When Should You Choose a Right-Angle Bevel-Helical Gearbox for a Medium Cone Crusher?

This guide is for informational purposes only. Always consult a qualified engineer for final selection.

“We need a right-angle drive for our cone crusher because space is tight, but do we really need a heavy-duty gearbox for a medium crusher?”

The answer depends on three factors that show up together in every medium cone crusher application:

1. Space constraints – cone crushers are often installed in existing plant layouts where motor placement is limited; a right angle gearbox like the B series allows the motor to mount perpendicular to the crusher shaft

2. Starting torque and shock loads – medium cone crushers experience high starting torque and occasional tramp metal events; gears must withstand impact without failure

3. Torque requirement within 290 kN·m – medium crushers do not need the largest gearboxes, but reliability under continuous duty is non-negotiable

The B series bevel-helical gearbox is a standalone right-angle product line designed exactly for this duty. It delivers right-angle output in a compact package, features hardened ground gears for shock resistance, and covers torque up to 290 kN·m — making it the right choice for medium cone crushers where a larger H series would be overkill.

At a Glance: B Series for Medium Cone Crushers

A bevel helical speed reducer like B series offers the right combination of compact footprint, shock resistance, and torque capacity for medium cone crusher applications.

Why Right-Angle Matters for Cone Crushers

Cone crushers are typically driven by a motor mounted alongside or above the crusher frame. In many medium-sized installations — particularly in retrofits or space-constrained plants — the available floor space does not allow for a long, inline motor-gearbox-crusher arrangement.

A parallel-shaft gearbox pushes the motor outward along the same axis, requiring more floor space and often interfering with access platforms or other equipment. Choose a right angle gear reducer when space constraints prevent

parallel shaft mounting. A right-angle bevel-helical gearbox like the B series right-angle bevel-helical gearbox solves this by turning the power flow 90°. The motor mounts perpendicular to the crusher shaft, keeping the overall

footprint compact._{[1] DBY/DCY vs K/F Series: Which Right Angle Gearbox Fits Your Port or Power Plant Belt Conveyor?}

For a medium cone crusher, this means:

● Reduced drive footprint in tight plant layouts

● Motor positioned for easier maintenance access

● Simpler belt or coupling alignment

Why Medium Cone Crushers Need Hardened Gears

Medium cone crushers are not light-duty machines. They process aggregates, ores, and minerals at throughputs of 50–300 tonnes per hour, with feed sizes that can include occasional tramp metal or oversize rock.

The impact on the gearbox:

● High starting torque – cone crushers often start under load, creating torque spikes that standard gears cannot absorb

● Shock loads from tramp metal – uncrushable objects pass through the crushing chamber, transmitting impact forces directly to the gear train

● Continuous operation – quarries and mines run 24/7; gearboxes must withstand constant duty without premature wear

The B series addresses these with case-hardened and precision-ground gears. Hardened gears resist tooth surface fatigue from shock loads, while precision grinding ensures smooth meshing and reduced noise. For medium cone crusher applications, apply the appropriate service factor from the B series selection tables based on load classification and operating hours.

B Series – Key Features for Medium Cone Crushers

Right-angle bevel-helical configuration

The B series uses a bevel gear input stage to change power direction by 90°, followed by helical stages for torque multiplication. As a bevel gear reducer, the B series delivers high torque density in a compact right-angle package — ideal for space-constrained crusher installations. This industrial bevel helical gearbox is engineered for the shock loads and continuous duty of medium crusher applications.

Hardened and precision-ground gearing

Gears are case-hardened and precision-ground, ensuring resistance to pitting and tooth fatigue under shock loads. This is the single most important feature for cone crusher duty, where starting torque spikes and tramp metal events are routine.

Multiple stage configurations

The B series gearbox is available in:

◆ B3 – 3-stage, ratios 20–90

◆ B4 – 4-stage, ratios 80–355

Both configurations share the same rugged cast iron housing and modular design, allowing for flexible installation.

Thermal capacity for continuous duty

Medium cone crushers run continuously during production shifts. The B series is designed with thermal capacity ratings that match continuous quarry and mine duty cycles. For demanding applications, forced lubrication and cooling options are available.

Selection Steps for Medium Cone Crusher Drives

First, determine the required output torque at the crusher input shaft. For medium cone crushers, torque typically falls within the B series range of up to 290 kN·m. This is the key differentiator from larger crushers that would require H

series for higher torque requirements. _{[2] When F Series Torque Is Not Enough — Choosing Between ZY and H/B Series for Large Crushers}

Next, determine the required reduction ratio from motor speed to crusher input speed. Verify that the required ratio falls within the B series range of 20–355. For cone crusher applications, this typically corresponds to output speeds below 75 rpm (at 1,500 rpm input) before any additional belt reduction.

Then, select the appropriate stage configuration:

◆ Ratios 20–90 → B3 (3-stage)

◆ Ratios 80–355 → B4 (4-stage)

A right angle helical gearbox such as B series is designed for crusher duty, with hardened gears and service factor ratings that match the demanding conditions of medium cone crusher applications.

Next, apply the appropriate service factor. For medium cone crushers with heavy shock loads and 24-hour continuous duty, apply the service factor from the B series selection tables. Confirm that the selected B series frame meets or exceeds your power requirement with this service factor applied.

Finally, verify thermal capacity. For crushers operating in hot climates, confirm that the gearbox thermal rating meets your continuous duty requirement. Forced lubrication may be recommended — contact our technical team to verify against your specific operating conditions.

Common Mistakes to Avoid

The right approach is straightforward: Choose B series for medium cone crushers with torque up to 290 kN·m. Specify right-angle configuration to save floor space where space is tight. Select case-hardened, precision-ground gears that resist tooth surface fatigue from tramp metal events. Apply the appropriate service factor from the B series selection tables for heavy shock duty — don't underestimate the starting torque of a cone crusher under load.

📍 Case Studies

Case Study: Medium Cone Crusher – South America

Customer: Copper mine in Peru

Challenge: A medium cone crusher in a retrofit installation required a right-angle drive with limited floor space. The existing parallel-shaft gearbox extended too far into the access aisle. Torque requirement was 180 kN·m with

                   frequent tramp metal events.

Solution: HelmeDrive supplied a B series right-angle bevel-helical gearbox (B3 configuration) with hardened precision-ground gears and the appropriate service factor from the B series selection tables.

✅ Result: Drive footprint reduced by 40%. No gear failures in 18 months. The mine standardized B series for all medium cone crusher retrofits.

Case Study: Aggregate Cone Crusher – Turkey

Customer: Limestone quarry in Turkey

Challenge: A 200 t/h cone crusher needed a reliable right-angle drive in a space-constrained crushing plant. The previous gearbox failed every 12 months from tooth fatigue. Ambient temperatures exceeded 40°C during summer.

Solution: HelmeDrive supplied a B series right-angle bevel-helical gearbox with forced lubrication.

✅ Result: Oil temperature stabilized within limits. No gear failures in 24 months. The quarry ordered B series units for two additional crushers.

How to Work with HelmeDrive

As a specialized bevel helical gearbox manufacturer, HelmeDrive engineers B series gearboxes specifically for crusher and mill applications.

→ Remote video support – installation guidance, alignment verification, and troubleshooting within your working hours

→ Crusher drive verification – send your crusher size, motor power, torque requirement, and duty cycle; we verify the appropriate B series configuration and service factor

→ Mounting drawings – horizontal, vertical, foot, and flange mounting configurations available

→ Lead time – standard configurations: 6–8 weeks; expedited options available

→ Service factor verification – we confirm the correct service factor from the B series selection tables for your heavy shock duty

Contact our technical team for HelmeDrive gearbox solutions tailored to your specific crusher application.

Why Mines and Quarries Choose HelmeDrive B Series

🔹 Right-angle output – saves floor space in tight plant layouts

🔹 Hardened precision-ground gears – resists shock loads from tramp metal

🔹 Torque up to 290 kN·m – covers the medium cone crusher range

🔹 Service factor verified – apply the correct factor from the B series selection tables for your duty

🔹 Multiple stage configurations – B3 (20–90), B4 (80–355)

🔹 High efficiency – reduces energy cost in continuous quarry operations

🔹 Proven in mining – widely used in crushers, conveyors, and mills

🔹 Temperature range – -10°C to +40°C

Get a B Series Selection Proposal for Your Cone Crusher

Send us:

● Crusher type and size (cone crusher, model, throughput)

● Motor power and speed

● Required output torque (or crusher operating speed)

● Available floor space and preferred motor orientation

● Site ambient temperature and altitude

● Duty cycle (hours per day, days per year)

📩 Sales inquiry: shawn.zhu@helmedrive.com

❓ FAQ

Q1: What torque range does the B series cover for cone crushers?
A: The B series covers torque up to 290 kN·m for medium cone crusher applications. For torque above this range, H series (up to 900 kN·m) is recommended.

Q2: Why choose B series instead of K series for a cone crusher?
A: K series is a gearmotor designed for lower torque applications like conveyors. B series is a heavy-duty industrial gearbox designed specifically for high-torque crusher and mill applications with shock loads.

Q3: What service factor applies to medium cone crushers?
A: Apply the service factor from the B series selection tables based on your specific load classification and operating hours. For heavy shock loads with 24-hour continuous duty, consult the tables for the correct value.

Q4: Can B series be mounted vertically?
A: Yes. The B series supports both horizontal and vertical mounting configurations.

Q5: How do I know if I need B3 or B4?
A: It depends on your required ratio. B3 for ratios 20–90, B4 for ratios 80–355.

📩 Contact our technical team for B series sizing, service factor verification, and mounting configuration selection for your cone crusher application.

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✦ HelmeDrive.com - Professional manufacturer of industrial gearbox in China ✦

^✦ Gear Motor | Gear Unit | Industrial Gearbox ^✦

🌐 Contact us for a comparison quote:

📩  shawn.zhu@helmedrive.com  

📞 WhatsApp:  [+86-13196785788]