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Twin-Shaft Mixer Gearbox
Heavy-duty helical/bevel-helical reduction and synchronising gearbox driving both shafts of the AVL-CBP twin-shaft concrete mixer.
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At a glance
| Gear type | Helical / bevel-helical multi-stage with synchronising pair |
|---|---|
| Gear material | 20CrMnTi or 42CrMo4, HRC 58–62 case-hardened, ground |
| Housing material | Nodular cast iron GGG50 |
| Output shaft speed | 18–30 rpm — model specific |
| Gear accuracy class | ISO 6 or better (ground tooth flanks) |
| Oil capacity | 3–12 litres — model specific |
| Lubrication system | Splash standard; forced-lubrication option |
| Motor interface | Foot- or flange-mount, IEC standard frame |
Overview
The Twin-Shaft Mixer Gearbox is a purpose-engineered drive unit mounted externally on the end wall of the AVL-CBP mixer trough. It accepts input from one or two electric drive motors and delivers equal, synchronised torque to both mixer shafts through two or three stages of helical or bevel-helical gearing. A synchronising gear stage (often a spur or helical timing gear pair) locks both output shafts to a precise speed ratio — typically 1:1 — to prevent arm-to-arm collision inside the trough.
The gearbox is the single highest-value mechanical component in the mixing unit and its condition directly governs shaft synchronisation, energy efficiency, and the plant's ability to process zero-slump and stiff concrete mixes without overload.
Function
Shaft speed synchronisation within ±0.5 rpm is mandatory to prevent the counter-rotating arms from colliding inside the trough — an event that causes catastrophic structural damage to arms, shafts, and the trough itself. The gearbox must sustain rated output torque across a duty cycle of thousands of batches per month with minimal oil temperature rise, maintaining full gear-flank film thickness on stiff or high-aggregate-volume mixes. Gearbox oil condition directly determines bearing and gear life; oil analysis and scheduled oil changes are the primary predictive maintenance activities on this assembly.
Construction & quality
Housings are nodular cast iron (GGG50) or fabricated structural steel, precision-bored and aligned on CNC machining centres. Gear stages are hobbed from alloy steel (20CrMnTi or 42CrMo4), case-carburised or induction-hardened to HRC 58–62 on tooth flanks, and profile-ground to ISO 6 or better accuracy class. Output and synchronising shafts are precision-turned, keyway-broached, and dynamically balanced. Bearings are heavy-series spherical roller units from established Tier 1 suppliers. Splash lubrication with an oil-level sight-glass and magnetic drain plug is standard; forced-lubrication with a gear pump and oil cooler is available for high-cycle or tropical-climate installations. External surfaces are painted with chemical-resistant epoxy.
When to replace
- Gearbox oil temperature exceeding 80 °C at rated load during normal operation
- Metallic particles found in oil sample during scheduled oil change
- Audible gear whine, periodic impact noise, or vibration at constant mixer load
- Oil leakage at output shaft seals or housing joint faces
- PLC shaft synchronisation fault alarm or unequal arm torque indication
Compatibility & fitment
Avelta supplies matched drive gearboxes for AVL-CBP 750, 1000, 1500, 2000, and 3000 series mixers; dimensional-equivalent replacement units for third-party twin-shaft mixers can be engineered and tested to the customer's torque and centre-distance drawings.
Why buy from Avelta
Avelta manufactures or sources mixer gearboxes to the same torque ratings and shaft-centre geometry as the original OEM specification, supplying each unit with a test certificate and oil charge — enabling a bolt-on swap with minimal downtime and no requirement for on-site alignment shimming.
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