The latest generation of Hansen I4 industrial gear units (IGUs) – recently introduced by industrial solutions provider BMG – are designed for tough mining and conveying applications.

These compact, invertible units are engineered to deliver high torque capacity, dimensional accuracy and operational reliability in both underground and surface applications, while ensuring minimal maintenance requirements and extended service life.

Important advantages of the Hansen I4 programme include reduced lead times and original equipment manufacturer- (OEM-) backed technical support throughout Africa.

“By standardising the core materials [ . . .] in key Hansen I4 models, we are able to improve supply efficiency, while maintaining the original torque ratings, gear geometry and bearing performance required for heavy-duty mining and conveying applications,” explains BMG gears regional manager Barry Stoltz.

The revised I4 platform incorporates a standardised bill of materials across the core resilient distributed dataset, rotating detonation engine and refuse-derived fuel configurations, with gear ratios between 16:1 and 35:1. This rationalisation enables bulk procurement of critical components, including bearings, seals, spacers, bolts and nuts.

As a result, accessibility and cost-efficiency are improved, without compromising on performance, even in arduous conditions. Local sourcing also strengthens supply continuity.

Design Features

The Hansen I4 is built around precision-manufactured helical gearing and designed to American Gear Manufacturers Association-rated standards to balance high torque density with controlled noise levels. High torque geometry is applied to low-speed gears, while high-speed stages are configured to reduce noise emission. Detailed service factor and operating life calculations underpin the shaft and bearing design, ensuring suitability for continuous-duty conveyor and mining drives.

Installation flexibility is a core feature of the Hansen I4 range. The gearbox can be inverted through 180°C. A robust, horizontally split housing facilitates easy inspection and maintenance, while horizontal or vertical shaft configurations provide adaptability for different mechanical interfaces. Hansen’s Oil-Lock sealing arrangement helps to ensure long-term oil retention and reduce contamination risk in abrasive environments.

Availability, Technical Support

As the official OEM for Hansen gearboxes in Southern Africa, BMG is authorised to repair Hansen IGUs. 

Every unit undergoes detailed incoming inspection, full disassembly and dimensional verification of housings, shafts and gears before reassembly to factory-defined clearances. Bearings and seals are replaced as standard, fasteners are torqued to specified values and gear contact patterns are verified to meet correct mesh alignment requirements.

No gearbox is released before a controlled running test confirms mechanical, thermal and lubrication performance.

BMG affirms the next generation Hansen I4 range meets the requirements of customers seeking a standardised, high-torque, cost-efficient IGU.