EP-60W – 120W Output Range DC Motor
One of the more practical aspects of this series is the way the three power ratings share nearly identical mounting geometry. An engineer who validates a motor mount for the 60W variant can upgrade to the 90W or 120W model for a higher-throughput line revision without any structural changes — only the motor lead current rating needs reconfirming with the dc motor drive controller.
The pre-fitted 300 mm motor lead cable is routed to a CW/CCW wiring standard — red lead positive for clockwise rotation as viewed from the output shaft end.
EP Series | 60W – 120W Output Range
EP-60-120W DC Motor
Engineered for applications that demand more power without sacrificing footprint, the EP-60-120W dc motor series covers three output ratings — 60W, 90W, and 120W — across three operating voltages: 12V, 24V, and 90V. Built on the proven K5D frame with a 90×90 mm face-mount flange, these brushed permanent magnet dc motor units combine rated speeds up to 3,300 RPM with load torques reaching 4.7 kg·cm, making them a practical workhorse for conveyor drives, automated production lines, and precision equipment worldwide. Whether you are sourcing a high torque dc motor for an industrial retrofit or speccing a drive platform for a new machine build, the EP-60-120W range offers the versatility and supply-chain simplicity that OEM engineers appreciate.
Motor Performance Parameters
All figures below are measured at standard ambient conditions (20°C, sea level). The □ suffix in the model number denotes the shaft output type — see the output shaft dimension table for details.
| Model | Voltage (V) | Power (W) | No-load | Full Load | Brush Life (H) | Weight (kg) | Remarks | |||
|---|---|---|---|---|---|---|---|---|---|---|
| Speed (RPM) | Current (A) | Speed (RPM) | Torque (kg·cm) | Current (A) | ||||||
| K5D60-12□ | 12 | 60 | 3000 | 2.0 | 2600 | 2.3 | 9.0 | 3000 | 2.2 | — |
| K5D60-24□ | 24 | 60 | 3100 | 1.0 | 2800 | 2.1 | 3.5 | 3000 | 2.2 | — |
| K5D60-90□ | 90 | 60 | 3100 | 0.3 | 2900 | 2.0 | 1.0 | 3000 | 2.2 | — |
| K5D90-12□ | 12 | 90 | 3100 | 2.0 | 2600 | 3.4 | 12.0 | 3000 | 2.2 | — |
| K5D90-24□ | 24 | 90 | 3300 | 1.0 | 2800 | 3.2 | 5.0 | 3000 | 2.2 | — |
| K5D90-90□ | 90 | 90 | 3000 | 0.3 | 2800 | 3.2 | 1.4 | 3000 | 2.2 | — |
| K5D120-12□ | 12 | 120 | 3100 | 2.0 | 2500 | 4.7 | 15.0 | 3000 | 2.2 | — |
| K5GD120-24□ | 24 | 120 | 3200 | 1.2 | 2600 | 4.5 | 7.0 | 3000 | 2.2 | — |
| K5D120-90□ | 90 | 120 | 3000 | 0.3 | 2600 | 4.5 | 2.0 | 3000 | 2.2 | — |
Compatible Gearbox Overall Dimensions — 5GN Series
All four gearbox variants listed below bolt directly to the EP-60-120W motor's 90×90 mm flange. The L dimension (mm) reflects the gearbox body length excluding the motor; combined assembly length equals L + motor length. Mounting uses four M6 bolts (or 4×ø6.5 through holes per variant).
| Gearbox Model | L Dimension (mm) | Weight (kg) |
|---|---|---|
| 5GU3K – GU9K | 65 | 1.21 |
| 5GU10K – GU18K | 65 | 1.30 |
| 5GU20K – GU75K | 65 | 1.40 |
| 5GU90K – GU200K | 65 | 1.45 |
Allowable Torque — 4GN□K Gearbox Series (K2D10-24□)
The allowable output shaft torque values below apply when the K2D10-24□ motor is paired with the 4GN□K gearbox. Confirm that the required application torque does not exceed the listed allowable value at the chosen reduction ratio before finalising your motor-gearbox selection.
| Model | அளவுரு | 3 | 3.6 | 5 | 6 | 7.5 | 9 | 10 | 12.5 | 15 | 18 | 20 | 25 | 30 | 36 | 40 | 50 | 60 |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| K2D10-24□ | Output (r/min) | 1100 | 916 | 660 | 550 | 440 | 366 | 330 | 264 | 220 | 183 | 165 | 132 | 110 | 91 | 82 | 66 | 55 |
| Torque (N·m) | 0.64 | 0.76 | 1.05 | 1.27 | 1.58 | 1.90 | 1.90 | 2.38 | 2.85 | 3.42 | 3.44 | 4.30 | 5.16 | 6.19 | 6.88 | 8.60 | 10.31 | |
| Torque (kgf·cm) | 6.53 | 7.75 | 10.76 | 12.92 | 16.12 | 19.37 | 19.40 | 24.25 | 29.10 | 34.92 | 35.08 | 43.85 | 52.62 | 63.15 | 70.16 | 87.70 | 105.24 |
Allowable Torque — 2GN□K Gearbox Series (K2D10-24□)
| Model | அளவுரு | 75 | 90 | 100 | 120 | 150 | 180 | 200 |
|---|---|---|---|---|---|---|---|---|
| K2D10-24□ | Output (r/min) | 44 | 36 | 33 | 27 | 22 | 18 | 16 |
| Torque (N·m) | 12.89 | 13.83 | 15.37 | 18.44 | 19.60 | 19.60 | 19.60 | |
| Torque (kgf·cm) | 131.56 | 141.12 | 156.80 | 188.17 | 200.0 | 200.0 | 200.0 |
Bare Motor Output Shaft Dimension Options
| Shaft Type | Gear Shaft | Flat Type | Milled Keyway |
|---|---|---|---|
| Model Code | DC5GU90-□ | DC5A90-□ | DC5A190-□ |
| Typical Use | Gearbox interface | Pulley / pinion | Keyed coupling / sprocket |
Five Key Advantages of the EP-60-120W DC Motor
① Three Power Ratings, One Platform
A single mechanical frame covers 60W, 90W, and 120W output options, so machine designers can scale drive power between product variants without redesigning the mounting structure or cable routing. This platform approach shortens development timelines and simplifies spare-parts inventory across multi-line facilities.
② Wide Voltage Compatibility
With 12V, 24V, and 90V motor variants available across the range, the EP-60-120W dc electric motors integrate into battery-backed mobile equipment, 24V industrial DC bus systems, and 90V regulated power supplies found in North American and European process lines — all without step-down converters or custom windings.
③ Rated 3,000-Hour Brush Life
Factory-verified brush life of 3,000 hours across all models supports predictive maintenance scheduling and reduces unplanned downtime on continuous-duty production lines. The low-spark carbon brush geometry minimises electromagnetic interference with nearby sensors, servo drives, and PLCs — a meaningful advantage in dense control cabinet environments.
④ Direct Gearbox Compatibility
The 90×90 mm flange and standardised shaft options mate directly with the 5GN gearbox series (reduction ratios 3:1 to 200:1), converting the motor into a compact high torque electric motor assembly covering output speeds from under 20 r/min to over 1,000 r/min. No adaptor plates or custom couplings are required, cutting assembly cost and lead time.
⑤ ISO 9001:2015 Certified Production
Every unit is manufactured under a documented quality management system, with each motor passing a functional verification test covering no-load speed, rated-load current, insulation resistance, and commutation quality before despatch. This traceability supports end-customer compliance documentation for medical, food-processing, and export-regulated applications across Australia, the UK, and the EU.
DC Motor Working Principle
To understand why the EP-60-120W performs predictably across its rated power range, it helps to review the dc motor working principle that underpins this class of brushed motor. The operating mechanism relies on the interaction between a direct current flowing through a wound armature coil and the static magnetic field produced by the surrounding permanent magnets in the stator. When energised, the current-carrying conductors in the armature experience a Lorentz force — a tangential push that drives rotation. The mechanical commutator — a segmented copper ring — switches the direction of current through each winding group in synchrony with rotor position, sustaining the torque-producing force continuously and producing smooth shaft rotation.
A key characteristic of this design is natural back-EMF regulation. As the armature accelerates, it generates a counter-voltage that limits further speed increase. When shaft load rises, this back-EMF drops, automatically allowing more current to flow and torque to increase — a self-regulating behaviour that stabilises operating speed under varying mechanical demands. This property distinguishes the brushed permanent magnet dc motor from a dc stepper motor, which moves in discrete angular steps and requires external step sequencing electronics. It also differs from a dc servo motor, which incorporates a position feedback encoder and requires a dedicated closed-loop servo drive to operate.
The absence of electronic commutation hardware is what makes the brushed dc motor so cost-effective relative to a bldc motor or brushless dc motor at this power level. The BLDC motor delivers higher efficiency and longer maintenance-free life, but requires a dedicated three-phase inverter drive and rotor position sensing — components that add cost and complexity that is not justified in many general-purpose drive applications. For machine builders asking the question — why would you use a dc motor here instead of a brushless alternative? — the answer lies in simplicity, repairability, and total system cost at the 60–120W output level.
Materials & Build Quality
The structural housing of the EP-60-120W dc motor is formed from cold-rolled steel, finished with an electrostatic powder coat for corrosion protection in industrial workshops, light outdoor enclosures, and high-humidity agricultural environments. Unlike thin-wall aluminium castings found in some budget motor ranges, the steel housing provides a rigid bearing seat geometry that maintains shaft alignment throughout the rated service life — an important factor in gearbox-mounted configurations where off-axis loads are present.
The stator uses high-coercivity sintered neodymium-ferrite permanent magnets, selected for their stable flux density at the motor's operating temperature range of up to 80°C continuous. The armature core is laminated silicon steel with inter-lamination varnish insulation, keeping eddy-current losses to a minimum at the 2,600–3,300 RPM operating band. Armature windings use enamelled copper wire rated to Class B thermal limits (130°C maximum), providing comfortable margin above the expected winding temperature rise of 50–60 K under rated load.
Carbon brushes are precision-moulded and spring-loaded against a CNC-ground copper commutator. The commutator surface finish is maintained within tight runout tolerances to ensure even brush contact pressure and minimal electrical arcing — a key factor in achieving the 3,000-hour brush service life across all nine model variants in the range. Pre-greased sealed deep-groove ball bearings are fitted at both shaft ends, requiring no scheduled lubrication during normal service.
All materials in the EP-60-120W comply with current RoHS 2 directives, supporting CE marking documentation for sales into EU member states and the United Kingdom, and meeting the material disclosure requirements for Australian industrial equipment registers.
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The stepped power range of the EP-60-120W series — 60W, 90W, 120W — gives engineers the flexibility to match motor output precisely to load requirements without over-specifying. The following sectors represent the most common deployment environments for this motor family.
🏭 Conveyor & Material Handling
Belt conveyors in food processing, electronics assembly, and logistics sortation facilities regularly specify a high torque dc motor in the 90–120W range to handle variable product loads. The EP-90W and EP-120W variants, when combined with a 2GN gearbox at a 100:1 ratio, deliver low-speed, high-torque output that suits accumulation conveyors and pallet transfer systems across UK and EU distribution centres.
🌾 Agricultural Equipment
Grain augers, seed metering drives, and fertiliser spreader mechanisms commonly run from 12V or 24V DC supplies matching the tractor's electrical system. The K5D90-24□ and K5D60-24□ models fit directly into these systems, pairing with a 5GN gearbox to deliver the shaft speeds that match standard agricultural sprocket and chain drive configurations used across North American and Australian farms.
🖨️ Industrial Printing & Finishing
Wide-format printing and laminating machines drive media transport rollers using brushed dc electric motors for precise speed control via PWM drive controllers. The 60W variant at 90V is popular in this segment — its dc motor high speed no-load characteristic at 3,100 RPM, stepped down through a low-ratio gearbox, provides the roller surface speeds needed for accurate registration on long production runs.
💊 Pharmaceutical & Lab Automation
Tablet coaters, centrifuge pre-drives, and reagent carousel rotators in South Korean and European pharmaceutical facilities demand consistent speed under varying viscous or inertial loads. The EP-60-120W's back-EMF self-regulation provides adequate speed stability for these applications without the servo amplifier overhead, keeping control system BOM cost down on lower-criticality stations where a full dc servo motor is not warranted.
🔩 Machine Tool Auxiliaries
Coolant pump drives, chip conveyor motors, and tool changer actuators on CNC machining centres often use a compact dc motor in the 90–120W bracket — small enough to mount within the machine base, powerful enough to handle the duty without thermal derating. The 90V variant is particularly suited to retrofitting older machine tool DC bus systems where 90V regulated supplies are already present.
🚐 Mobility & Specialty Vehicles
Electric mobility aids, golf cart accessories, airport ground support equipment, and autonomous guided vehicle (AGV) ancillary drives use 12V or 24V dc electric motors at the 60–120W power level for steering actuators, lift mechanisms, and ancillary pump drives. The motor's 3,000-hour brush life comfortably fits the typical annual duty cycle of intermittent-use vehicle accessories in these sectors.
About Our Manufacturing Facility
Our production operation has accumulated more than a decade of hands-on experience in mechanical power transmission, with engineering expertise spanning dc motor design, gear reduction systems, hydraulic actuation, and mechanical drive assemblies for global industrial markets. This depth of in-house capability — from winding and commutator grinding through gear hobbing and final assembly — allows us to maintain tight quality control across every product family without relying on external subcontractors for core manufacturing steps.
Our product range covers agricultural gearboxes, worm gear reducers, planetary gear drives, power take-off shafts, hydraulic cylinders, drive chains, and a full series of dc electric motors. The facility holds ISO 9001:2015 quality management certification, with production processes documented and audited to ensure consistent output quality across all order volumes — from prototype quantities to high-volume OEM supply runs. We design and manufacture gearboxes and mechanical assemblies in ductile iron, cast iron, cast steel, precision cast steel, and cast aluminium, alongside gears, sprockets, worm gears, pulleys, worm shafts, and a broad range of standard and non-standard mechanical transmission components.
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Complete Drive System — Related Products
The EP-60-120W dc motor is designed to function as part of a broader drive system rather than a standalone component. Our facility produces the full range of complementary drive products, offering machine builders a single-source supply pathway that eliminates cross-supplier tolerance mismatches and simplifies after-sales support.
Our complete மின்சார மோட்டார்கள் range spans AC induction, DC brushed, and DC brushless types across a wide power spectrum. Specifying motor and drive components from a single source means consistent flange standards, shared engineering documentation, and straightforward warranty processes — advantages that procurement teams at European and North American OEMs consistently prioritise when evaluating new suppliers.
எங்கள் புழு கியர்பாக்ஸ் range offers right-angle reduction from 5:1 to 100:1 with self-locking characteristics that hold load position when power is removed — ideal for gate actuators, elevator drives, and valve control mechanisms. Mounting the EP-120W against a 60:1 worm reducer transforms the high torque dc motor combination into a slow-speed, high-torque output stage with built-in position holding at no additional cost.
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பதிப்பாசிரியர்: PXY
