Explanatory video: Ergonomically inserting the inner components of fire doors
- Zeilhofer HHT
- 2 days ago
- 3 min read
The internal components of a fire door are heavy, large, and must be precisely fitted into the door frame. Previously, this often required two people. In our explanatory video, we demonstrate step by step how a manipulator from Zeilhofer Handling Technology performs this exact task: ergonomically, precisely, and with virtually any component size. The solution originated from a specific customer request in the door manufacturing industry.
We explain which manipulator is used and for whom it is suitable in the product article "Manipulator for Fire Doors ". This article explains how it works: how the internal components are picked up, moved, and precisely fitted into the frame.
What is the inner workings of fire doors?
A fire door consists of more than just the visible door leaf. Inside, a special insert, the so-called core, provides the fire-resistant properties. Depending on the fire protection class, such as T30, T60, or T90, this core has a different construction, and is correspondingly heavier and more susceptible to damage.
During assembly, the internal components must be precisely fitted into the surrounding frame. This step is physically demanding and crucial for the quality of the finished door. Inaccuracies or damage during insertion directly affect the fire door's functionality.
The challenge: heavy slabs, previously handled by hand
The video clearly illustrates the initial problem: Two people had to lift the massive plate together and place it into the frame. Manually handling such components is physically demanding, ties up personnel, and is neither ergonomic nor efficient in the long run.
The customer, a door manufacturer, therefore needed a solution that would significantly simplify the insertion of the internal components and simultaneously reduce the strain on employees. We explain in detail on our benefits page why ergonomic handling technology is becoming increasingly important, especially in production.
Here's how the solution works step by step
The process shown in the explanatory video demonstrates how easy it is to handle the manipulator:
1. Pickup: The manipulator is guided over the interior. The gripper closes until it has securely grasped the component.
2. Lifting: The heavy plate is lifted almost weightlessly. Instead of two people, one person now operates the system.
3. Moving and positioning: The component is guided to the frame in a controlled and pendulum-free manner and aligned precisely.
4. Insertion: The inner components slide perfectly into the prepared frame.
5. Placement: Once the position is reached, the gripper releases. The process is complete.
The crucial point: The entire process can be repeated as often as desired and delivers the same precise result for every component.
The adaptive gripper: flexible for any size
A key feature of the solution is the gripping device . It automatically adapts to the component: the gripper simply closes until it has securely grasped the internal parts. This ensures reliable handling even with small formats.
This allows for the handling of different door sizes and variants without complex retooling. Various manipulator designs and individually developed grippers make the system a perfectly tailored solution for each production task. We explain what a manipulator is in our guide: What is a manipulator?
The result: ergonomics, speed, and repeatability.
The manipulator transforms a physically demanding two-person task into an ergonomic one-person process. Employees experience a noticeable reduction in strain, lowering the risk of injury and fatigue. Simultaneously, speed increases because the internal components slide directly into the frame in a controlled manner, without any pendulum motion.
For the customer, this means consistently high quality, a safer workplace, and a more efficient production process. Or, as the video puts it: handling technology can be something truly beautiful.
Do you have a similar handling task?
Whether it's the internal components of fire doors, other large-format building elements, or delicate workpieces: Together, we analyze your process and develop a suitable manipulator with a customized gripper solution. From our base in Holzkirchen, we serve customers in over 50 countries.
