Bonfiglioli W86 80/90-B5 Worm Gear Reducer 20:1 Ratio Gearbox 35mm Shaft

The Bonfiglioli W86 80/90-B5 worm gear reducer is a right angle drive solution engineered for applications that require a 20:1 reduction ratio and a 35 mm output shaft. Built on the proven W series platform, this gearbox combines a precision machined worm shaft with a bronze worm wheel to deliver smooth and reliable motion control. The 80/90-B5 designation indicates compatibility with IEC 80 and 90 frame motors using a B5 flange configuration, making it a flexible choice for many industrial installations.

Product Overview

The W series from Bonfiglioli is known for its robust cast iron housing, efficient heat dissipation, and long operational life. The W86 model is a mid sized unit within the range and is frequently selected for conveyor drives, mixing equipment, and general machinery where a compact right angle solution is required. The 20:1 ratio offers a balanced combination of output speed and torque, while the 35 mm shaft provides sufficient strength for moderate radial and axial loads.

The worm gear design allows for high reduction ratios in a small footprint. Unlike parallel shaft gearboxes that require multiple stages to achieve the same reduction, the W86 accomplishes a 20:1 ratio in a single compact stage. This simplicity contributes to lower maintenance requirements and higher reliability in continuous duty applications.

Key Features

• 20:1 reduction ratio for controlled output speed and increased torque

• 35 mm solid output shaft with keyway for secure coupling

• Cast iron housing for structural rigidity and vibration damping

• Bronze worm wheel and hardened ground worm shaft for quiet operation

• 80/90-B5 motor flange compatibility for direct IEC motor mounting

• Self locking behavior under many load conditions for holding applications

• Multiple mounting positions to suit different installation layouts

• Synthetic oil lubrication for extended service intervals

Technical Specifications

• Model: W86 80/90-B5

• Reduction ratio: 20:1

• Output shaft diameter: 35 mm

• Mounting configuration: B5 flange with IEC 80 and 90 motor interface

• Housing material: Cast iron

• Gear type: Worm and wheel

• Lubrication: Synthetic or mineral oil depending on configuration

• Protection class: IP55 when correctly assembled

• Operating temperature: Standard industrial range

Performance and Efficiency

The worm gear configuration of the W86 provides smooth and quiet operation across a wide speed range. Because the worm wheel is made from bronze and the worm shaft is case hardened and ground, the contact between the two surfaces is optimized for minimal wear and consistent efficiency. The 20:1 ratio allows the gearbox to multiply torque effectively while reducing the input speed to a level suitable for driven equipment such as conveyors and mixers.

Thermal performance is an important factor in worm gearbox operation. The cast iron housing of the W86 helps dissipate heat generated by sliding contact between the worm and wheel. This allows the unit to sustain continuous duty in many industrial environments without overheating. Proper selection of the service factor and correct installation position further support stable thermal behavior and long bearing life.

Applications

The W86 80/90-B5 is well suited to a variety of industrial duties. Typical uses include belt conveyors, screw conveyors, rotary valves, mixers, agitators, packaging machines, and material handling equipment. Its 20:1 ratio is especially useful in applications where moderate speed reduction is needed without sacrificing compactness. The 35 mm shaft can accommodate pulleys, sprockets, and couplings commonly found in these systems.

Because the gearbox accepts IEC 80 and 90 frame motors with B5 flanges, it can be paired with a broad range of standard electric motors. This flexibility simplifies system design and allows operators to select the motor that best matches their power supply and control requirements. The direct flange mounting also reduces alignment effort during installation.

Installation Guidelines

Correct installation begins with selecting an appropriate mounting position. The lubrication system inside the gearbox is designed to work properly in specific orientations, so the unit should be mounted according to the configuration specified for the application. The gearbox must be aligned carefully with the driven equipment to avoid excessive radial loads on the output shaft. Couplings should be fitted with the correct interference and checked for runout before operation.

Bolts and fasteners should be tightened to the recommended torque values to prevent movement under load. Electrical connections to the motor should follow local regulations and the motor manufacturer instructions. After installation, a brief no load run in period helps confirm that the assembly rotates freely and that no abnormal noise or vibration is present.

Maintenance Recommendations

Routine maintenance helps preserve the performance and service life of the W86 gearbox. Oil level and oil condition should be inspected at regular intervals, and the first oil change should be performed after the initial running in period. Subsequent oil changes depend on operating conditions such as load, temperature, and duty cycle. Seals and bearings should be checked periodically and replaced if leakage or abnormal noise is detected.

Keeping the exterior of the gearbox clean supports efficient heat dissipation. Adequate ventilation around the housing helps maintain stable operating temperatures. If the gearbox is used in a dusty or humid environment, additional protection measures may be advisable to prevent contamination of the lubricant and premature wear of internal components.

Selection Considerations

When specifying the W86 80/90-B5, engineers should consider the required output torque, the input speed from the motor, the duty cycle, and the environmental conditions. The 20:1 ratio is fixed, so the output speed is determined by dividing the motor speed by twenty. The resulting torque depends on the motor power and the efficiency of the gearbox. A service factor should be applied to account for shock loads and starting conditions.

The 35 mm output shaft provides a balance between strength and compactness. For applications with high radial loads, additional bearing support may be required. The B5 flange interface ensures that the motor and gearbox form a rigid assembly that is easy to align and install, reducing downtime and improving overall system reliability.

Conclusion

The Bonfiglioli W86 80/90-B5 worm gear reducer offers a dependable 20:1 reduction solution with a 35 mm shaft and IEC 80/90 B5 motor compatibility. Its cast iron construction, bronze worm wheel, and hardened worm shaft ensure smooth and efficient torque transmission for a wide range of industrial applications. When correctly installed and maintained, this gearbox delivers consistent performance and long service life.