended shaft handles our sprocket loads with room to spare. Delivery was 9 days to Adelaide — good timing for our project. One point less than 5 stars because the motor support bracket is sold separately — would be convenient to have it included for larger motors.”

— Chris W., Operations Engineer, Adelaide SA

★★★★★

“We OEM WPDS units into our roller table drives for the ceramics industry in WA. The combination of direct motor mount and high overhung load rating is exactly what we need — single unit instead of gearbox plus coupling plus motor base. Ever-Power supply has been consistent and the IEC flange dimensions are spot on every batch.”

— Ian K., OEM Design Manager, Perth WA

Why Choose Ever-Power for WPDS Worm Gear Reducers in Australia?

Ever-Power Worm Gear Reducer Co., Ltd. (Australia), 27 Harley Crescent, Condell Park NSW 2200, provides WPDS units in standard and custom configurations with 5–10 business day dispatch from Sydney to all Australian states. Our engineering team offers free overhung load calculation and IEC flange compatibility confirmation before you commit to an order — reducing the risk of incorrect specification. Visit our About Us page for details on our capabilities and our technical resource site at worm-gearbox.top.

Frequently Asked Questions — DS Series (WPDS) Worm Gear Reducer

1. How do I know if I need WPDS instead of WPDA for my chain-drive application?+
Calculate your overhung load: F_OH = (2 × output torque in N·m) / (sprocket PCD in metres). Compare this with the WPDA rated overhung load at the mid-shaft reference point for your chosen frame size. If F_OH exceeds 85% of the WPDA rated value, specify WPDS. If F_OH is below 70% of the WPDA rated value, the WPDA is sufficient. The WPDS costs approximately 5–10% more than the WPDA at the same frame size — a small premium for significantly improved bearing life under heavy overhung loads. Contact Ever-Power’s engineering team with your sprocket PCD, output torque, and service factor for a free written calculation and recommendation.
2. Can the WPDS output shaft be extended further with a stub shaft adaptor for offset mounting?+
Yes — the WPDS output shaft can be extended using a solid stub shaft adaptor machined to connect to the standard keyway on the WPDS output shaft stub. For long extensions (more than twice the standard shaft protrusion length), add an external pillow-block bearing at the far end of the extended shaft to prevent excessive bending moment at the gearbox output bearing. Note that the overhung load rating applies at the standard mid-shaft reference point — when the sprocket or pulley is mounted at a different axial position, scale the load limit proportionally (closer to the housing = higher allowable load; further from housing = lower allowable load). Ever-Power stocks standard stub shaft adaptors for all WPDS frame sizes.
3. Is the WPDS compatible with brake motors for gravity-loaded chain conveyor drives?+
Yes — the IEC B5 flange on the WPDS accepts brake motors using the same dimensional standards as standard induction motors, since brake motors retain the same IEC B5 flange geometry. The WPDS’s self-locking at ratios 20:1 and above provides inherent static load holding, but for gravity-loaded conveyors a power-off brake motor is still recommended for safety compliance per AS 4024. The brake motor’s weight and the additional axial force from the brake solenoid at engagement are both within the WPDS input flange design limits at standard IEC motor frame sizes up to 132.
4. What is the typical service life for the WPDS output bearing under rated chain drive loading?+
Under rated overhung load applied at the standard mid-shaft reference point, with ISO VG 220 mineral oil changed at 2,500-hour intervals, the WPDS output bearing L10 life (basic rated life at 90% survival probability) is approximately 20,000 hours per the AGMA 6034 design calculations. In practical Australian chain conveyor service at 70–80% of rated overhung load, actual bearing life typically exceeds 25,000 hours before replacement is needed. Using synthetic ISO VG 220 oil improves bearing life by approximately 15–20% due to better film formation at the bearing-race interface. At overhung loads exceeding 90% of rated, bearing L10 life drops significantly — always apply a service factor of at least 1.25 to the calculated overhung force before comparing with the rated value.
5. Does the WPDS come with a motor support bracket as standard?+
A motor support bracket is not included as standard with the WPDS. For motor frame sizes 63–90, the motor weight (typically 5–18 kg) is fully supported by the IEC flange engagement alone — no additional support is required. For motor frame sizes 100–132 (motor weight 20–55 kg), a motor support bracket is strongly recommended to prevent resonant vibration at the flange under motor weight and torque reaction forces. The bracket is available as a stocked accessory item from Ever-Power in four versions matching WPDS sizes 80–155. Specify “motor support bracket” at time of order and include your motor IEC frame size.
6. What Australian Standards apply to WPDS chain conveyor drives?+
For Australian chain conveyor applications, relevant standards include: AS 4024.1 (machinery safeguarding) — requires guarding of the chain-sprocket drive and output shaft; AS/NZS 3000 (electrical installation) — applies to motor connection and VFD wiring; AS 1418 (crane and hoist standards) — applies if the WPDS drives a hoist or lifting mechanism; and AS 1397 (chain standards) — for matching chain specification to sprocket. The WPDS gearbox itself is not subject to a direct Australian Standard, but its rated torque and overhung load calculations per AGMA 6034 are the recognised international design standard for worm gear drives, referenced in machine design documentation for AS compliance purposes.

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