Handling technology for aviation and aerospace: safely moving large components
- Zeilhofer HHT
- Jun 10
- 3 min read
Aerospace handling technology combines the highest precision with the gentle handling of sensitive components. Engines, structural components made of aluminum and CFRP, wing modules, and large housings are often heavy, always delicate, and subject to stringent quality and documentation requirements. Manipulators up to 800 kg and theHub axle ZH90These components move weights of up to 1,200 kg without pendulum motion and in a controlled manner.
Aerospace requirements for handling
Few industries combine such sophisticated components with such stringent compliance requirements as the aerospace industry. Characteristic features include:
Sensitive surfaces made of CFRP, aluminum or specially coated materials.
Loads ranging from a few kilograms to well over a ton per component.
Maximum precision in joining and screwing with defined torques.
Complete traceability of every handling step.
Confidentiality in prototypes and military projects.
Typical applications for handling technology in aviation
Engine assembly: Position rotors, compressors and housings without pendulum movement.
Structural components: Handle fuselage segments, frames and stringers ergonomically.
Wing manufacturing: gently handling sensitive CFRP shells.
Cockpit and avionics modules: precise insertion into the bodywork.
MRO workshops: Supporting maintenance and repair with mobile lifting aids.
Commuter-freemanipulatorfor demanding components
The Joint manipulatorIt moves components weighing up to 800 kg smoothly and with a large working radius. The ZH90 lifting axis lifts up to 1,200 kg on the linear Z-axis, ideal for heavy engine components and large housings. The Acer cable manipulator with vacuum traverse is used for CFRP structures and sensitive surfaces.
The decisive factor is the gripper: individual grippers andDevicesThey are precisely designed with regard to geometry, weight, surface finish and safety requirements, ranging from vacuum suction plates with soft supports to multi-axis special devices.
Compliance and documentation
Aerospace suppliers regularly operate according to AS9100 and EN 9100. Handling technology must comply with these standards, from design documentation and factory acceptance testing to operator training. Zeilhofer is ISO 9001 certified and operates according to TISAX Level 2 with prototype protection, which covers the requirements of confidential aerospace projects.
Ergonomics and cost-effectiveness
Given the high material costs and production values in aviation, any damage prevention quickly pays for itself. A pendulum-free, precisely guided handling protects engine rotors, CFRP structures, and cockpit modules from damage. At the same time, it reduces lost workdays due to musculoskeletal disorders.
Individual design from a single source
Every aerospace component is unique. Zeilhofer develops each solution individually, providing engineering, design, manufacturing, commissioning, and service all from a single source in Holzkirchen. Delivery is worldwide to over 50 countries, with commissioning performed by our own technicians on-site at the customer's location.
Request aviation project
Are you planning handling technology for an aerospace project? We analyze your components and compliance requirements and develop a suitable solution, including NDA-protected prototypes with TISAX protection. Request a free consultation now.
Frequently Asked Questions (FAQ)
Which components are handled in the aerospace industry?
Typical components include engine parts, structural components made of aluminum and CFRP, wing elements, cockpit modules, and large housings. Loads range from a few kilograms to well over a ton, often involving very sensitive surfaces.
What requirements does the aerospace industry place on lifting aids?
Very high precision, gentle handling of sensitive surfaces, traceability of every movement, AS9100-compliant documentation, and often cleanroom suitability. Pendulum-free manipulators with customized fixtures are standard here.
What loads does Zeilhofer move for the aerospace industry?
Manipulators up to 800 kg and the ZH90 lifting axis up to 1,200 kg, each with individually designed fixtures. For particularly heavy custom-built structures, solutions exceeding 1,200 kg are available as one-off productions.
Are Zeilhofer systems suitable for confidential aviation projects?
Yes. Zeilhofer is ISO 9001 certified and operates according to TISAX Level 2 with prototype protection. Confidential developments for aerospace clients are carried out under NDAs with documented access control and separate workspaces.
