WPS Series Single Standard Worm Gear Reducer

When Australian industrial drives demand more than the standard WPA can provide — larger frame sizes up to 250, a heavier output shaft section, higher overhung load ratings, and output torques reaching well beyond 1,000 N·m — the WPS Series worm gear reducer is the engineered answer. The WPS is the extended-capacity sibling in the WP worm reducer family, scaling from size 40 through to size 250 and delivering the torque density required for medium-to-heavy-duty Australian industrial applications: screw conveyors under sustained grain or cement loads, large agitated vessels in chemical processing plants in Perth and Adelaide, automated flood-gate drives in water treatment facilities, and heavy rotary-drum systems in Queensland mining operations. Input power spans from 0.4 kW (size 50) to 15 kW (size 250), gear ratios cover 10:1 to 60:1, and output shaft diameters scale from 40 mm (size 50) to 140 mm (size 250) — providing the shaft stiffness to carry belt, chain, and sprocket overhung loads that would overstress a WPA of the same frame size. 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.

Key Specifications & Parameters — WPS Series Worm Gear Reducer

Complete dimensional and performance data for all standard WPS frame sizes. All data referenced to ISO 9001:2015, AGMA 6034, and DIN 3975.

What Is the WPS Series and How Does It Differ from the WPA?

Both the WPA and WPS are single-standard foot-mount worm reducers in the WP family. The distinction lies in the output shaft section and bearing design. In the WPS, the output shaft diameter at each frame size is 10–15% larger than the equivalent WPA centre distance, and the output bearing span — the distance between the two output shaft support bearings — is proportionally wider. These two factors combine to increase the rated overhung radial load capacity at the mid-shaft reference point by approximately 30–40% compared with the WPA at the same frame size.

This difference matters significantly in chain and belt-drive applications. When a sprocket or pulley is mounted on the output shaft, the chain or belt tension creates a radial force — the overhung load — at the shaft. For a chain conveyor with a 300 mm pitch-circle-diameter sprocket transmitting 500 N·m of torque, the overhung load is approximately 3,330 N. At WPS size 100, this load is well within the rated capacity. At WPA size 100, the same load may exceed the bearing rating by 15–25%, leading to premature output bearing failure — the most common cause of early WP reducer removal in Australian heavy-duty chain-drive applications.

The WPS also extends the frame size range to 250 — well beyond the WPA’s maximum size 155 — delivering output torques up to approximately 15,000 N·m at 60:1 from the size 250, making it one of the highest-torque single-stage worm reducers available to Australian industry for flood-gate drives, heavy aggregate conveyor head drives, and large-diameter rotary drum systems in mineral processing.

Material specification follows the same WP family standard: 20CrMnTi worm shaft (carburised & quenched, HRC 56–62), ZCuSn10Pb1 tin-bronze worm wheel, 45# chromium steel output shaft in h6 tolerance per DIN 748, and GG25 grey cast-iron housing. All gear quality is produced to DIN 3975 Class 8 or better, referenced in the selection calculations against AGMA 6034 rated torque and thermal power methodology.

WPA vs WPS — Head-to-Head Comparison for Australian Buyers

How to Select and Install the WPS Series Worm Gear Reducer

Selection:

1. Calculate Design Torque with Service Factor: T_design = (Motor kW × 9,550 / Output rpm) × SF. Apply SF 1.25 for smooth loads (agitators, slow conveyors), SF 1.5 for moderate shock, SF 2.0 for heavy shock (stone crushers, impact feeders). Select the smallest WPS frame where rated torque ≥ T_design.
2. Calculate Overhung Load: F_OH = (2 × T_output) / D_sprocket (N). Compare with the WPS rated overhung load at the mid-shaft reference point for your frame size. If the overhung load exceeds the WPS rating, move to the next larger WPS frame or specify a hollow-shaft hollow-bore variant (WPWKT/PWDKO series) which provides a significantly higher effective overhung load capacity through the torque-arm mounting arrangement.
3. Verify Thermal Rating in Australian Summer: Confirm the thermal rated power from the WPS datasheet covers your motor kW at the local ambient temperature. For Queensland, WA, and NT operations where summer ambient exceeds 40 °C, derate the thermal power limit by 10% per 10 °C above the 20 °C reference temperature. Specify synthetic ISO VG 220 oil if the thermal margin is less than 15%.
4. Confirm Self-Locking: At ratios 20:1 and above, the WPS is self-locking under static loads. At 10:1 and 15:1, a supplementary brake is required for gravity-loaded applications per AS 4024.

Installation:

1. Foot-Mount Foundation: For WPS units size 120 and above (weight 63 kg+), pour a reinforced concrete base pad with a minimum 150 mm grout thickness. Allow 48 hours grout cure before tightening anchor bolts. Anchor bolt torque: M16 grade 8.8 = 180 N·m; M20 = 360 N·m.
2. Input Shaft Alignment: Align the motor shaft to the WPS input shaft to within 0.1 mm TIR using a dial gauge. Misalignment above this threshold causes premature input shaft seal and bearing wear — the most common root cause of early failure in foot-mount worm reducer installations across Australian industry.
3. Oil Fill: The WPS is dispatched without oil. Fill to the centre of the sight glass (for horizontal worm-below-wheel mounting) with ISO VG 220 mineral oil before first run. For size 135 and above, fill slowly through the top fill plug to avoid air locks. Initial fill volume is approximately 0.8 L (size 50) to 18 L (size 250) — confirm with the orientation-specific fill level diagram for your mounting position.
4. Run-In Procedure: Run unloaded for 30 minutes, at 50% load for 2 hours, then apply full rated load. Monitor housing surface temperature; expected stabilised temperature is 40–70 °C above ambient. Temperatures above 90 °C indicate thermal overload or incorrect lubrication — stop and investigate before continuing.

Accessories We Also Supply: IEC motor adaptor flanges (B5/B14), output shaft jaw and disc couplings, finished-bore sprockets, foot-mount shim packs, replacement oil seals (NBR and Viton), and replacement worm wheel and worm shaft matched sets. Contact Ever-Power Australia for pricing.

WPS Series Applications in Australian Heavy Industry

The WPS’s extended torque and overhung load capacity make it the preferred worm drive gearbox in Australian applications where the WPA cannot meet the load or where frame sizes above 155 are required:

• Screw Conveyors (Sydney, Brisbane, Melbourne): Bulk material screw conveyors carrying grain, cement, fly ash, and fertiliser in Australian industrial and agricultural facilities. At chain-sprocket outputs with sustained loads, the WPS size 100–135 provides the overhung load capacity that WPA units at the same frame size cannot sustain reliably over 15,000+ hours.
• Agitated Vessels & Reactor Drives (Perth, Adelaide): Large-diameter paddle agitators in chemical processing vessels and bioreactors, where the impeller shaft creates significant radial load on the gearbox output shaft during start-up and at maximum viscosity. WPS size 100–175 at 40:1–60:1 covers the majority of these applications.
• Flood Gate & Sluice Gate Drives (Brisbane, Perth, Melbourne): Water infrastructure gate drives in Australian irrigation districts, water treatment facilities, and dam outfall structures where reliable slow-speed drive, self-locking at 20:1+, and large torque output from a compact single-stage unit are all required. WPS 175–250 at 40:1–60:1 is the standard choice.
• Rotary Drum Systems (QLD Mining, WA Mineral Processing): Trommel screening drums, rotary kilns, and drum dryers in Queensland and WA mining operations. The WPS size 250 at 60:1 from a 15 kW motor input produces approximately 24 rpm output with rated torque approaching 15,000 N·m — sufficient for large-diameter trommels without requiring a secondary reduction stage.

International Compatibility & Sustainable Supply Chain

The WPS series follows IEC and AGMA dimensional standards that are used as the basis for foot-mount worm reducer dimensions across all major international brands. The WPS is the direct dimensional equivalent of: SEW-Eurodrive WS series, Bonfiglioli VF-S series, and Motovario TS series at common frame sizes. For Australian procurement managers maintaining multi-brand spares inventories, the WPS can replace any of these brands at standard frame sizes without base plate modification.

From a sustainability perspective, the WPS’s cast-iron housing contains approximately 25% post-industrial recycled iron content in the casting charge, consistent with Australian foundry industry practices. The bronze worm wheel alloy is fully recyclable at end of service life through copper recycler networks that operate in Sydney, Melbourne, and Brisbane. The ISO VG 220 synthetic lubricant option extends oil change intervals by 100% (2,500 to 5,000 hours), reducing lubricant consumption and disposal volume over the gearbox service life — contributing to the environmental management goals increasingly required by Australian manufacturers under their ISO 14001 environmental management system commitments.

What Australian Customers Say About the WPS Series

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

Ever-Power Worm Gear Reducer Co., Ltd. (Australia), 27 Harley Crescent, Condell Park NSW 2200, holds WPS stock across common frame sizes for fast 5–10 business day dispatch to all Australian states. We provide free overhung load calculations and confirmed interchange checks against SEW-Eurodrive WS, Bonfiglioli VF-S, and Motovario TS units before you order. Read about our full capabilities at About Us. Additional technical reference at worm-gearbox.top.

Frequently Asked Questions — WPS Series Worm Gear Reducer