UD100 Planetary Disc Step-Less Speed Variator | 5.5-7.5 kW / 4P Continuously Variable Speed Drive
UDL100 Planetary Disc Step-Less Speed Variator Continuously Variable Mechanical CVT
The UD100 step-less speed variator (also: continuously variable transmission, CVT drive, mechanical speed regulator, infinitely variable speed drive) provides smooth, stepless mechanical speed adjustment from 200-1000 rpm rpm output speed range. The UD100 is the largest in the UDL series, supporting 5.5 to 7.5 kW motors and delivering output torques from 45 to 118 Nm | designed for the most demanding variable-speed industrial applications.
The UD100 UDL planetary disc variator | robust mechanical continuously variable transmission for industrial production machinery.
? Product Overview | UD100 Step-Less Speed Variator
The UD100 UDL step-less speed variator uses a purely mechanical planetary disc (discone) mechanism that requires no electrical control components, operates reliably in electromagnetically noisy environments, and delivers constant torque across the entire speed range.
Unlike electronic variable frequency drives (VFDs), the UD100 eliminates electronic component failure modes, requires no PLC programming, and is immune to EMI | the preferred choice for food processing, pharmaceuticals, printing, and textile manufacturing where live speed adjustment and mechanical simplicity are critical.
The UD100 can be combined downstream with NMRV or NRV gearbox stages to multiply torque and further reduce the output speed range. Learn about our drive system expertise.
? Technical Specifications
| Parameter | Value |
|---|---|
| Motor Power Range | 5.5-7.5 kW / 4P |
| Output Speed Range (n2) | 200-1000 rpm |
| Output Torque Range (M2) | 45-118 Nm |
| Speed Adjustment Tolerance | |3-8.8% |
| Max Temperature Rise | < 50 |C |
| Variator Type | Planetary disc step-less mechanical CVT |
| Input Speed (n1) | 1,400 rpm (4-pole motor) |
| Mounting Style | B3 (foot) / B5 (flange) |
| Combination Options | Can be combined with NMRV/PC-NMRV for additional ratio reduction |
| Certifications | ISO 9001:2015, CE |
The planetary disc (discone) mechanism continuously varies the effective friction radius to change the transmission ratio in real time.
⚙️ Working Principle
The UD100 uses a planetary disc (discone) mechanism at its core. The motor drives a central input shaft, rotating planetary friction discs (discones) arranged around the axis. An adjustable pressure ring changes the axial position of the discones, varying their effective contact radius on the output ring | continuously changing the transmission ratio from minimum to maximum. Adjustment is via an external handwheel (standard) or motorised actuator (optional), allowing speed to be changed smoothly while the drive is running under load. The UD100 delivers constant torque output across the speed range | an important advantage over VFDs, which often de-rate torque at low speeds.
⚡ Core Advantages
|
⚙️ Purely Mechanical CVT The UD100 requires no electronics, PLC programming, or electrical control | mechanical simplicity reduces failure modes and maintenance complexity. |
? Live Speed Adjustment Handwheel-adjustable speed during operation allows real-time process fine-tuning without stopping machinery. |
|
⚡ EMI Immune Zero electronic components make the variator immune to electromagnetic interference from welders, inverters, and high-power RF equipment. |
?️ Low Temperature Rise Optimised friction contact geometry limits temperature rise to < 50 |C | ensuring long lubricant and component life. |
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? Simple Maintenance Periodic friction disc inspection and lubricant change are the only routine tasks | no electronic calibration or drive replacements needed. |
? Combine with Gearboxes The UD100 output connects to NMRV or NRV gearboxes to further multiply torque and reduce the speed range for demanding slow-speed variable applications. |
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? Low Total Cost of Ownership Absence of electronic drive components eliminates costs associated with VFD replacement, maintenance, and EMI filtering equipment. |
? Universal Motor Compatibility Standard IEC motor interfaces (B5, B3) allow coupling to any 4-pole motor brand worldwide. |
Factory assembly of the UDL series: each variator is calibrated and run-in tested to verify speed range accuracy and temperature performance.
? Structure & Material Craftsmanship
Input Interface: IEC B5 motor flange (standard) or B3 foot mounting. Motor shaft connects directly to the variator input via precision keyway coupling | no intermediate coupling required for B5 mounting. Planetary Disc Mechanism: Precision-ground steel discones with friction-optimised surface coating in a hardened steel housing. Pressure ring and adjustment screw maintain optimal contact force across all speed settings. Adjustment Mechanism: External handwheel with graduated scale indicates approximate output speed setting. Optional remote-adjustable motorised or pneumatic actuator available. Output Shaft: Precision-ground output shaft with keyway, suitable for direct coupling to driven equipment or downstream NMRV/NRV gearbox. Housing: Die-cast aluminium alloy, CNC-machined bearing bores, sealed oil bath lubrication, powder-coated exterior.
? Typical Application Scenarios
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? Food Processing & Packaging Conveyor belt speeds, filling speeds, and labelling rates are adjusted live with the UD100 to match production demands without stopping the line. |
? Pharmaceutical Manufacturing Tablet press feed rates, blender speeds, and granulator drives use UDL variators for precise, repeatable speed setting and live adjustment. |
|
? Printing & Paper Machinery Web tension control, feed roller speeds, and printing head rates are fine-tuned with the UDL to ensure print quality across different media types. |
? Textile Production Spinning frame twist-per-inch adjustment and weaving loom speed control use the UDL for precise mechanical control without electronics. |
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? Chemical Processing Reactor agitator speeds and pump drive rates in chemical plants benefit from the UDL's EMI-immune mechanical control. |
? General Manufacturing Assembly conveyors, test bench drives, and batch process feeders all benefit from UDL mechanical CVT live speed adjustment. |
? Selection Guide
| Requirement | Recommendation |
|---|---|
| Determine required speed range | Confirm your required n2_min and n2_max fall within 200-1000 rpm rpm. If further reduction is needed, combine the UD100 with a downstream NMRV gearbox. |
| Match motor power | Select motor matching 5.5-7.5 kW / 4P (4-pole, 1,400 rpm). The UD100 is designed for specific motor frame sizes | refer to the UDL motor interface table. |
| Verify output torque | Confirm your required torque falls within 45-118 Nm Nm. For higher torque, combine with an NMRV downstream gearbox stage. |
| Choose mounting style | B3 (foot mount) and B5 (flange mount) are standard. Select based on machine structure and available motor frame size. |
| Handwheel vs. actuator control | Standard handwheel for manual adjustment. Specify optional motorised actuator for automated or remote speed control. |
| Downstream gearbox combination | To achieve output speeds below 200 rpm or torques above 118 Nm, combine the UD100 with a downstream NMRV or NRV gearbox. |
? Quality Certifications & Service Commitment
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✅ ISO 9001:2015 Certified Manufacturing processes certified under international quality management standards, ensuring consistency across every unit. |
?? CE Marked Full compliance with European Machinery Directive 2006/42/EC, enabling direct sale and use across EU member states. |
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? Custom Engineering OEM/ODM: shaft dimensions, flange configs, mounting positions, and finishes tailored on request. |
? Global Logistics Partnerships with major freight forwarders ensure safe, on-time delivery to 80+ countries with full export documentation. |
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? 24-Month Warranty Every gearbox covered by a 24-month warranty against manufacturing defects, backed by responsive after-sales engineering support. |
? Technical Support Dedicated engineering team available for selection assistance, custom specifications, and field troubleshooting worldwide. |
❓ Frequently Asked Questions
Q: How does the UD100 achieve stepless speed variation?
A: The UDL series uses a planetary disc (discone) mechanism where adjustable conical discs vary the effective contact radius on the friction discs, continuously changing the transmission ratio and output speed without steps or electrical components.
Q: Can the speed be adjusted while the machine is running?
A: Yes. The UDL variator is specifically designed for live speed adjustment | the handwheel can be turned under load, making it ideal for production processes requiring real-time speed fine-tuning.
Q: What is the speed range ratio of the UDL series?
A: The UD100 provides output from 200-1000 rpm rpm at 1,400 rpm input | a speed range ratio of approximately 5.9:1 (UDL005/010) or 5.2:1 (UDL002).
Q: How does the UDL differ from an electronic VFD?
A: The UDL is a purely mechanical variator with no electronic components | immune to EMI, simpler to maintain, and delivers constant torque across the speed range. VFDs may de-rate torque at low speeds.
Q: Can the UDL be combined with a gearbox?
A: Yes. The UD100 can be combined with NMRV or NRV gearboxes downstream to multiply torque and further reduce output speed while maintaining the variable speed capability of the UDL stage.
? Case Studies | Engineer Field Notes
?? Germany
Application: Pharmaceutical tablet press feed control
The UDL010 allowed our operators to fine-tune granule feed rate in real time without any PLC involvement. In a GMP environment, the simplicity of a mechanical CVT is invaluable.
?? Italy
Application: Pasta drying conveyor speed adjustment
We replaced electronic drives with UDL variators and eliminated all drive-related downtime caused by humidity ingress into VFD enclosures. The mechanical variator just works.
?? China
Application: Textile spinning frame speed control
UDL005 units allow operators to adjust twist-per-inch on the fly without stopping the line. Production efficiency increased by 8% in the first month after installation.
?? Mexico
Application: Beverage bottling line conveyor control
The EMI immunity of the UDL series was a significant advantage in our bottling hall where multiple high-frequency welders operate nearby. VFDs were causing interference that the UDL completely eliminated.
?? Turkey
Application: Printing press web tension control
Web tension consistency improved significantly after switching to UDL mechanical variators from worn-out electronic drives. The graduated handwheel scale allows operators to reproduce settings precisely between job changeovers.
?? Poland
Application: Chemical reactor agitator drive
In our ATEX-classified plant area, the motor-only electrical components of the UDL system drastically simplified hazardous a
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