ZF Maschinenantriebe GmbH

Industrial Drives

Hysteresis brakes
Hysteresis clutches
Electronic control unit

Right angle gearboxes

Tw o - s p e e d g e a r b o x e s

Planetary gearboxes

Customer specif ic gearboxes

Tw o - s p e e d c l u t c h e s

Precision in movement
The ZF Maschinenantriebe is able to
offer you a wide range of machine drives,
brakes and clutches for applications in
engineering as well as customer-specif ic
drive solutions.

Hysteresis brakes

Our development and production

activities are focused on servo gearboxes
for automation technology, two-speed
gearboxes for machine tools as well as
customer-specif ic drives, such as for
printing machines and robot applications.
Our innovative standard products
range from low-backlash servo gearboxes
(ZF Servoplan), robust two-speed
gearboxes (ZF Duoplan) and two-speed
clutches (ZF Duoshift) to hysteresis
applications which are characterized by
the non-contact torque transmission
(ZF Tiratron).

ZF Hysteresis products

ZF Hysteresis components
are brakes, clutches and ERM
electronic control unit.
ZF Tiratron, i.e. the combination
of the brake with the electronic
control unit or the clutch with
the electronic control unit, enables
the exact control of tensile forces
as well as a def ined setting of a
torque.
Exemplary operation
The ZF hysteresis technology can
be used and applied wherever products, such as paper, wire etc., are
processed by winding. Loads can
be simulated with Tiratron on test
benches or in ergometers.
Non-contact torque transmission
The non-contact torque transmission via the airgap of the mechanical componentes brake or
clutches, is continuously variable,
then constant and free of any wear.

Continuously adjustabel torque

The brake torque or the transferable
torque depends only on the current.
It is largely speed-independent and
form zero to maximum speed constantly available.
High slip power in continuous mode,
overload capability
The brakes of the power optimized
series can bear high slip power
continuously. Overloads can be
applied for a short-term period.

The system, consisting of the break

or clutch and the universal usable
control unit, is standardized and can
be used for most of the applications.
Operating principles
The operating principles of hysteresis
brakes and clutches are based on the
magnetic force effect of attracting
poles in synchronous mode and on
continuous magnetic reversal in slip
mode.

Installation examples
Abb.1: Hysteresis brakes to produce a def ined thread tension.
Abb.2: Hysteresis brakes with flyer for unwinding flexible leads with constant tensile force.
Abb.3: Hysteresis clutches to wind up a foil with constant tensile force.
Abb.4: Hysteresis brake to unwind a tape with constant tensile force.
A toothed belt is used to produce a higher braking torque.
5

Hysteresis brakes

Types:
- Torque-optimized series
- Power-optimized series
- Power-optimized series with gearbox
The armature and the brake magnet
are the individual components making
up the ZF hysteresis brake.

ZF Hysteresis brakes are offered

with a nominal torque ranging from
0.05 Nm to 520 Nm, depending on
the size, available as bearing version
with shaft end or non-bearing version
as individual components.
The brakes have a power capacity of
up to 2000 W during continuous operations and of 4000 W during shortterm operations (interval operations).

Typical torque-current-diagram
Only the current preset in the magnet
solenoid defines the slip and holding
torque, which can be infinitely adjusted
from zero to the maximum value.
The torque is almost independent from
speed. Major temperature increases
cause a slight reduction of torque.

They can be used both in the slip

mode range and as a holding brake.

Fig.: Reversal of magnetization

Slip power
During continuous slip mode, heat
generation caused by slip power
must also be taken into account.
Permissible continuous slip power
limits are included in the selection
tables. Required continuous slip
power is calculated as follows:
ns
P s = T s .
or P s = F . v
9.55

PS:

Slip power in W

TS:

Slip torque in Nm

nS:

Slip speed in rpm

F:

Te n s i l e f o r c e i n N

v:

Band pull speed in m/s

Residual magnetism
Torque ripple occurs as a result of
residual magnetism when the current
is changed to below 50% of the initial
value either abruptly or without turning the armature/rotor.
A reliable way to avoid torque ripple
is to reduce the current while simultaneously turning the armature and
rotor resp. brake solenoid during
approx. 1 turn (relative).

Manufacturing and torque tolerances:

When ordering the standard design
according to the catalog, the deviation
between individual units will amount
to +/-10 % in relation to the nominal
torque.
We offer specially adjusted pairs/series
for applications requiring lower tolerances on request. The above tolerances of +/-10 % shall also apply to the
nominal torque when the nominal
current is constant.

Every following operation cycle

is removing possible residual
magnetism.

The current-torque-curve is exactly

reproducable under the same
conditions.

To r q u e
Current

1. Brake magnet with solenoid

2. Armature with hysteresis ring
Fig.: Bearing version with shaft

P o w e r- o p t i m i z e d h y s t e r e s i s b r a k e s

Sizes:
Te c h n i c a l d a t a :

EBU
250/1

EBU
500/3

EBU
1000/10

EBU
2000/30

Nominal torque*

TN

(Nm)

0.6

2.5

26

Nominal torque*
at speed n

TP

(Nm)

0.75

3.0

12.5

38

Permitted speed in continuous

mode at nominal torque

(rpm)

3 200

1 500

750

500

Permitted slip power in

continuous mode

(W)

250

500

1 000

2 000

Max. slip power in

short time mode

Pmax (W)

500

1 000

2 000

4 000

Nominal current

IN

(A)

1.1

1.4

1.9

2.7

Nominal voltage

UN

(V)

24

24

24

24

Max. speed

nmax (rpm)

10 000

6 500

4 500

3 000

Shaft side inertia torque

JW

(kgcm2) 4.8

33.5

244.5

1 157

Power consumption at coil

temperature 70C

P70

(W)

19

24

33

47

Mass

(kg)

1.4

3.7

11

45

EBU
250/1

EBU
500/3

EBU
1000/10

EBU
2000/30

55
24.5
25
12.5
50
75
93
10.5
11
M4
M5
60
12
28
3
2
7
11
23
18
31
32.5
39.5
4
2.5
6 001

68
32
32,5
14.5
80
112
140
13
14
M5
M6
100
15
35
4
2.5
8
13
30
22
40.5
41
51
5
3
6 202

92
40
41
20.5
110
168
210
20
19
M6
M8
130
20
52
4
3.5
12
15
40
28
54
52
68.5
6
3.5
6 304

122
53.5
54
28
180
233
292
25
24
M8
M 12
215
25
80
6
4
16
20
50
36
69.5
71
89
8
4
6 405

Dimensions (mm):
* To l e r a n c e s :
S e e S c a t t e r i n g / To r q u e t o l e r a n c e s
All bearing types balanced,
balance quality 6.3
Non-bearing types when supported
in d5: balance quality: 23.6
Ambient temperature up to 40oC

A1
B1
B2
B3
D1 h7
D2
D3
E
d1 k6
d2
d3
d4
d5 S7
d6 H7
a
b
c
e
l1
l2
l3
l4
l5
v P9
w +0.2
LA DIN625

Av a i l a b l e v e r s i o n s :

* Centering DIN 332 (D)

**

* * c o n n e c t i n g l e a d s 0 , 5 m m 2, l e n g t h 5 0 0 m m

B1

45

A: Bearing type, shaft right side

l1
l2

l3

D2

d4

d1
*

D3

D1

d2

l4

d3 (4x90)

LA

c
**

B: Bearing type, shaft left side

B2

EBU
500/32000/30

l1
a
l4

l2

*
LA

D3

D2
d4

d4 (4x90)

d1

D1

d2

l5

b
c

C: Non-bearing type for integrated solutions

A

D1

d4

d6

d5

B3

d3 (4x90)

D3

0,1 A

b
c

To r q u e - o p t i m i z e d h y s t e r e s i s b r a k e s

Sizes:
Te c h n i c a l d a t a :

10

EBU
0,05 L

EBU
0,1 LA

EBU
0,1 LW

0.08

0.15

0.15

Nominal torque*

TN

Max. slip power in

short time mode

Pmax (W)

15

32

32

Nominal current

IN

(A)

0.225

0.4

0.4

Nominal voltage

UN

(V)

23

30

30

Max. speed

nmax (min-1) 15 000

15 000

15 000

Armature side
inertia torque

Jarm (kgcm2) 0.14

0.1

0.1

Power consumption at coil

temperature 70C

P70 (W)

4.8

10

10

Mass

0.37

0.5

0.5

EBU
0,05 L

EBU
0,1 LA

EBU
0,1 LW

53.5
49
45
70
30
34.5
4
24/2 x180
M4
62
4.3
29
3
19 +/-0.5
15
5
6
4
-

51
35
54
25
32/3 x120
M3
40
M4
5
7.5
-

49
54
5
40
M4
6
30

(Nm)

(kg)

Dimensions (mm):
* To l e r a n c e s :
S e e S c a t t e r i n g / To r q u e t o l e r a n c e s
Ambient temperature up to 40oC

A
C
D1
D2
D7
D8 h8
E
c
dj 6
d2
d3
d4
d5
d11
e
f1
f2
f3
f4
f5
l

Av a i l a b l e v e r s i o n s :
A
E

f1

f2

10

2kt SW 14

d5

1 MAX.

D2

D8

d11

d2

D1

d3

D
7

120

f4
f3

d4

f5

19.51

EBU
0,05L

200 x10

d3

300

AMP plug
Steckverbinder
connection

d2

EBU
0,1LA

120

d
4

d5

D1

D8

60

e
f2

C
A

300

EBU
0,1LW

d5

120

d
4

D1

60

34

e
A

34

11

To r q u e - o p t i m i z e d h y s t e r e s i s b r a k e s

Sizes:
Te c h n i c a l d a t a :

(Nm)

EBU
1L

EBU
3L

EBU
10 L

EBU
30 L

0.4

1.1

3.3

12

39

63

125

250

500

1 000

Nominal torque *

TN

Max. slip power

Pmax (W)

Nominal current

IN

(A)

0.75

1.25

1.25

1.5

2.2

Nominal voltage

UN

(V)

30

30

30

30

30

Max. speed

nmax (min-1) 10 000

6 500

4 500

3 000

2 000

Armature side
inertia torque

Jarm (kgcm2) 1

13

81

404

Power consumption at
coil temperature 70oC

P70

(W)

18

30

30

36

53

Mass

(kg)

1.1

2.2

5.6

18

47

EBU
0,3 L

EBU
1L

EBU
3L

EBU
10 L

EBU
30 L

58
74
62
22 K7
55
608
6 000
2
7 h7
50
M5
7
3
16
8
34
32.5
1

56.5
102
91
35 H7
64
6 201
6 201
4
9 h7
60
M5
7
5
20
10
43.7
20.8
1

76.5
138
120
42 K6
131 f7
95
6 004
6 004
2
14 h7
60
M6
M 5 x12.5
14.5
5
30
22
57
38
5x3
-

102
210
180
80 H7
160 h8
6 006
6 006
6
24 h7
106
M8
M 8 x19
20
5
50
40
82.5
51
8x4
-

136
310
266
140 H7
240 h8
6 209
6 209
8
38 h7
170
M8
M10 x24.5
30
4
80
63
132.5
59
10 x 5
-

Dimensions (mm):
* To l e r a n c e s :
S e e S c a t t e r i n g / To r q u e t o l e r a n c e s
Ambient temperature up to 40oC

12

EBU
0,3 L

A
D1
D2
D3
D7
D8
LA DIN625
LB DIN625
b
d
d4
d5
d10
e
f1
f2
l
l1
l2
l3
vxw
w

300*
d5

120

d2
D2

D8

D3
b

EBU
0,3L30 L

f1

f2
l

l3

l2

l1

v
w

l3

LA

LA

LB

LB

d10

D7

D1

l1
13

To r q u e - o p t i m i z e d h y s t e r e s i s b r a k e s

Sizes:
Te c h n i c a l d a t a :

EBU
1

EBU
3

EBU
10

EBU
30

0.4

1.1

3.3

12

39

63

125

250

500

1 000

Nominal torque *

TN

Max. slip power

Pmax (W)

Nominal current

IN

(A)

0.75

1.25

1.25

1.5

2.2

Nominal voltage

UN

(V)

30

30

30

30

30

Max. speed

nmax (min-1) 10 000

6 500

4 500

3 000

2 000

Armature side
inertia torque

Jarm (kgcm2)

0.7

9.1

59

340

Power consumption at
coil temperature 70oC

P70

(W)

18

30

30

36

53

Mass

(kg)

1.0

1.8

5.0

16

42

EBU
0,3

EBU
1

EBU
3

EBU
10

EBU
30

55
74
62
22 K7
19
32 K7
26 K7
19
11
10
42
M4
50
M5
7
5.2 +0.1
25

51.5
102
91
35 H7
32 K6
42 K7
17
4
15
50
M5
60
M5
7
10.7 +0.1
18.2
8.4

71.5
138
120
42 K6
42 K6
52 K7
16.5
16.5
80
M5
60
M6
11
12.0 +0.1
19.2
22.8

102
210
180
80 H7
80
90 H7
202
160 h8
26
47
10
105 +/-0.1
M8
106 +/-0.2
M8
186 +/-0.2
M8
20
5
12
-

136
310
266
140 H7
140
110 H7
300
240 h8
43
57
14
130 +/-0.1
M8
170 +/-0.2
M8
275 +/-0.2
M 10
20
4
11
-

(Nm)

Dimensions (mm):
* To l e r a n c e s :
S e e S c a t t e r i n g / To r q u e t o l e r a n c e s
Ambient temperature up to 40oC

14

EBU
0,3

A
D1
D2
D3
D4
D5
D6
D7
a
b
c
d2
d3
d4
d5
d6
d7
e
f
g
h

D1

D2

D2
D1

d2

d
4

d3 (4x90)

300

D4

D1

D2

d2

D5

D6

DIN 472

d2

f
D5

d5

D3

d
4

D2

300

D4
b

D4

d3 (4x90)

d5

g
a

90

d
6

D3

D3

d4

d7

D7

120

D6

120

120

A
e
b

A
0,1 A

A
EBU
0,3

h
0,1 A
EBU1
EBU3

c
a

45

EBU10
EBU30

0,1 A

15

300

d3 (4x90)

d5

P o w e r- o p t i m i z e d b r a k e s w i t h g e a r b o x
Sizes:
Te c h n i c a l d a t a :

EBU

EBU

500/30 G

1000/100 G

2000/300 G 2000/600 G

EBU

10

10

10

20

Ratio

Nominal torque*

TN

(Nm)

25

90

260

520

Nominal torque*
for speed n

TP

(Nm)

30

125

380

760

Idling torque

TL

(Nm)

0.5

Permitted speed in
continuous mode

(rpm)

150

75

50

25

Max. slip power in

continuous mode

(W)

500

1 000

2 000

2 000

Max. slip power in

short time mode

Pmax (W)

1 000

2 000

4 000

4 000

Nominal current

IN

(A)

1.4

1.9

2.7

2.7

Nominal voltage

UN

(V)

24

24

24

24

Max. speed

nmax. (rpm)

600

400

300

100

Shaft side
inertia torque

JW

24 500

116 000

232 000

Power consumption at coil

temperature 70C

P70 (W)

29

40

60

60

Mass

6.5

18

60

82

EBU

EBU

EBU

EBU

500/30 G

1000/100 G

2000/300 G 2000/600 G

236
155
140
59.5
16
75
70
5.5
3
8
5
28
33
48
22
5
3
60

330
222
210
89.5
32
120
110
9
4
12
5
58
65
88
50
10
5
90

412
270
292
111.5
40
165
141
11
5
15
5
82
87
112
70
12
5
112

(kgcm2) 350

(kg)

Dimensions (mm):
* To l e r a n c e s :
S e e S c a t t e r i n g / To r q u e t o l e r a n c e s
Ambient temperature up to 40oC

16

EBU

A
B
D3
D11
d1 k6
e1
f1
s1
a
b
c2
l1
l2
l3
l6
v P9
w +0.2
Z2 h7

522
380
292
144.5
55
215
200
14
5
26
5
82
88
119
70
16
6
145

Sizes:
ZF-Type:

EBU

EBU

EBU

500/30 G

1000/100 G

2000/300 G 2000/600 G

EBU

500/3

1000/10

2000/30

2000/30

50

200

500

500/1200

Brake EBU
Gear PG

Av a i l a b l e v e r s i o n s :

* Centering DIN 332

* * c o n n e c t i n g l e a d s 0 , 5 m m 2, l e n g t h 5 0 0 m m

EBU
G

l3
c2

**

l2
l1

D3

f1

D11

xs1

z2

45

xe1

d1

l6

45

4x90

17

Permanent magnet hysteresis brake

Remarkable features of the permanent magnet (PM) hysteresis brake are its high nominal torque with a compact design.
The brakes permanent magnet excitation makes it independent of any power supply. The torque values can be set and
reproduced easily and in a user-friendly fashion with the 37-times detented setting ring. The tolerance of the nominal torque amounts to +/- 5 %.

To r q u e ( N c m )

To r q u e c u r v e

Setting detents (A)

Size:

DBU
0,2 L

Te c h n i c a l d a t a :
* To l e r a n c e s :
S e e S c a t t e r i n g / To r q u e t o l e r a n c e s

Max. nominal torque *

Ambient temperature up to 40oC

Min. nominal torque *

TNmax (Nm)

0.35

TNmin (Nm)

0.08

Number of detens
Permitted slip power in
continuous mode
Max. speed
Inertia torque
Mass
Bearing type

18

37
P

(W)

nmax (min-1)

20
10 000

Jw

(kgcm2) 0.63

(kg)

LA

DIN625 6 000

0.36

Av a i l a b l e v e r s i o n :

Torque-adjustment
37 Detents (1-1.25-1.5- -9.5-9.75-10)
10 marked numbers (1-2- -9-10)
10 intermediate numbers (1.5-2.5- -9.5)

72.5
6

28.5

34

LA

60

90

35

42 h8

80

DBU
0,2 L

62

M4

10

M4

12

3x

7
3.5

71

4
5

4-0.5
All dimensions in mm

19

Hysteresis clutches

Rotor, armature and clutch magnet

are the components that make up
the ZF hysteresis clutch.
The nominal torque as offered
ranges from 0.4 Nm to 12 Nm.
The maximum continuous slip
power of the hysteresis clutch
amounts to 500 W.

The magnitude of scattering and

torque tolerances correspond to
the values of the ZF hysteresis
brakes.
As is the case with the brakes,
special series are available on
demand.

The ZF hysteresis clutch distinguishes itself by a stepless transition from synchronous to slip
operations.

20

Slip power
During continuous slip mode, heat generation caused by slip power must also be
taken into account.
Permissible continuous slip power limits
are included in the selection tables.
Required continuous slip power is calculated as follows:
ns
P s = T s .
or P s = F . v
9.55

PS:

Slip power in W

TS:

Slip torque in Nm

nS:

Slip speed in rpm

F:

Te n s i l e f o r c e i n N

v:

Band pull speed in m/s

Residual magnetism
Torque ripple occurs as a result of
residual magnetism when the current
is changed to below 50% of the initial
value either abruptly or without turning
the armature/rotor.
A reliable way to avoid torque ripple is
to reduce the current while simultaneously
turning the armature and rotor resp. brake
solenoid during approx. 1 turn (relative).

1. Clutch magnet with solenoid

2. Armature wih hysteresis ring, usually output
3. Rotor, usually input
21

3
1

Hysteresis clutches

Sizes:
Te c h n i c a l d a t a :

EKU
1

EKU
3

EKU
10

0.4

12

Nominal torque*

TN

Max. slip power

Pmax (W)

63

125

250

500

Nominal current

IN

(A)

0.9

1.3

1.5

1.8

Nominal voltage

UN

(V)

30

30

30

30

Max. speed

nmax (min-1)

10 000

6 500

4 500

3 000

Side inertia torque

Rotor

JRotor(kgcm2) 5.7

16.2

79.0

830.0

Armature side
inertia torque

Jarm (kgcm2) 0.7

2.0

9.1

59.0

Power consumption at coil

temperature 70C

P70 (W)

22

31

36

43

Mass

1.5

2.4

EKU
0,3

EKU
1

EKU
3

EKU
10

A
D1
D2
D3 H8
D4 h8
D5
d2 +/-0.1
d3
d4 +/-0.1
d5
a
b +1/-0.5
c
e
f +0.1
g
z

60
82
62
50
80
32 K7
42
M4
62
M4
17
3
10
5
5.2
40
3

59
110
91
80
107
42 K7
50
M5
92
M5
18
3
15
7
10.7
38
3

79
148
119
100
140
52 K7
80
M5
116
M6
25
4
16.5
12
12.0
50
3

118
225
180
150
205
90 H7
105
M8
174
M8
32
6
10
20
80
4

d1 H7
vxw
d1 H7
vxw
d1 H7
vxw

15
5 x 1.3
12
4 x 1.1
12
-

30
8 x 1.7
25
8 x 1.7
20
6 x 1.7

40
12 x 2.1
30
8 x 1.7
20
6 x 1.7

50
14 x 2.6
40
12 x 2.1
30
8 x 1.7

(Nm)

(kg)

Dimensions (mm):
* To l e r a n c e s :
S e e S c a t t e r i n g / To r q u e t o l e r a n c e s
Ambient temperature up to 40oC

22

EKU
0,3

300

45
90

D1

d1

D3

D4

d2
D2

DIN 472

D5
d3 (4x90)*

w
d5

d4

0,1 A

x0,1 A

c
a

e
A

EKU

* E K U 0 , 3 : d 3 ( 3 x 1 2 0 )

23

Electronic control unit ERM

24

The ZF hysteresis electronic control unit

makes it possible to set individual operating
modes for the most diverse applications.
The programming variations allow the
electronic control unit to be used for all
brake and clutch types.

1. DIL switch for coding sizes and functions

2. LED function and error indicators
3. Diagnosis interface (Mobi Dig 200)
4. Jumper

25

2
4

Electronic control unit ERM

ZF hysteresis clutches and brakes can be controlled in open or closed loop with the ZF electronic control unit,
depending on their application in different operating modes. The electronic components are micro-processor
controlled and have programming, operating and diagnosis interfaces. The ERM electronic control unit has been
set so as to feed the ZF hysteresis clutches and the ZF hysteresis brakes in an optimal way.

26

Open-loop control

Open-loop control

Open-loop control

(current)

(torque)

with -sensing

ERM operating modes:

Open loop control:
- current
- torque
- -sensing
- -calculation
Cloesd loop control:
- PD position control
- PI force control
- PID mixed control
- freely programmable (with
diagnosis device Mobi Dig)

The ERM also offers the following

special functions, depending on the
operating mode:
- Maximum current:
Output of the nominal current,
depending on the size
- Zero current:
the power output is set to zero
- Web-break detector in the operating
mode -calculation
- Compensation of the friction
existing in the system

Open-loop controlled operating

modes with a size codification are
less suitable for the power-optimized
brake series.
Please refer to the ERM operating
manual for further information on
the functions, connections etc.

Open-loop controlled

Closed-loop controlled -

Closed-loop controlled -

with -calculation

with dancer force control

with storage/position
control

27

Telefax: +49(0)75 41-77-3470

Telefon: +49(0)75 41-77-0

e-Mail: industrial-drives@zf.com

Internet: http://industrial-drives.zf.com

The data contained in this borchure have no binding force. For the purpose of mounting tests, please ask for the relevant assembly drawings as only the details stated there are binding.

Ehlersstrasse 50

Sheet-No.: 6627 750 101

ZF Maschinenantriebe GmbH

88046 Friedrichshafen/Germany