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The BRC Series Helical Gearbox is a modular inline helical gear reducer built on a die-cast aluminum alloy housing with ground hardened helical gears. Four frame sizes (BRC01, BRC02, BRC03, BRC04) cover rated power from 0.12 kW to 4 kW, reduction ratios from 3.66:1 to 54:1, and output torque from 116 N.m to 491 N.m. Two-stage mechanical efficiency reaches 96%, and the hollow shaft input with IEC-normalized motor flange accepts standard IEC motors, brake motors, explosion-proof motors, inverter motors and servo motors without an adapter.
Every unit is produced in Raydafon's Ningbo factory under an ISO 9001 quality system, with ground helical gears that reduce vibration and noise compared to spur gears. OEM customization covers reduction ratio, input and output shaft dimensions, flange type, mounting position and port placement.
The BRC Series Helical Gearbox is an inline helical gear reducer that uses angled helical gear teeth to transmit power between parallel shafts at a reduced output speed and multiplied torque. Unlike a worm gearbox, which relies on sliding contact between a worm and a wheel, the BRC uses rolling contact between hardened helical gears. This is why two-stage efficiency reaches 96% while a typical worm gearbox loses 20% or more of its input power to heat and friction.
The die-cast aluminum alloy housing holds the gear train rigidly while keeping the overall unit light enough to mount directly on the driven machine. The hollow shaft input with IEC-normalized motor flange is the standard configuration: an IEC motor slides onto the input and bolts to the flange, eliminating the need for a separate coupling or adapter plate. This modular interface is what allows a single BRC housing to accept standard motors, brake motors, explosion-proof motors, inverter motors and servo motors from different manufacturers without changing the gearbox.
The table below lists the standard specifications for all four BRC Series frame sizes. For a replacement or OEM application, confirm the required output torque, reduction ratio and mounting interface against the machine drawing before ordering.
| Model | Output Torque | Rated Input Speed | Max Input Speed | Reduction Ratio | Rated Power |
|---|---|---|---|---|---|
| BRC01 | 116 N.m | ≤1500 rpm | 3000 rpm | 3.82 – 53.33 | 120 – 1500 W |
| BRC02 | 197 N.m | ≤1500 rpm | 3000 rpm | 3.66 – 54 | 180 – 1500 W |
| BRC03 | 300 N.m | ≤1500 rpm | 3000 rpm | 3.74 – 51.3 | 370 – 4000 W |
| BRC04 | 491 N.m | ≤1500 rpm | 3000 rpm | 3.74 – 51.3 | 750 – 4000 W |
| Parameter | Specification |
|---|---|
| Gearbox Type | Inline helical gear reducer, 2-stage |
| Housing Material | Die-cast aluminum alloy |
| Gear Material | Hardened helical gears, ground tooth flanks |
| Mechanical Efficiency | 96% (2-stage) |
| Mounting Positions | 6 spatial orientations, foot or flange mount |
| Input Configuration | Hollow shaft with IEC-normalized motor flange / solid shaft input |
| Output Configuration | Solid shaft with B5 output flange / solid shaft with B14 output flange |
| Compatible Motors | IEC standard motors, brake motors, explosion-proof motors, inverter motors, servo motors |
| Centre Distance Range | 80 mm – 200 mm (by frame size) |
| Input Shaft Diameter | 24 mm – 55 mm |
| Output Shaft Diameter | 40 mm – 90 mm |
| Customization | Ratio, bore, shaft, flange, mounting, port position |
| Certification | ISO 9001 |
Five design characteristics separate the BRC Series from a commodity helical reducer. Each one is measurable in field service.
Ground helical gears run on rolling contact rather than sliding contact. A worm gearbox of comparable torque typically loses 20-40% of input power as heat; the BRC loses approximately 4%. On a 2.2 kW continuous-duty conveyor drive running 6,000 hours per year, that difference equates to roughly 2,400 kWh of electricity saved annually.
The hollow shaft input is machined to IEC 60072 motor flange dimensions. An IEC motor mounts directly to the gearbox flange with the shaft engaging the hollow input. This removes the coupling, the alignment jig and the associated maintenance point. Where a specific non-IEC motor is used, a solid shaft input is available.
The BRC housing is symmetrical. The same unit can be mounted horizontally, vertically, or on the side by repositioning the oil fill, drain and breather plugs. For OEM machinery builders, this means one gearbox part number can serve multiple machine configurations, reducing spare parts inventory.
Helical gear teeth engage gradually rather than abruptly, which reduces the impact force at each tooth mesh. The ground tooth flanks reduce transmission error. The result is a gearbox that operates below 65 dB(A) at one metre under rated load — a measurable difference in packaging, textile and food processing lines where operators work alongside the machinery.
Die-cast aluminum alloy delivers the housing rigidity needed to hold gear centres under load at approximately one-third the weight of an equivalent cast iron housing. For machinery where the gearbox mounts on a moving arm or a cantilevered frame, the weight reduction directly reduces structural load on the machine.
Every BRC unit is assembled in Raydafon's Ningbo factory under an ISO 9001 quality system. Material certificates are retained against the production batch, and each unit receives a run-in test and leak check before packing. Traceability documentation is available with the shipment.
The BRC Series is specified wherever an inline helical reducer with IEC motor compatibility and moderate torque is required. The applications below are the ones most often quoted on a Raydafon BRC enquiry.
A common procurement question is whether to specify a helical gearbox or a worm gearbox for a given application. The comparison below uses the same rated output torque class for both types.
| Parameter | BRC Helical Gearbox | Worm Gearbox (comparable class) |
|---|---|---|
| Efficiency (2-stage) | 96% | 60-80% |
| Heat Generation | Low (4% loss) | High (20-40% loss) |
| Self-Locking | No — brake required for holding | Often self-locking at low ratio |
| Noise Level | Below 65 dB(A) at 1 m | Typically 60-70 dB(A) |
| Mounting Flexibility | 6 orientations from one housing | Limited by oil level position |
| Duty Cycle | Suitable for continuous duty | Thermal limit at high duty |
| Initial Cost | Higher | Lower |
| Energy Cost Over 5 Years | Lower (96% efficiency) | Higher (heat loss) |
To confirm the correct BRC Series model and issue a quotation, Raydafon needs the five items below. For a replacement unit, the original gearbox nameplate data or a dimensioned drawing is usually sufficient.
| # | Required Detail | Typical Format |
|---|---|---|
| 01 | Required output torque | N.m or kg.m, with safety factor if known |
| 02 | Reduction ratio or output speed | e.g., 20:1 or 75 rpm output |
| 03 | Motor interface | IEC frame size, motor power, or solid shaft dimensions |
| 04 | Mounting configuration | Foot mount or flange mount, orientation, B5 or B14 output |
| 05 | Quantity and delivery date | Units required and required-on-site date |
Whether you are replacing a worn helical reducer, specifying a new drive for an OEM machine build, or sourcing BRC Series gearboxes in production volume, Raydafon can quote to your ratio, torque, motor interface and mounting requirements. OEM and project quantities supplied directly from the Ningbo factory. ISO 9001 certified.
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Luotuo Industrial Area, Zhenhai District, Ningbo City, China
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