ZR200 Winch Drive Planetary Gearbox — Right-Angle

The Largest Electric Crane Conversions (120-160 t)

Hydraulic-to-electric conversions on the largest cranes in existence — 120-160 t SWL offshore heavy-lift, shipyard, and harbour cranes — where the machinery room constrains the motor to perpendicular. The ZR200 at 175,000 Nm exceeds every 4xxW model up to and including the 415W3 from a right-angle mount. The slewing drive and wheel drive complete the all-electric mega-class platform.

The Largest Athwartship Marine Winches

Main winches on the largest AHTS vessels, FPSOs, and semi-submersible platforms where the drum runs athwartship at torques above 160,000 Nm. The ZR200 at 175,000 Nm with 368,000 Nm peak provides the anchor deployment, chain tensioning, and emergency holding capacity from a right-angle electric motor at 3,000 rpm. Dual-ZR200 configurations extend to 350,000 Nm continuous for the very largest marine winch requirements.

The Deepest Right-Angle Mining Winders

Main production winders at the deepest mine shafts served by the electric catalogue — 800-1,100 metres with 22-25 tonne skip loads. The ZR200 at 175,000 Nm with 1,000-1,500 kW motors provides the absolute ceiling of right-angle electric winding torque. Beyond this depth and skip size, the 4xxW mega-class (416W3-419W3) or dual-ZR200 configurations are required.

Why does the ZR200 require 4-stage minimum when the ZR150 requires only 3?

At 175,000 Nm through a 3-stage ZR configuration, the bevel tooth stress during the 368,000 Nm peak would reach 88-92% of the endurance limit — marginally safe for continuous but inadequate for the design life when the cumulative peak-event count over 100,000 hours is considered. The 4th planetary stage redistributes the torque such that the bevel tooth stress at peak drops to 70-75% — the most conservatively loaded bevel stage in the entire ZR series. The 4-stage minimum is the engineering decision that ensures the ZR200 bevel survives the full design life at the highest torque the right-angle architecture can deliver.

Can a dual-ZR200 achieve 350,000 Nm continuous from a right-angle platform?

Yes. Two ZR200 units driving one drum through a torque-combining gearbox produce 350,000 Nm continuous — matching the 419W3 mega-class ceiling. Each motor drives its own ZR200 right-angle gearbox, and the two outputs combine through a planetary torque combiner on the drum shaft. The dual configuration provides full redundancy: if one motor or gearbox fails, the remaining unit carries the load at 175,000 Nm — sufficient for emergency operation. This is the ultimate right-angle electric winch drive configuration in the Korea Ever-Power catalogue.

Does the ZR200 share planetary spare parts with the ZL200?

Yes — the same principle applies across every ZR/ZL pairing. The planetary stages are interchangeable between ZR200 and ZL200 at overlapping ratios. Only the bevel stage and input housing are ZR-specific. For fleet operators running both models — for example, ZR200 deck winches and ZL200 crane hoists on the same vessel — the planetary spare parts inventory is fully shared.

What is the installed depth of the ZR200 at 4-stage behind the drum?

Approximately 560-650 mm behind the drum mounting face at 4-stage, depending on the specific ratio. At 5-stage: approximately 640-740 mm. For comparison: the ZR150 at 3-stage is approximately 480-550 mm. The ZR200 4-stage adds approximately 80-100 mm versus the ZR150 3-stage — the cost of the additional planetary stage that protects the bevel. For installations where 650 mm of depth is available, the ZR200 fits. For installations limited to 500-550 mm, the ZR150 at 160,000 Nm is the maximum.

What comes after the ZR200 in the Korea Ever-Power catalogue?

Nothing. The ZR200 is the last product. Beyond 175,000 Nm from a single right-angle unit, the paths are: dual-ZR200 (350,000 Nm continuous), ZL200 coaxial (same torque, different geometry), 4xxW mega-class for sustained hydraulic duty, or custom engineering for unique requirements. The standard catalogue — 18 models in the 4xxW series, 10 in the ZL series, and 7 in the ZR series — covers every standard winch drive application from 870 to 175,000 Nm across three architectures. Contact Korea Ever-Power for any requirement beyond the standard catalogue.

150 t all-electric heavy-lift crane on a next-generation construction vessel. ZR200 at ratio 120, 4-stage, 1,400 kW PMSM at 3,000 rpm. The drum runs athwartship — no coaxial option at this torque without the adapter gearbox we have now eliminated. The ZR200 replaced the entire adapter-plus-415W3 assembly with a single integrated product — saving 520 kg and one complete oil system. The 368,000 Nm peak absorbed the classification proof-load test at 187.5 t equivalent drum torque. Commissioning: 4 days. The previous adapter-plus-hydraulic configuration on our older vessels took 16 days. This vessel is the flagship of our all-electric fleet — and the ZR200 is the most capable right-angle electric winch drive we have installed on any vessel, anywhere.

Main production winder at a 1,050-metre copper mine — the deepest shaft operating on a ZR electric winch drive. ZR200 at ratio 350, 4-stage, 1,200 kW AC motor mounted vertically. Skip weight 24 tonnes; rope weight at full depth 6,800 kg. Sustained drum torque during loaded hoist: 172,000 Nm — 98% of ZR200 continuous. This mine is operating at the absolute ceiling of the right-angle electric catalogue. The regen recovery is projected at USD 580,000 per year — the highest of any ZR installation. The mine engineering team has noted that at 98% utilisation, the next mine level extension (to 1,150 metres) will exceed the ZR200 capacity and require either a dual-ZR200 or a 4xxW mega-class specification. The ZR200 has served this mine to the limit of the electric catalogue.

Dual-ZR200 main anchor handling winch on the largest all-electric AHTS vessel in the global fleet. Two ZR200 units at ratio 200, each with 1,000 kW motor, torque-combined at 350,000 Nm continuous. The vessel completed its first 3,000-metre ultra-deepwater anchor deployment — 320 tonnes of chain through the dual-ZR200 with full regen during recovery. Energy saving versus the hydraulic twin-419W3 equivalent: 35% per deployment cycle. The 4-star reflects the integration learning consistent with all dual-unit configurations: the torque combiner adds weight and length that must be planned from the first stern arrangement drawing. Additionally, the 4-stage ZR200 is approximately 100 mm longer than the 3-stage ZR150 — and with two units plus the combiner, the total stern assembly is 1,850 mm long. For the next vessel in the series, we are designing the stern structure around the dual-ZR200 envelope from day one instead of retrofitting it into an existing stern design.