Direct-drive solutions engineered to withstand the high-frequency vibration and acidic corrosion inherent in intensive tomato harvesting operations.
Engineer’s Field Log: The Vibration Challenge
In my 18 years of analyzing drivetrain failures in agricultural machinery, few environments are as hostile as the tomato harvest. Unlike grain harvesting, where the load is relatively consistent, tomato harvesting—specifically the rotary shaker mechanism—involves intentional, high-frequency imbalance.
The gearbox driving the rotary shaker on machines like the Ploeger или Guaresi isn’t just transmitting power; it’s surviving an earthquake. I’ve seen OEM gearboxes in East Anglia fail within two seasons because the seal retention systems couldn’t handle the lateral thrust generated by the eccentric weights. At EVER-POWER, we don’t just copy the dimensions; we re-engineer the bearing preload and upgrade the housing metallurgy to QT450-10 nodular cast iron to dampen these vibrations before they destroy the gear mesh. We are talking about converting 540 RPM PTO input into a precise, high-torque oscillation that detaches the fruit without bruising it—a delicate balance of brute force and precision.
Technical Data Sheet: EVER-POWER Series RS-T
The following parameters are derived from our standard testing protocols (ISO 10300) and are customizable based on specific harvesting head configurations.
| Категория параметров | Технические характеристики | Техническая заметка |
|---|---|---|
| Номинальная входная мощность | 45 kW (60 HP) | @ 540 RPM |
| Максимальный выходной крутящий момент | 1450 Нм | Peak shock load capacity: 2,100 Nm |
| Передаточное число | 1:1.35 (Ускоритель) | Customizable 1:1.92 available |
| Входная скорость | 540 об/мин / 1000 об/мин | Dual-speed options |
| Материалы для корпуса | QT450-10 Nodular Iron | Superior vibration damping |
| Материал шестерни | 20CrMnTiH | Carburized to 58-62 HRC |
| Входной вал | Шлицевой вал Z6 1-3/8″ | DIN 9611 Standard |
| Выходной вал | Tapered or Cylindrical Keyed | Specific to shaker cam interface |
| Тип подшипника | Конический ролик (для тяжелых условий эксплуатации) | Preloaded for axial thrust |
| Материал уплотнения | FKM (Viton) Double Lip | Acid and heat resistant |
| Смазка | EP 85W-140 Gear Oil | Bath lubrication |
| Емкость нефтяного бака | 2,8 литра | Includes sight glass |
| Рабочая температура | от -20°C до +110°C | Continuous duty |
| Тепловая мощность | 32 kW | Without auxiliary cooling |
| Уровень шума | < 78 дБ(А) | На расстоянии 1 метра |
| Покрытие краской | Epoxy Powder Coat (Red/Black) | Corrosion resistance Class C4 |
| Вентиляционная заглушка | Фильтр из спеченной бронзы | Предотвращает попадание пыли. |
| Схема крепления | 4x M16 Threaded Holes | 140mm x 140mm spacing |
| Вес (сухой) | 42 kg | – |
| Эффективность | > 96% | Bevel gear efficiency |
| Обратная реакция | 0,15 – 0,25 мм | Прецизионно притертые шестерни |
| Дизайнерская жизнь | 10,000 Hours | L10 Bearing life |
| Класс защиты | IP66 | Water jet resistant |
| Предел вибрации | 8 mm/s RMS | Allowable housing vibration |
| Коэффициент обслуживания | 1.5 – 2.0 (Ag. Heavy Shock) | AGMA Application Class II |
| Интервал технического обслуживания | Initial 50h, then 500h | – |
| Гарантия | 18 месяцев | Factory defect coverage |
| Country of Origin | China (Hangzhou) | ISO 9001 Certified Plant |
| HS Code | 84834090 | – |
| Сертификация | CE, RoHS | Compliant with UK/EU Machinery Directive |
UK Field Conditions: Beyond the Poly-Tunnel
While much of the UK’s tomato production is greenhouse-based (Isle of Wight, Norfolk), open-field machinery requires gearboxes that can handle the transition from damp, clay-heavy soils to the high-speed operation of the harvest.
The Acid Test: When harvesting processing tomatoes, the rupture of fruit creates an acidic environment (pH 4.3 – 4.9). Standard NBR seals degrade rapidly here. Our research in collaboration with farms in Lincolnshire showed that after 300 hours, standard seals hardened and cracked. EVER-POWER implements Витон (ФКМ) seals exclusively for this line, maintaining elasticity even when coated in tomato pulp and soil grit.
UKCA & EU Machinery Directive Compliance
Post-Brexit, navigating component certification can be complex. EVER-POWER ensures all agricultural gearboxes meet the essential health and safety requirements of the Правила обеспечения безопасности при поставке машин и оборудования 2008 года (UK) and the EU Machinery Directive 2006/42/EC.
- Guarding: Input shafts are designed to mate seamlessly with ISO 5674 compliant PTO guards.
- Noise Emission: Precision gear grinding (DIN Class 6) reduces operational noise, contributing to lower operator daily exposure levels (LEP,d).
- Traceability: Every unit carries a unique serial number for full batch tracing, a requirement for many large-scale UK agricultural contractors.
Global Harvest Reports: Real Solutions for Real Problems
📍 Расположение: Norfolk, UK | Crop: Glasshouse Tomatoes
“We run our shakers 18 hours a day during peak. The OEM boxes were overheating, causing oil to froth and leak. EVER-POWER suggested a box with a finned aluminum housing instead of the standard cast iron for better heat dissipation.”
— Result: Operating temp dropped by 15°C.
📍 Расположение: Foggia, Italy | Crop: Roma Tomatoes
“The soil here is basically rock dust in summer. It eats seals. Your engineer recommended the cassette seal design with a mud slinger. We haven’t changed a seal in two seasons.”
— Result: Maintenance downtime reduced by 80%.
📍 Расположение: Fresno, USA | Crop: Processing Tomatoes
“Shock loads were snapping the input shafts when the shaker hit large vines. EVER-POWER switched the material to 20CrMnTi with a deeper carburized layer. Tough as nails now.”
— Result: Zero shaft failures in 2024 season.
📍 Расположение: Goiás, Brazil | Crop: Industrial Tomato
“We needed a gearbox that could handle the ‘tropical’ humidity without rusting internally during the off-season. The anti-corrosion additives in your recommended oil and the breather upgrade saved us.”
— Result: Extended equipment lifespan.
Market Comparison: Why Upgrade?
| Особенность | EVER-POWER RS-T Series | Standard Market Equivalent |
|---|---|---|
| Технология герметизации | Dual-Lip Viton (FKM) | Standard NBR (Nitrile) |
| Точность зубчатых передач | Класс DIN 6 (заземление) | DIN Class 8 (Shaved) |
| Housing Design | Reinforced Ribs + High-Flow Breather | Стандартное литье |
*Disclaimer: All references to original equipment manufacturer (OEM) names or part numbers (such as Comer, Bondioli & Pavesi, Omni) are for identification and compatibility purposes only. EVER-POWER products are not affiliated with, endorsed by, or sponsored by these brands.
The Critical Link: PTO Shaft Integration
А коробка передач is only as good as the shaft driving it. In tomato harvesters, the PTO shaft often operates at steep angles during turns. Using a mismatched shaft can induce “cardan error” (velocity fluctuation) that destroys the gearbox input bearings.
EVER-POWER provides fully compatible Широкоугольные (ШРУС) валы отбора мощности designed specifically for the RS-T gearbox series.
- ✅ Ограничитель срезного болта: Protects the gearbox from sudden jams (e.g., a large stone entering the shaker).
- ✅ Профильные трубы: Lemon or Star profile options, hardened to prevent seizing under load.
- ✅ Защитные ограждения: Fully enclosed, UV-resistant plastic guards meeting UK Health & Safety standards.
Часто задаваемые вопросы (FAQ)
How do I check the oil level on the shaker gearbox without removing the guard?
We’ve designed the RS-T series with an extended sight glass or a dipstick that is accessible through standard inspection ports on UK-spec harvester guards, so you don’t need to dismantle safety equipment for daily checks.
Can this gearbox replace the drive on a Sandei harvester operating in Norfolk clay?
Yes, absolutely. Our mounting bolt patterns match the standard Italian specs used by Sandei. Plus, our improved shaft sealing is specifically engineered to resist the ingress of fine clay particles common in Norfolk and Suffolk fields.
What is the lead time for a custom ratio gearbox for a specialized harvesting rig?
For custom ratios not in our standard catalog, our “Rapid-Proto” service allows us to engineer and ship a test unit to the UK within 25-30 days, ensuring you don’t miss the narrow harvest window.
Do you supply the hydraulic motor adaptors for self-propelled units?
We certainly do. Whether you are running Sauer-Danfoss or Parker hydraulic motors, we provide the SAE A or SAE B flanges pre-mounted to the gearbox input, making it a true “plug-and-play” solution.
My current gearbox overheats after 4 hours. How does EVER-POWER solve this?
Overheating is usually oil shear or low capacity. We increased the oil sump capacity by 20% and added external cooling fins to the housing casting, which increases thermal dissipation significantly under continuous load.
Is the output shaft keyed or splined for the shaker weights?
We offer both. However, for high-vibration shaker applications, we strongly recommend our splined output shaft option as it resists fretting corrosion much better than a single keyway connection over time.
Where can I buy replacement parts in the UK if something breaks?
We have established logistics channels that allow for air-freight delivery of critical spares (seals, bearings, gears) to the UK within 3-5 business days, minimizing your downtime during the critical harvest season.
Does the gearbox come pre-filled with oil or do I need to fill it?
For shipping safety regulations, units are usually shipped dry. However, we include a tag specifying the exact volume and grade (usually 85W-140) required. We can supply pre-filled sealed units upon special request for bulk OEM orders.
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