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YCLZ Rear-Mounted Speed-Increasing Hydraulic Gearbox: Installed between the engine and the working unit to ensure smooth power transmission.

Release time:

2025-11-21 15:14

Source:

Zhongxing

YCLZ Rear-Mounted Speed-Increasing Hydraulic Gearbox Technical Specification

The YCLZ rear-mounted speed-increasing hydraulic gearbox is a specialized power-transmission hydraulic component designed specifically for the construction machinery industry. Installed between the engine and the working mechanism, its core function is to efficiently transmit power. It features the ability to start the engine under no-load conditions, and under constant engine-speed operation, it can smoothly adjust the working mechanism’s speed continuously—from zero up to its rated speed (encompassing torque, speed, and power parameters)—perfectly meeting the demands of varying operating conditions.

I. The Core Advantages of Hydrodynamic Flexible Transmission

Enhance starting performance and energy efficiency : It significantly enhances the engine's starting capability, enabling smooth startup while fully leveraging the engine's maximum torque and efficient operating range. This allows electric motors and diesel engines to effortlessly handle both light and heavy-load starts, effectively reducing unnecessary equipment configurations and boosting overall energy efficiency.
Easy to maintain and long-lasting : The product requires no special maintenance during long-term operation, as it employs a frictionless torque transmission method, ensuring a service life of over 10 years and significantly reducing equipment operation and maintenance costs.
Wide-range stepless adjustment : The stepless adjustment range covers 0 to 98.5%, allowing precise adaptation to actual operating conditions and enabling dynamic parameter adjustments.
Excellent vibration and shock resistance performance : The rated hydraulic damping value ranges from 1.5% to 3% (based on slip), effectively enhancing the torsional stiffness of the shaft system while imparting a flexible characteristic to the transmission system. It can efficiently absorb and isolate torsional vibrations, as well as mitigate impact loads, providing robust protection for the engine, gears, and driven machinery. This helps reduce the risk of damage caused by shock overloads, ultimately extending the overall service life of the equipment and improving operational reliability.

II. Scope of Application

This gearbox is particularly well-suited for diesel engine- and electric motor-driven centrifugal machinery, with typical applications including centrifugal pumps, fans, compressors, and other equipment that require frequent operation under varying conditions.

III. Structural Composition and Operating Principle

(1) Explanation of Specification Code Meanings

Taking "500YCLZ400-1:1.6" as an example, the meanings of each part are as follows:
500: Effective Diameter of the Working Chamber Circulation Circle
YCL: Hydrodynamic Gear (Core Type Identifier)
Z: Growth-oriented (Functional Type Identifier)
400: Transmission Power
1:1.6: Rotational Speed Ratio

(II) Core Structural Features

The YCLZ rear-mounted speed-increasing hydraulic gearbox consists of three core modules: the hydraulic gear transmission mechanism, the oil supply and heat exchange system, and the electrical control system—each working in harmony to ensure stable equipment operation.

1. Hydrodynamic Gear Transmission Mechanism

This assembly consists of a housing, a hydrodynamic transmission component, a gear assembly, and internal pipelines—it serves as the core carrier for power transmission, with each component designed to balance both strength and precision requirements.
Box body : Featuring a split-type welded structure with thick plates and excellent rigidity, both the upper and lower housing units are equipped with lifting holes for easy installation and maintenance. The material is high-quality carbon structural steel, which undergoes two-stage aging treatments to relieve internal stresses, ensuring dimensional stability. The weld surfaces are smooth and flawless, free from defects such as cracks, weld beads, or slag inclusions. Additionally, the exposed joint edges are neatly aligned and uniformly finished, with misalignment kept within 1 mm. Before leaving the factory, each housing unit must pass a leak-test; the robust sealing design of the mating surfaces guarantees long-term, oil-free operation. Precision machining is carried out using a high-accuracy boring machine, achieving bore accuracy no lower than Grade 5, thereby providing stable support for the smooth operation of the transmission components.
Gear (shaft) : The material is high-quality, low-carbon alloy steel forging, manufactured under MQ-level quality control standards. The tooth surfaces undergo carburizing and quenching treatment, achieving a hardness of HRC58–62. Additionally, the gears are precision-ground using a hardened-tooth surface process, ensuring accuracy at Grade 5 for stable bidirectional operation—both forward and reverse rotations. All gears feature optimized tooth profile modifications at both the tooth flank and tooth tip, effectively reducing meshing impact noise. Furthermore, the shaft system undergoes rigorous dynamic balancing control: standard gear shafts adhere to GB G1.6 grade, while high-speed gear shafts are upgraded to GB G1.0 grade, guaranteeing smooth performance even at elevated speeds.
Transmission and Lubrication : The hydrodynamic transmission components achieve flexible power transmission through working oil, while the gear assembly handles the speed-increasing function. The shaft system is supported by either fixed hydrostatic sliding bearings or high-precision imported rolling bearings, ensuring stable high-speed rotation. The lubrication system employs pressurized oil lubrication, with each lubrication point equipped with an independent oil spray nozzle—providing precise oil supply to both the meshing-in and meshing-out sides of the gear engagement. Additionally, all welded pipelines undergo acid pickling and phosphating treatment, offering exceptional corrosion resistance and guaranteeing reliable lubrication performance.
Sealing and Monitoring : Featuring a non-contact sealing design, the front oil-blocking ring effectively prevents most of the lubricating oil from flowing back into the housing, while the three-stage comb-tooth seal design ensures balanced air pressure between the inside and outside of the gearbox, delivering exceptional sealing performance. In terms of temperature monitoring, each bearing is equipped with either a pre-embedded or insert-type PT100 temperature sensor, keeping bearing temperatures below 85°C during normal operation. Additionally, shell or shaft vibration sensors can be optionally configured based on user requirements. All sensor cables are neatly routed and centrally housed in a dedicated junction box, making maintenance and inspection convenient and efficient.

2. Fuel Supply and Heat Exchange System

The system's working oil level is precisely controlled by an electric actuator. Circulating working oil is supplied via a thin-oil station, and when combined with a highly efficient heat-exchange device, it effectively removes the heat generated during operation, ensuring that the working oil temperature remains stably within a reasonable range.

3. Electrical Control System

Designed with a flexible control mode, it can be configured with either remote or local control functionality based on the user’s specific application needs, offering convenient operation and seamless adaptation to varying levels of automation requirements.

(III) Hydraulics Operating Principle

1. Principle of Power Transmission

The power transmission process works as follows: The pump impeller receives energy from the prime mover (engine or electric motor), converting mechanical energy into hydraulic energy to drive the working fluid at high speed. This high-speed fluid then pushes the turbine to rotate, restoring the hydraulic energy back into mechanical energy and transferring it to the working machine. Through the continuous circulation of the working fluid, a flexible power transfer between the prime mover and the working machine is achieved. During this process, the flexible coupling between the pump impeller and the turbine generates a hydrodynamic damping effect equivalent to 1.5% to 3% of the rated power. This damping effectively absorbs fluctuations in dynamic loads by converting them into thermal energy. Subsequently, heat is efficiently dissipated via the circulating working fluid inside and outside the working chamber, ensuring stable system temperatures.

2. Stepless Adjustment Principle

By adjusting the working oil fill volume within the working chamber via an electric actuator, the chamber is brought into a specific fill state, enabling seamless switching among the three core parameters—torque, speed, and power—to precisely meet the operational demands of various conditions.

IV. Main Technical Parameters

Specification Model
Rated Transmission Power (kW)
Rated Input Speed (RPM)
Rated Output Speed (RPM)
Rated Maximum Efficiency (%)
500YCLZ
670–1640
3000
≤13000
≥95
560YCLZ
1180~2885
3000
≤13000
≥95
580YCLZ
1200~3440
3000
≤11000
≥95
620YCLZ
1675~4780
3000
≤11000
≥95
650YCLZ
2500–5850
3000
≤9000
≥95
680YCLZ
2800 to 7150
3000
≤9000
≥95
720YCLZ
3450–9100
3000
≤8000
≥95
760YCLZ
4550 to 12,000
3000
≤8000
≥95
800YCLZ
5650 to 15,200
3000
≤8000
≥95

V. Simplified Structural Diagram (Using 620YCLZ as an Example)

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