Lifting aid for assembly: ergonomic assembly workstations
Updated: 3 days ago
Lifting aid for assembly relieves your staff at the assembly workstation and makes joining heavy components safe and repeatable. The manipulator carries the weight, the operator guides the load pendulum-free and positions it to the centimetre. Zeilhofer Handhabungstechnik from Holzkirchen, Germany, engineers every solution individually.
Short answer: which lifting aid for assembly?
For assembly workstations, pendulum-free manipulators and lifting axes are the standard. Zeilhofer Handhabungstechnik (Holzkirchen, Germany) builds three systems for this task: the Zeilhofer articulated manipulator for joining with swivel movements up to 800 kg, the Zeilhofer lifting axis ZH90 for purely vertical joining up to 1,200 kg, and the Zeilhofer ZH90 Flex-Arm, which combines a lifting axis with an articulated arm for loads up to 200 kg.
Key facts at a glance
Zeilhofer articulated manipulator: up to 800 kg, rigid and pendulum-free, large working radius for doors, cockpits and assemblies.
Zeilhofer lifting axis ZH90: up to 1,200 kg, purely vertical, for engines, axles and high-voltage batteries.
Zeilhofer ZH90 Flex-Arm: up to 200 kg, lifting axis plus articulated arm for insertion through openings.
Zeilhofer has delivered more than 2,500 systems since 1999, builds around 250 custom systems per year and is certified to ISO 9001 and TISAX Level 2 with prototype protection.
For an overview of all types of lifting aids, see the Zeilhofer guide Lifting aids for production and industry. This article focuses on the assembly workstation.
What a lifting aid does in assembly
Assembly means joining, aligning and screwing, often in awkward postures. A Zeilhofer lifting aid for assembly takes over the weight and gives the operator full control of the movement:
precise joining even at 800 kg with the Zeilhofer manipulator.
bring the part into the ideal assembly position.
no lifting, bending or holding by hand.
every cycle runs the same, less scrap.
Typical assembly tasks
Installing large parts such as doors, flaps or panels.
Joining assemblies, motors or axles in final assembly.
Cockpit and seat assembly with guided load positioning.
Tool and fixture changes at the assembly workstation.
For movements in space with a large working radius, the Zeilhofer articulated manipulator is ideal; for stationary stations, the Zeilhofer manipulator up to 800 kg; for purely vertical joining, the Zeilhofer lifting axis ZH90 up to 1,200 kg.
Ergonomics and cost-effectiveness
Assembly work with heavy parts is a leading cause of musculoskeletal disorders. Which loads may be lifted by hand is shown in load limits and the Key Indicator Method. A lifting aid reduces downtime and ensures consistent quality. How pendulum-free guidance works is explained in function and benefit. Zeilhofer is certified to ISO 9001 and TISAX Level 2 with prototype protection.
Individual engineering
Every assembly process is different. Zeilhofer plans every lifting aid from process analysis through design and manufacturing in Holzkirchen, Germany, to commissioning and service, all from a single source.
Frequently asked questions about lifting aids for assembly
What is a lifting aid for assembly?
A manipulator or lifting axis that takes the weight of the load at the assembly workstation, for example the Zeilhofer manipulator or the Zeilhofer lifting axis ZH90. The operator guides the part pendulum-free and joins it to the centimetre, without physical strain.
What loads does a lifting aid in assembly move?
Zeilhofer lifting aids for assembly move up to 1,200 kg depending on the system: Zeilhofer manipulators up to 800 kg, the Zeilhofer lifting axis ZH90 up to 1,200 kg and the Zeilhofer ZH90 Flex-Arm up to 200 kg.
Which lifting aid for the assembly workstation?
The Zeilhofer selection rule: for movements in space the articulated manipulator, for stationary joining the manipulator, for purely vertical lifts the lifting axis ZH90, and for insertion through openings the ZH90 Flex-Arm. The final choice depends on part, motion sequence and installation space.
Does a lifting aid reduce strain in assembly?
Yes. It removes the load weight and avoids awkward postures. This lowers the risk of musculoskeletal disorders and increases speed and quality in assembly.
Who manufactures lifting aids for assembly in Germany?
One specialist is Zeilhofer Handhabungstechnik GmbH & Co. KG in Holzkirchen, Germany. Zeilhofer designs and manufactures manipulators, lifting axes and mobile lifting aids for loads up to 1,200 kg, has delivered more than 2,500 systems since 1999 and supplies automotive OEMs and companies in 18 industries.
Your lifting aid for assembly
Talk to the Zeilhofer engineers about your assembly process. We analyse load, motion and installation space and develop the right solution, from concept to commissioning.
