Heavy-load handling up to 1,200 kg: solutions for extreme loads
- Zeilhofer HHT
- Jun 10
- 4 min read
Heavy-load handling up to 1,200 kg means moving heavy components pendulum-free, precisely and ergonomically, instead of heaving them with brute force or unguided aids. The Zeilhofer ZH90 lifting axis lifts up to 1,200 kg on the linear Z-axis, manipulators move up to 800 kg stationary and pendulum-free. This way even extreme loads become controllable.
What does heavy-load handling mean?
Heavy-load handling describes the controlled movement of large and heavy components in the production process. Unlike a crane that lets loads swing freely, a manipulator guides the load in a controlled, pendulum-free manner. This makes positioning safe, precise and repeatable, even in the ton range close to the load limit of the component and the environment.
Solutions for loads up to 1,200 kg
For extreme loads, the ZH90 lifting axis (up to 1,200 kg) is the central solution: a linear Z-axis for controlled lifting and lowering. The manipulator (up to 800 kg) moves components stationary and pendulum-free, the articulated manipulator opens up variant-rich processes. The gripper is decisive: individual grippers and fixtures are precisely matched to the component.
Load classes at a glance
Which lifting aid suits which load depends on weight, geometry and process. The overview below shows the capacity of each system:
ZH90 lifting axis: up to 1,200 kg, linear Z-axis, pneumatic, electro-pneumatic or electric. For e-axles, motors, castings and machine components.
Articulated manipulator: up to 800 kg, column or ceiling mounting. For cockpits, windshields, axles and battery modules.
ZH90 Flex-Arm: up to 200 kg, combination of linear axis and articulated arm. For delicate components and final assembly.
Rope manipulator ZH70 / Acer: up to 150 kg, rope-guided, pneumatic. For high-frequency lifting and order picking.
ZH lift assist: up to 100 kg, mobile, battery-powered. For machine loading, workshop and warehouse.
For the top load class from 800 kg to 1,200 kg, the ZH90 lifting axis is the central solution.
Why pendulum-free guidance is decisive
The heavier the load, the more dangerous uncontrolled swinging becomes. Pendulum-free guidance prevents jerky movements, protects operators and environment, and allows precise threading and joining of heavy parts. What a lifting axis is and how it works is explained in the Guide: What is a lifting axis?.
Heavy-load handling vs. crane and chain hoist
A crane lets the load swing freely, a chain hoist only lifts vertically without absorbing moments. The ZH90 lifting axis guides the load rigidly and pendulum-free on the Z-axis and safely absorbs off-centre loads and the resulting moments. This makes it safer and more precise than free-hanging lifting equipment for heavy, bulky components.
Ergonomics and cost-effectiveness
Even in the heavy-load range the rule applies: anyone who guides loads technically instead of heaving them manually reduces physical strain and days lost, lowers scrap on expensive components and increases cycle reliability. The benefit of ergonomic handling technology is felt directly in safety, quality and throughput.
Pneumatic, electro-pneumatic or electric?
The ZH90 lifting axis is available in three drive variants, matched to the plant environment. Pneumatic for intuitive, low-effort guidance in air-cushion operation. Electro-pneumatic as a combination of compressed air and electric control. Fully electric for sites without a compressed-air network and for precise, programmable positioning in cycled lines. A process analysis determines the right variant.
Customized engineering from a single source
Heavy loads require robust, precisely dimensioned systems. That is why every solution is created individually: engineering, design, manufacturing, commissioning and service from a single source in Holzkirchen. Zeilhofer Handling Technology is ISO 9001 certified and works according to TISAX Level 2 with prototype protection, with solutions for 18 industries and customers in over 50 countries. Related: Battery module handling in e-mobility.
Industries for heavy-load handling
Heavy-load handling up to 1,200 kg supports demanding manufacturing:
Metalworking, forging and machining operations
Automotive and e-mobility
Machine and plant construction
Aerospace
Glass industry and large-format components
Heavy load? Get your process analysed
Are you moving components close to or above the limit of safe manual lifting? We analyse your process and develop a fitting heavy-load solution. Request now, no obligation.
Frequently asked questions (FAQ)
Which loads does the ZH90 lifting axis move?
The ZH90 lifting axis lifts up to 1,200 kg on the linear Z-axis and is therefore designed for particularly heavy components.
What distinguishes a manipulator from a crane?
A manipulator guides the load pendulum-free and precisely, while a crane lets it swing freely. This makes positioning heavy parts safe, exact and repeatable.
Up to which weight do Zeilhofer manipulators work?
Manipulators move loads up to 800 kg stationary and pendulum-free. For heavier loads up to 1,200 kg the ZH90 lifting axis is used.
Are heavy-load solutions individual or standard?
Every solution is designed individually. Grippers and fixtures are matched to the geometry and weight of the component, manufactured and commissioned from a single source in Holzkirchen.
Which drive type is suitable for cycled assembly lines?
For cycled and automated lines, the fully electric variant of the ZH90 lifting axis is suitable thanks to precise, programmable positioning. Pneumatic and electro-pneumatic are also available, matched to the plant environment.
Can the ZH90 lifting axis handle off-centre loads?
Yes. The rigid linear Z-guidance safely absorbs off-centre loads and the resulting moments, without the load swinging or tilting.
What loads can I move with Zeilhofer Handhabungstechnik's lifting aids?
With lifting aids and lifting axes up to 1,200 kg (ZH90 lifting axis) and manipulators up to 800 kg, you move components such as castings, glass panels, battery modules, motors and machine components, pendulum-free and ergonomically guided. For loads above the standard range, we develop project-specific custom solutions.
