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Handling Technology Glossary: Key Terms from A to Z

  • Zeilhofer HHT
  • 3 days ago
  • 4 min read

Updated: 2 days ago

This handling-technology glossary from Zeilhofer explains the key terms around handling technology, manipulators and lifting aids – concise, vendor-neutral and to the point. From balancer and key indicator method to vacuum lifter.


Articulated-arm manipulator
Articulated-arm manipulator

Systems and designs


Manipulator

  • A manipulator is a guided handling device that takes the weight of a load so the operator can move it with little effort, pendulum-free and precisely. Unlike a crane, it carries the load via a rigid, articulated mechanism.


Industrial manipulator

  • A manipulator for continuous industrial use, designed for load capacity, cycle time and process reliability – up to 800 kg and more depending on the design.


Articulated-arm / knuckle-boom manipulator

  • A manipulator with an articulated arm that positions loads freely in space. Robust and precise for joining heavy parts. See articulated-jib manipulator.


Parallelogram manipulator


Rope manipulator

  • A lightweight manipulator that guides the load sensitively via ropes – fast and flexible for lighter loads.


Lifting axis (hub axis)

  • A linear load guide with an aluminium profile that lifts heavy loads purely vertically and pendulum-free – up to 1,200 kg. See the ZH90 lifting axis.


Balancer / rope balancer

  • A lifting device that holds the load almost weightlessly via a wire rope so it can be guided by hand. See what is a rope balancer.


Mobile lifter

  • A mobile, often battery-powered lifting aid that works without compressed air and can be used at changing workstations.


Pillar jib crane

  • A crane system with a rotating jib on a column; it serves as a carrier structure but does not provide pendulum-free load guidance like a manipulator.


Chain hoist


Load handling and gripping


Gripper / load-handling attachment

  • The component that grips the load mechanically – for example clamping, form-fit or magnetic grippers, designed individually for the geometry.


Vacuum lifter / suction lifter

  • A lifting device that picks up loads via negative pressure – gentle on smooth and sensitive surfaces. See what is a suction device.


Suction device / vacuum gripper

  • The load-side attachment of a vacuum system that adheres to the part by vacuum and sits on a manipulator or lifting axis.


Area suction cup

  • A large suction plate that distributes the holding force evenly – for panels, sheet metal and glass.


Vacuum tube lifter

  • A vacuum lifter with a lifting tube in which lifting and holding are controlled via the same airflow.


Function and technology


Pendulum-free handling

  • Load guidance without after-swing – the operator positions the part to the centimetre without counter-steering.


Load capacity

  • The maximum load a system safely picks up; at Zeilhofer from 70 to 1,200 kg depending on the system.


Working radius

  • The horizontal action range of a manipulator around its pivot point.


Drive: pneumatic or electric

  • Manipulators run pneumatically, electro-pneumatically or fully electrically – each variant has its own strengths.


Ergonomics and occupational safety


Lifting aid

  • An umbrella term for technical systems that replace or relieve manual lifting – from the manipulator to the vacuum lifter. See manipulator as a lifting aid.


Manual handling limits

  • Legal requirements (in Germany the Load Handling Ordinance) oblige employers to avoid or reduce hazardous manual handling.


Key indicator method (KIM/LMM)

  • A method by the German Federal Institute (BAuA) for assessing physical strain during manual handling. See how many kg may you lift.


UVV inspection / DGUV Regulation 54


Musculoskeletal disorders (MSD)

  • The most common work-related illnesses; a central reason for using ergonomic lifting aids.


Practical examples


How do these terms work together in practice? Three typical examples from everyday Zeilhofer work:


Glass handling: An articulated-arm manipulator with a vacuum area cup picks up a 120 kg glass pane pendulum-free and guides it to the façade with millimetre precision – without mechanical pressure on the sensitive surface.


Heavy loads in the foundry: A ZH90 lifting axis raises a 900 kg mould box purely vertically and shock-free while the operator positions it precisely at the control handle.


Mobile assembly: A battery-powered Mobile Lift ZH brings parts up to 100 kg to changing workstations without a compressed-air connection – ideal in order picking.


Frequently asked questions


What is the difference between a manipulator and a crane?

  • A crane lifts a load freely swinging and vertically. A manipulator guides it pendulum-free via a rigid, articulated mechanism and positions it precisely – including turning, tilting and joining. See the comparison Manipulator vs crane.


Which lifting aid suits which load?

  • For vertical heavy loads up to 1,200 kg the lifting axis, for movements in space the articulated-arm manipulator, for light, fast loads the cable manipulator, and for compressed-air-free mobile use the mobile lift. Overview in the lifting aids guide.


How much does a manipulator cost?


From what weight is a lifting aid advisable?

  • As soon as the key indicator method shows a high risk – as a guide from about 25 kg (men) or 15 kg (women), or at high lifting frequency. More in How many kg may you lift?.


Pneumatic or electric – which is better?

  • There is no universal winner: without compressed air or for mobile, hygienic applications electric has the edge; for sensitive balancing with compressed air, pneumatic is often better. See the drive types guide.


Your handling task?


Do you have a specific handling task? Our engineers will be glad to advise you and design your solution individually – Made in Germany, from a single source.



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