Agricultural Stalk Shredders Gearbox For Flail Mowers
Product Description
The Role of the Gearbox in a Straw Chopper/Flare Mower
Speed Boost/Optimization: While some agricultural gearboxes reduce speed, many flare mower gearboxes are designed to maintain or slightly increase the speed of the power take-off (PTO) to achieve the very high speeds required for the flails (hammers or blades) to effectively cut and shred tough plant material. Proper rotor speed is critical for efficient shredding and mulching.
Torque Transmission: Shredding heavy straw requires a lot of torque. The gearbox efficiently transmits this high torque from the power take-off (PTO) to the flare rotors, enabling them to powerfully impact and shred dense vegetation.
Right-Angle Power Transmission: Flail mowers typically have horizontal rotors that rotate perpendicular to the direction of travel of the tractor. The gearbox uses right-angle drive (usually using helical bevel gears) to redirect the direction of power from the tractor's longitudinal power take-off (PTO) to the mower's transverse rotor shaft.
Load Management and Protection: Gearboxes must withstand constant heavy loads, sudden shocks when the flails hit hard material or obstacles, and vibrations generated during the chopping process. Gearboxes are designed to absorb these stresses, protecting the tractor's PTO and the flail mower's rotor from damage.
Safety Device Integration: Many gearboxes have an integrated flywheel clutch (also known as an overrunning clutch). This critical safety feature allows the flail mower's heavy rotor to continue to decelerate naturally after the tractor's PTO is disengaged, preventing the rotor's inertia from back-driving and potentially damaging the tractor's PTO drivetrain.
Reliability in Harsh Environments: Chopping straw is a very dirty and demanding job. The gearbox's rugged, sealed design protects against dust, dirt, moisture and crop residue, ensuring reliable operation even in harsh field conditions.
Benefits of This Gearbox
Optimized Chopping Performance: By delivering precise speed and torque to the flail rotor, the gearbox ensures that the flail mower effectively shreds tough crop residue into fine, easily disintegrated mulch. This promotes faster recycling of nutrients back into the soil and creates a cleaner seedbed for the next crop.
High durability and long life: These gearboxes are designed to withstand the extreme forces and wear conditions created during the straw shredding process. Features such as a rugged housing (typically cast iron), high-strength alloy steel gears (carburized, hardened and ground), heavy-duty bearings and effective seals help extend service life and reduce downtime.
Increased safety: An integrated flywheel clutch is a major safety benefit that protects the tractor's power take-off (PTO) from damage by the mower's inertia and allows the rotor to coast safely.
Versatility in residue management: The gearbox enables the mower to handle a variety of crop residues (corn, cotton, wheat, sunflower, etc.) and other tough vegetation, making it a versatile tool for different farming practices.
Improved soil health: By effectively shredding and spreading residue, the gearbox promotes faster decomposition and nutrient return, and helps control erosion, which indirectly improves soil health.
Reduced Wear on Equipment (to Other Components): A well-matched and robust gearbox ensures smooth power transmission, reducing undue stress and wear on the mower rotor bearings and tractor PTO shaft.
Efficient Field Preparation: Being able to shred straw quickly and thoroughly means fields can be prepared for the next planting season more quickly, saving farmers valuable time and energy.
GEAR MATERIALS
20CrMnTi/20CrMnMo for your choice
CASTINGS MATERIALS
Gray cast iron HT250 according to standard GB/T 1348-2009 Ductile iron QT450-10 according to standard GB/T 1348-2009 Cast steel ZG310-570 according to standard GB/T 5613-2014
SHAFTS MATERIALS
40Cr,45#,20CrMnTi,20CrMnMo for your choice according to your request.
POWER To ensure the correct use of the product we recommand to pay attention to the specifications mentioned on our technical sheet.Consider also the input rotation speed,the power input and the transmission ratios.Where the rotation or other working conditions are different,please contact LongQuan technical department.
LUBRICATION
The reducer is usually supplied without lubricant.The recommended quantity of lubricant is indicated on our catalogue and the first replaced must be done after 50-60 hours of running,then replaced after 600-800 working hours. The emptying of the gearbox should be made immediately after the working,with the oil still hot,in order to avoid the deposition of sludge.Check frequently the oil level and top up the oil whenever necessary.
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