{"id":979,"date":"2026-06-22T03:48:45","date_gmt":"2026-06-22T03:48:45","guid":{"rendered":"https:\/\/planetary-gearboxes.com\/?post_type=product&p=979"},"modified":"2026-06-22T03:48:45","modified_gmt":"2026-06-22T03:48:45","slug":"zl95-winch-drive-planetary-gearbox","status":"publish","type":"product","link":"https:\/\/planetary-gearboxes.com\/et\/toode\/zl95-winch-drive-planetary-gearbox\/","title":{"rendered":"ZL95 Winch Drive Planetary Gearbox"},"content":{"rendered":"
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<\/p>\n

\n
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FIRST 5,000 RPM<\/span>
\nRATIO 4,800 \u2014 NEW RECORD<\/span><\/div>\n
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ZL95 \u2014 115,000 Nm<\/h2>\n

Smaller motors. Higher speeds. Deeper ratios.<\/p>\n

The EP-ZL95 is the winch drive planetary gearbox<\/a> where the ZL series stops competing with the 4xxW hydraulic era and starts defining a capability that the hydraulic catalogue never imagined: 115,000 Nm of continuous torque from a platform that accepts the newest generation of high-speed PM and induction motors \u2014 motors that did not exist when the 4xxW series was designed.<\/p>\n<\/div>\n

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Pidev<\/span>115,000<\/span><\/div>\n
Peak<\/span>245,000<\/span><\/div>\n
Input RPM<\/span>5,000<\/span><\/div>\n
Max Ratio<\/span>4,800<\/span><\/div>\n
Stages \/ Pt<\/span>1-5 \/ 26-90<\/span><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n

Two firsts define the ZL95. The 5,000 rpm input speed means the helical gear teeth and the input bearing arrangement have been validated for tooth peripheral velocities 25% higher than any previous ZL model \u2014 enabling smaller, lighter motors that produce the same shaft power at higher speed. And the ratio 4,800 at five stages extends the catalogue ceiling by 37% beyond the ZL85 record \u2014 producing drum rotations so slow that the practical positioning limit is no longer the gearbox resolution but the elastic stretch of the wire rope under load.<\/p>\n<\/section>\n

<\/p>\n

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ZL95 Electric Winch Drive Planetary Gearbox \u2014 Technical Parameters<\/h2>\n
\n\n\n\n\n\n\n\n\n\n\n\n\n
Continuous torque (N2xh=100,000)<\/td>\n115,000 Nm<\/td>\n<\/tr>\n
Peak torque<\/td>\n245,000 Nm (2.13x continuous)<\/td>\n<\/tr>\n
Gear ratio range<\/td>\n5.07 to 4,800 (1-5 stages, catalogue record)<\/td>\n<\/tr>\n
Maximum input speed<\/td>\n5,000 rpm (catalogue first)<\/td>\n<\/tr>\n
Thermal power (Pt)<\/td>\n26 – 90 kW (varies by stage count)<\/td>\n<\/tr>\n
Gear type<\/td>\nHelical planetary, 3-planet, DIN 5-6<\/td>\n<\/tr>\n
Integrated brake<\/td>\nNone (motor brake or external brake)<\/td>\n<\/tr>\n
Sealing<\/td>\nMulti-lip FKM, IP67+<\/td>\n<\/tr>\n
Housing<\/td>\nDuctile iron QT600-3<\/td>\n<\/tr>\n
Gear material<\/td>\n20CrMnTi, HRC 58-62<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/section>\n

<\/p>\n

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5,000 RPM \u2014 Smaller Motors, Higher Speeds, Lower System Weight<\/h2>\n

Every ZL model from the ZL30 to the ZL85 accepts 4,000 rpm maximum. The ZL95 steps to 5,000 rpm \u2014 a 25% increase that changes the motor selection equation for every winch system designer.<\/p>\n

\"ZL95<\/p>\n

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Motor Downsizing<\/strong><\/p>\n

Shaft power = torque x speed. At 4,000 rpm, a 600 kW motor produces 1,432 Nm of input torque. At 5,000 rpm, the same 600 kW produces 1,146 Nm \u2014 a smaller motor frame achieves the same power because it runs faster. Alternatively, the 5,000 rpm motor produces 25% more power from the same frame: 750 kW instead of 600 kW. For crane OEMs, this means the ZL95 can be paired with the same motor frame as the smaller ZL85 while delivering 31% more continuous torque \u2014 or the motor frame can shrink by one IEC size for the same torque output.<\/p>\n<\/div>\n

System Weight Reduction<\/strong><\/p>\n

A typical IEC 355 frame motor at 4,000 rpm weighs approximately 850 kg and produces 500 kW. The same frame at 5,000 rpm produces 625 kW. If the application needs 500 kW, the motor can drop to an IEC 315 frame at 5,000 rpm \u2014 weighing approximately 650 kg. Weight saving: 200 kg. On a crane head where every kilogram affects the boom structural design and the counterweight requirement, this saving translates to structural cost reductions far exceeding the motor price difference.<\/p>\n<\/div>\n

VFD Control at Higher Speed<\/strong><\/p>\n

Modern VFDs (variable-frequency drives) produce better torque control and higher efficiency at higher motor speeds. At 5,000 rpm, the motor operates further from the low-frequency torque derate zone where current-limited drives lose controllability. The ZL95 allows the winch system to be designed with the motor running at 3,000-5,000 rpm for the primary hoisting duty and de-stroking to 500-1,500 rpm for precision positioning \u2014 keeping the motor in its efficient operating band throughout. Contact Korea Ever-Power<\/a> for motor-gearbox pairing recommendations at 5,000 rpm.<\/p>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

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Ratio 4,800 \u2014 The New Catalogue Maximum and the Diminishing Returns of Ultra-High Ratios<\/h2>\n

At five-stage ratio 4,800 with a 3,000 rpm motor on a 300 mm PCD drum, the line speed is 0.59 m\/min \u2014 9.8 millimetres per second. With the 5,000 rpm motor at maximum speed: 0.98 m\/min. These numbers approach the limit where increasing the gear ratio no longer improves practical positioning accuracy.<\/p>\n

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Where Ratio 4,800 Still Helps<\/h3>\n

Applications where the motor must maintain efficient mid-speed operation while the drum barely moves: deep borehole logging at 5,000+ metres where the wireline speed must be held constant at 0.5-1.0 m\/min for the entire descent. At ratio 4,800, the motor runs at 2,400-4,800 rpm for this line speed \u2014 firmly in the efficient torque band. At ratio 2,000, the motor would need to run at 1,000-2,000 rpm \u2014 closer to the low-speed derate zone where torque ripple and thermal limits degrade the cable speed consistency.<\/p>\n<\/div>\n

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Where Higher Ratios Stop Helping<\/h3>\n

At ratio 4,800, the encoder resolution through the gearbox produces cable position increments of 20 microns or less. But the wire rope stretches 0.1-0.5% under load \u2014 which at 5,000 metres of deployed cable is 5-25 metres of elastic elongation. The position uncertainty from cable stretch is 100,000 times larger than the encoder resolution. Beyond ratio 4,800, increasing the ratio improves the theoretical gearbox resolution without improving the practical cable position accuracy. The cable, not the gearbox, is the precision bottleneck.<\/p>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

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115,000 Nm at 5,000 RPM \u2014 The Electric Winch Drive for the Newest Motor Generation<\/h2>\n

\"ZL95<\/p>\n

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Heavy Electric Cranes With High-Speed Motors (60-100 t)<\/h3>\n

The ZL95 at ratio 80-200, 2-3 stage, paired with 500-900 kW high-speed PMSM motors at 5,000 rpm serves the 60-100 tonne electric crane class with motors one IEC frame smaller than the equivalent 4,000 rpm configuration. For offshore construction vessel cranes where the crane head weight directly affects the vessel stability, the motor downsizing translates to a lighter crane that can lift heavier cargo. The slewing drive<\/a> ja wheel drive<\/a> complete the all-electric crane system.<\/p>\n<\/div>\n

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Electric Mining Main Production Hoists<\/h3>\n

Main production winders at mines with shaft depths of 400-800 metres where the sustained drum torque stays within the ZL95 115,000 Nm continuous limit. The 5,000 rpm input allows a compact high-speed AC motor (500-800 kW, IEC 315-355 frame) to replace the larger, heavier motor frame that 4,000 rpm demanded \u2014 reducing the headframe winder house footprint and the structural load on the headframe. Regen recovery during skip descent returns 20-35% of the hoist energy to the mine grid.<\/p>\n<\/div>\n

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Deep Borehole and Wireline Winches<\/h3>\n

Wireline logging winches for oil and gas well logging, geothermal exploration, and deep scientific drilling at depths of 3,000-8,000 metres. The ZL95 at ratio 2,000-4,800 (4-5 stage) maintains constant wireline speed (0.5-2 m\/min) through the entire well depth with the motor running at efficient mid-speed (2,500-5,000 rpm). The 115,000 Nm continuous handles the combined tool string and cable weight at the deepest logging points. The DIN 5-6 gear accuracy ensures the depth encoder signal remains reliable through the full borehole depth<\/a>.<\/p>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

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The ZL Electric Winch Drive Family<\/h2>\n
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\"Winch<\/p>\n
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Full ZL Winch Drive Range \u2192<\/a><\/h3>\n

ZL120 (133,000 Nm) to ZL200 (175,000 Nm) for the heaviest electric winch systems.<\/p>\n<\/div>\n<\/div>\n

\"Slewing<\/p>\n
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Slewing Drive Planetary Gearbox \u2192<\/a><\/h3>\n

ZR series for heavy electric crane rotation on the same all-electric vessel and mine platforms.<\/p>\n<\/div>\n<\/div>\n

\"Precision<\/p>\n
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Precision Planetary Gearbox \u2192<\/a><\/h3>\n

EP-ZDS for wireline depth-tracking, crane heave compensation, and borehole tool positioning.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

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Electric Winch Drive Planetary Gearbox \u2014 ZL95 High-Speed FAQ<\/h2>\n
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What enables the ZL95 to accept 5,000 rpm when the ZL85 caps at 4,000?<\/h3>\n

The ZL95 input bearing arrangement uses a precision angular-contact bearing pair instead of the single deep-groove bearing used in the ZL30-ZL85 input design. The angular-contact pair handles the combined axial and radial loads at 5,000 rpm with adequate speed margin and L10 life. The first-stage sun gear tooth profile is also modified with a deeper crowning that reduces the contact stress concentration at the higher tooth peripheral velocity. These changes add approximately 5-8% to the manufacturing cost but enable the 25% input speed increase that drives the motor downsizing advantage.<\/p>\n<\/div>\n

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Can the ZL95 run at 4,000 rpm or below with standard motors?<\/h3>\n

Yes. The 5,000 rpm is a maximum, not a requirement. Any motor producing up to 5,000 rpm can drive the ZL95 \u2014 including the 1,500 rpm and 3,000 rpm motors commonly used in industrial applications. The 5,000 rpm capability is an option that the winch designer can utilise if the motor selection benefits from higher speed. If the application uses a standard 3,000 rpm motor, the ZL95 operates identically to the ZL85 at the same speed \u2014 with 31% more torque capacity.<\/p>\n<\/div>\n

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How much motor weight does the 5,000 rpm capability actually save?<\/h3>\n

For the same shaft power: approximately 15-25% motor weight reduction. A 600 kW motor at 3,000 rpm (IEC 400 frame): approximately 1,100 kg. The same 600 kW at 5,000 rpm (compact high-speed frame): approximately 800-950 kg. Saving: 150-300 kg. For a crane where the motor sits on the crane head, this weight saving is multiplied by the boom ratio \u2014 200 kg at the crane head saves 600-1,000 kg of counterweight at the rear. The total crane structural benefit exceeds the motor weight saving by 3-5x.<\/p>\n<\/div>\n

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Does the higher input speed increase gearbox noise?<\/h3>\n

At the same output speed and torque: no. The gearbox noise is dominated by the output-stage gear mesh, which operates at the same speed regardless of whether the input is 4,000 or 5,000 rpm (the input speed is reduced through the ratio to the same output speed). At the input stage, the higher speed produces a slightly higher-pitched noise component, but the amplitude is lower because the input-stage torque is lower (same power at higher speed = lower torque per tooth). The net effect is typically within 1-2 dB(A) of the 4,000 rpm noise level \u2014 imperceptible in practice.<\/p>\n<\/div>\n

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How does the ZL95 compare to the 4xxW 414W3 mega-class at overlapping torque?<\/h3>\n

The 414W3 delivers 140,000 Nm continuous at FEM M6 with -40 deg C Arctic rating and 1,250 kg. The ZL95 delivers 115,000 Nm continuous with 245,000 Nm peak. For applications needing 115,000-140,000 Nm sustained (mining production, AHTS), the 414W3 is the stronger choice because its continuous capacity exceeds the ZL95. For applications where the sustained torque stays below 115,000 Nm and the transient peaks reach up to 245,000 Nm (electric cranes, marine winches), the ZL95 provides higher peak capacity, regen braking, quieter operation, and motor downsizing \u2014 at a fraction of the 414W3 weight.<\/p>\n<\/div>\n

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What is the thermal power at 5,000 rpm versus 4,000 rpm?<\/h3>\n

The Pt rating (26-90 kW depending on stage count) is independent of the input speed \u2014 it is determined by the housing surface area and the oil-bath convection capacity, neither of which changes with input speed. However, the heat generated inside the gearbox is proportional to the power throughput, which is proportional to speed x torque. At 5,000 rpm at the same output speed and torque, the power throughput is the same as at 4,000 rpm \u2014 the input speed is higher but the input torque is proportionally lower. The thermal behaviour at 5,000 rpm is therefore identical to 4,000 rpm for the same output duty. Contact Korea Ever-Power<\/a> for a thermal analysis at your specific motor speed and duty cycle.<\/p>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

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Field Reports<\/h2>\n
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S<\/div>\n
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Stefan A. \u2014 Electric Heavy-Lift Crane OEM Technical Lead<\/div>\n
Verified Purchase \u00b7 Rostock, Germany \u00b7 March 2026<\/div>\n<\/div>\n
\u2605\u2605\u2605\u2605\u2605\u2605<\/div>\n<\/div>\n

80 t all-electric offshore crane, ZL95 at ratio 100, 2-stage, 750 kW PMSM at 4,800 rpm. The high-speed motor is an IEC 315 frame \u2014 one size smaller than the IEC 355 we would have needed at 3,600 rpm. Weight saving: 220 kg at the crane head. The naval architect used this saving to extend the boom by 1.5 metres, increasing the crane working radius by 8% without adding counterweight. The ZL95 245,000 Nm peak handled the classification society proof-load test (100 t at 1.25x) without any overcurrent trip. After 6 months of vessel operation, the VFD data log shows the motor has never exceeded 4,600 rpm during normal crane duty \u2014 the 5,000 rpm headroom is available but not routinely needed.<\/p>\n<\/div>\n

\n
\n
A<\/div>\n
\n
Andrew B. \u2014 Wireline Logging Systems Engineer<\/div>\n
Verified Purchase<\/div>\n<\/div>\n
\u2605\u2605\u2605\u2605\u2605\u2605<\/div>\n<\/div>\n

Wireline logging winch for a 6,500-metre geothermal exploration well. ZL95 at ratio 3,500, 5-stage, 40 kW servo motor at 5,000 rpm. The winch maintains 1.0 m\/min wireline speed through the entire well depth \u2014 the motor runs at 3,500-4,200 rpm in its efficient band while the drum barely turns. Depth accuracy verified by magnetic mark counting on the wireline: within 0.3% of the total depth at 6,500 m (approximately 19.5 metres cumulative error). The previous winch system (hydraulic, lower ratio) required the motor to crawl at 200 rpm to achieve the same wireline speed \u2014 causing torque ripple that produced 2-3% depth error at the same well depth. The ZL95 high ratio eliminated the motor-speed-related depth error entirely.<\/p>\n<\/div>\n

\n
\n
J<\/div>\n
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Johan V. \u2014 Mine Production Winding Manager<\/div>\n
Verified Purchase \u00b7 May 2026<\/div>\n<\/div>\n
\u2605\u2605\u2605\u2605\u2606<\/div>\n<\/div>\n

Main production winder at a 580-metre copper-gold mine, ZL95 at ratio 350, 4-stage, 600 kW AC motor at 4,500 rpm. The 5,000 rpm capability allowed us to specify an IEC 315 frame motor (720 kg) instead of the IEC 355 (950 kg) we had budgeted. The 230 kg saving simplified the headframe crane installation and reduced the winder bed foundation load. Regen recovery: 26% of the hoist energy, measured at 22 kWh per cycle for a 15-tonne skip from 580 m. The 4-star reflects a VFD compatibility note: our existing VFD switching frequency was set for 4,000 rpm maximum. Running the motor at 4,500 rpm required a firmware update and a higher switching frequency that slightly increased the VFD audible noise at the control cabinet \u2014 resolved by adding a line reactor, but it would have been caught earlier if the ZL95 data sheet had included a VFD minimum switching frequency recommendation for operation above 4,000 rpm.<\/p>\n<\/div>\n<\/div>\n<\/section>\n<\/div>","protected":false},"excerpt":{"rendered":"

Five thousand RPM. Ratio 4,800. The EP-ZL95 winch drive planetary gearbox breaks through two ceilings simultaneously: it is the first model in the entire Korea Ever-Power catalogue to accept 5,000 rpm at the input shaft, and its five-stage maximum ratio of 4,800 extends the ultra-slow positioning domain by 37% beyond the ZL85 record of 3,509. The higher input speed enables smaller, lighter high-speed motors to produce the same shaft power \u2014 a 115,000 Nm winch drive that previously required a 600-800 kW motor at 4,000 rpm can now be driven by a 500-650 kW motor at 5,000 rpm, saving 15-25% of motor weight and volume. At 245,000 Nm peak, the ZL95 approaches the 417W3 mega-class continuous (250,000 Nm) \u2014 from an electric platform that can be paired with the newest generation of high-speed permanent magnet servo motors.<\/div>","protected":false},"featured_media":980,"comment_status":"open","ping_status":"closed","template":"","meta":{"_et_pb_use_builder":"","_et_pb_old_content":"","_et_gb_content_width":""},"product_brand":[],"product_cat":[969],"product_tag":[],"class_list":["post-979","product","type-product","status-publish","has-post-thumbnail","product_cat-winch-drive-planetary-gearbox","first","instock","shipping-taxable","product-type-simple"],"_links":{"self":[{"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/product\/979","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/product"}],"about":[{"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/types\/product"}],"replies":[{"embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/comments?post=979"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/media\/980"}],"wp:attachment":[{"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/media?parent=979"}],"wp:term":[{"taxonomy":"product_brand","embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/product_brand?post=979"},{"taxonomy":"product_cat","embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/product_cat?post=979"},{"taxonomy":"product_tag","embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/et\/wp-json\/wp\/v2\/product_tag?post=979"}],"curies":[{"name":"t\u00f6\u00f6leht","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}