EP-ZDF-Serie Präzisionsplanetengetriebe mit quadratischem Flansch – Servogetriebe mit geringem Spiel

Der EP-ZDF-Serie Präzisionsplanetengetriebe mit quadratischem Flansch Das koreanische Modell Ever-Power ist die Plattenmontagevariante des EP-ZDE-Reihenmotors. Servo-Planetengetriebe Die quadratische Abtriebsflanschfläche lässt sich an jeder ebenen Maschinenplatte montieren – ohne kreisförmige Bohrung, ohne Zapfenausrichtung und ohne Anpassung der Bohrungstoleranzen. Vier Durchgangsbolzenlöcher in der Flanschfläche (Durchmesser D9: Φ3,5–Φ13,5 mm, abhängig vom Gehäuse) verbinden das Getriebe fest mit der Maschinenstruktur. Durch die ebene Auflagefläche wird das Abtriebsreaktionsdrehmoment auf die vier Bolzen anstatt über eine Bohrungspassung verteilt. Dies macht das EP-ZDF zur bevorzugten Wahl für koreanische OEM-Förderanlagen, automatisierte Schaltschrankhandhabung und halterungsmontierte Servoantriebe.

Intern ist die EP-ZDF identisch mit der EP-ZDE: gleiche einsatzgehärtete Planetenräder aus legiertem Stahl, gleiches Schrägkugellagerpaar am Abtrieb, gleiches Präzisions-Spannsystem am Eingang, gleiche werkseitig abgedichtete Lebensdauerschmierung. Die Spezifikation für das Zahnflankenspiel von <8 Bogenminuten (1-stufig, Baugröße 60–160), der Wirkungsgrad von 961 TP3T (einstufig), die Nennlebensdauer von 20.000 Stunden, die Schutzart IP54 und der Betriebstemperaturbereich von −25 °C bis +90 °C sind bei beiden Baureihen identisch. Koreanische Ingenieure, die eine Konstruktion von der EP-ZDE auf die EP-ZDF umrüsten, müssen lediglich das Lochmuster der Maschinenplatte anpassen – der Eingangsflansch, das Übersetzungsverhältnis und die Drehmomentwerte bleiben unverändert.

Three Installation Advantages of the EP-ZDF Square Flange

⚠ Installation Cautions: The square flange face must have full contact with the machine plate — a gap on one side concentrates bolt load and can cause flange fatigue. Do not weld or heat the gearbox housing. The sealed housing has no grease port — do not attempt external lubrication. Never exceed 4,500 rpm input speed. Do not apply impact force to the output shaft or input flange during installation.

✔ Zero Maintenance — Retrofit Tip: When retrofitting EP-ZDF in place of a previous square-flange gearbox, match the flange size D7 (□) and bolt-hole PCD D8. If the previous gearbox had a grease nipple that was periodically serviced, EP-ZDF eliminates that maintenance step entirely — no plugging or capping of the old grease port location is needed on the EP-ZDF unit.

Conveyor & Material Handling Systems

Korean automated warehouse, logistics, and production line conveyor systems use EP-ZDF-60 and EP-ZDF-80 as the servo gear reducer for belt-drive head pulleys and roller conveyors. The square flange bolts directly to the conveyor frame side plate — no precision bore in the structural steel section, just 4 drill-and-tap holes. At 3-shift operation rates typical in Korean e-commerce fulfilment centres, the 20,000-hour rated life and zero re-lubrication design reduces conveyor maintenance costs significantly compared to open-frame worm gear drives. For heavy-load conveyor drives above 800 N·m, see the EP-ZDS High Stiffness series.

Servo Press & Forming Machines

Korean servo press OEMs use EP-ZDF-120 and EP-ZDF-160 for the main drive reduction stage in servo-controlled stamping and forming presses. The square flange's 4-bolt pattern locks the gearbox rigidly to the press frame plate under the cyclic impact loads of press operation — where a bore-fit gearbox risks micro-rotation and fit fretting under the high-frequency torque reversals at the press cycle rate. The 2× instant stop torque (1,600 N·m for ZDF-160 at 800 N·m rated) absorbs stamping impact loads without gearbox damage.

Automated Panel & Glass Handling

Korean flat-panel display and glass substrate handling gantry systems use EP-ZDF-80 for the horizontal axis linear drive and EP-ZDF-60 for the vertical axis. The square flange allows direct attachment to the gantry beam web plate without boring — critical for Korean OEM panel handling machine builders who use laser-cut structural steel plates as the primary machine structure. IP54 sealing and lifetime lubrication are particularly valued in Korean display panel cleanroom-adjacent environments where maintenance access is restricted.

Packaging Machinery — Bracket-Mounted Actuators

Korean food and beverage packaging OEMs use EP-ZDF-60 and EP-ZDF-80 for servo-driven filling, sealing, and labelling station axes — as a Planetengetriebe für Servomotor drives where the gearbox is mounted on a removable bracket assembly. The square flange enables the entire motor-gearbox-bracket assembly to be unbolted from the machine frame in one motion and replaced as a module — reducing production line downtime during scheduled maintenance compared to bore-mount designs where the motor must be uncoupled before the gearbox can be extracted from the bore. For right-angle motor configurations saving axial space, see the EP-ZDWF right-angle square-flange series planetary gearbox.

Welded-Frame Machine Tools — No Post-Weld Boring

Korean non-mainstream machine tool builders using heavy welded steel frames for special-purpose CNC machines — pipe notching machines, tube bending centres, custom fixture mills — frequently specify EP-ZDF because the square flange eliminates the post-weld precision boring operation that would be required for a round-bore gearbox mount. After welding, the frame needs only a flat-ground mounting surface and 4 drilled holes — achievable with portable tooling on the shop floor without moving the frame to a machining centre for boring.

AGV & Mobile Robot Drive Modules

Korean AGV (Automated Guided Vehicle) and mobile robot manufacturers use EP-ZDF-40 and EP-ZDF-60 for drive wheel servo reduction stages. The square flange bolts directly to the aluminium or carbon-fibre chassis plate — a standard construction method in Korean AGV design that uses laser-cut flat-plate chassis assemblies. At 0.4–0.9 kg (single-stage, 40–60 frame), the low-mass EP-ZDF minimises the unsprung weight of the drive module. The <8 arcmin (frame 60) or <12 arcmin (frame 40) backlash provides the positioning accuracy required for Korean warehouse AGV lane-keeping and dock-positioning operations.

• ✔Präzision Planetengetriebe backlash measured per unit at ±3% of rated output torque — measurement certificate with every order
• ✔Square flange face flatness verified — output flange contact surface ground to <0.01 mm
• ✔Full-load torque test at rated output torque for each unit before shipment
• ✔IP54 ingress verification per IEC 60529 — every production batch
• ✔Materialzertifikat und Maßzeichnung werden jeder Lieferung beigefügt.

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EP-ZDF-80 at 16:1 two-stage for a 60 m/min belt conveyor head pulley drive — welded steel frame, no machining budget for bore operations. Previous project used a round-bore gearbox that required a boring contractor to come on site and machine the frame pocket. EP-ZDF eliminated that entirely — our fabricator drilled 4 holes, we bolted the gearbox, coupled the motor, and commissioned in one day. Now 26 months operating, no flange bolt loosening, backlash unchanged from installation. Korea Ever-Power confirmed our frame hole pattern was compatible with ZDF-80 within 2 hours of sending the plate drawing.

EP-ZDF-160 at 20:1 two-stage for a 250-tonne servo press main drive. Critical concern was gearbox movement under the cyclic press impact — at 60 strokes per minute, a loosely-fitted bore gearbox will walk. The EP-ZDF 4-bolt pattern combined with friction-grip bolts locks the unit completely; after 19 months at 60 spm two-shift operation we have had zero bolt re-torque events and the axis positioning repeatability remains within ±0.01 mm at the press ram. I was initially concerned about the square flange handling 800 N·m cyclic loads, but the Korea Ever-Power engineering data and our own trial confirmed it more than adequately.

EP-ZDF-60 at 10:1 single-stage for an AGV drive wheel module — aluminium chassis plate, 750 W Yaskawa motor. The square flange bolts to our laser-cut chassis plate in one operation; we previously used a competitor round-bore unit that required us to machine a precision bore into every chassis plate before assembly — an extra 45-minute machining step per AGV unit at our production volume. With ZDF-60, we drill 4 holes with a CNC router during the plate cutting process, then bolt the gearbox directly. At 200 AGVs per year, that is 150 hours of machining time eliminated. Backlash at <8 arcmin meets our lane-keeping algorithm requirement without any closed-loop correction needed from the wheel encoder.

EP-ZDE Series — Round Flange Output

Identical planetary gear stages and torque ratings as EP-ZDF, with a cylindrical round body (D7 = Φ40–Φ160 mm) that inserts into a precision circular bore. Choose EP-ZDE when the machine structure has a precision bore or when the gearbox is mounted in a CNC spindle head, robot joint, or other bore-fitted installation. Identical backlash, efficiency, IP54, and lifetime lubrication.

EP-ZDWF Series — Right-Angle Input, Square Flange

Square flange output with a right-angle (90°) bevel input — the servo motor is perpendicular to the output shaft, saving 30–50% of axial installation depth while retaining the square-flange plate-mount installation method. Use EP-ZDWF when space prevents inline motor placement on a plate-mount machine. Available in 60–160 mm frames.

EP-ZDS Series — High Stiffness, Heavy Load

When EP-ZDF-160 at 800 N·m is insufficient — EP-ZDS delivers up to 1,800 N·m (190-frame) with a square flange, IP65 protection, torsional stiffness up to 130 N·m/arcmin, and 28,000 N maximum axial force. Specify EP-ZDS for heavy conveyor drives, large servo press main stages, and high-force bracket-mounted actuators in Korean tier-1 automotive and heavy industry facilities.

QWhat is the difference between EP-ZDF and EP-ZDE, and when should I choose EP-ZDF?

EP-ZDF and EP-ZDE use identical planetary gear stages — same rated torque, same <8 arcmin backlash, same efficiency, same input flange. The only difference is the output housing: EP-ZDF has a square output flange (□45–□175 mm) that bolts to a flat machine surface with 4 through-bolts, while EP-ZDE planetary gearbox has a cylindrical body that inserts into a precision circular bore. Choose EP-ZDF when your machine structure is a flat plate, welded frame, aluminium extrusion profile, or any surface where drilling 4 holes is more practical than boring a precision round pocket.

QCan I use EP-ZDF as a direct retrofit for an existing square-flange gearbox from another manufacturer?

Often yes — the key dimensions to match are the square flange size D7 (□45, □60, □90, □120, □160, or □175 mm) and the bolt-hole PCD D8. If these match the existing machine plate holes, EP-ZDF is a direct bolt-in replacement without modifying the machine plate. You will also need to verify the output shaft diameter D4 and keyway width B1 match your existing coupling, and provide your servo motor model to Korea Ever-Power to confirm the correct input flange. Korea Ever-Power's Korean application team provides a dimensional compatibility check against competitor gearbox drawings on request — at no charge before order placement.

QDoes the EP-ZDF 160 have two flange size options — □160 and □175? Which should I choose?

Yes — the EP-ZDF-160 frame is available with either a □160 mm flange (bolt-hole PCD Φ185 mm, through-bolt Φ11 mm) or a □175 mm flange (bolt-hole PCD Φ200 mm, through-bolt Φ13.5 mm). The two options exist to accommodate the two most common machine plate hole patterns at this frame size. Both deliver identical rated torque (up to 800 N·m), identical <8 arcmin backlash, and identical gear internals. Select the flange size that matches your machine plate hole pattern. If you are designing a new machine, the □175 mm option provides a slightly wider bolt pattern for higher flange clamping stiffness at maximum torque.

QWhat bolt grade and torque should I use for the 4 through-bolt holes in the square flange?

Korea Ever-Power recommends minimum ISO class 8.8 hex-head bolts for all EP-ZDF flange mounting applications. For high-cycle dynamic loads (servo press, conveyor start-stop cycles), class 10.9 is preferred. Tighten in a cross pattern to the torque specified for the bolt class and diameter — for M5 class 8.8, approximately 5 N·m; for M12 class 8.8, approximately 60 N·m. Use thread-locking compound (medium-strength, e.g. Loctite 243) for applications subject to vibration. After the first 30-minute no-load run-in, re-check and re-torque the 4 bolts to compensate for initial joint settling.

QDoes EP-ZDF require the same maintenance schedule as EP-ZDE — is there any scheduled lubrication?

No scheduled lubrication is required. EP-ZDF uses the same factory-sealed lifetime lubrication as EP-ZDE — the sealed housing contains factory-injected grease that lasts the full 20,000-hour rated service life without re-greasing. The housing has no grease nipple or drain port. The only recommended periodic check is a visual inspection of the output shaft lip seal every 5,000 hours to confirm no contamination ingress. Additionally, check the 4 flange bolt torque values at the first 5,000-hour inspection to confirm no settlement has occurred since installation. At the end of the 20,000-hour rated life, replace the gearbox unit.