Manipulator with interchangeable spreading mandrel: One system for all roller diameters
Zeilhofer Handling Technology develops customized manipulators for rolls, tubes, sheets, and other components. Paper rolls, film rolls, plastic rolls: In many production processes, rolls are an integral part of the daily material flow. What may appear similar at first glance often differs considerably in practice, especially in core diameter. If each roll size requires its own fixture, this results in unnecessary setup times, additional investments, and more storage space for interchangeable fixtures.
We developed a manipulator with an interchangeable expanding mandrel specifically for this task. The article "Individual Grippers and Fixtures: Custom Construction for Every Geometry" also demonstrates how different component geometries can be represented in a single device.
A challenge that many companies are familiar with.
Rollers differ in weight, width, and material, but most importantly in core diameter. Anyone who regularly processes different types of rollers knows the problem: a separate fixture is needed for each size, or the equipment has to be laboriously reconfigured every time the rollers change. This costs time, ties up storage space, and increases investment costs.
Furthermore, manual tool changes on the fixture are often associated with tool use, waiting times, and an increased risk of injury. Our goal was therefore clear: a holder that reliably accommodates multiple core diameters without requiring a complete fixture replacement. The article "Efficient Handling of Rollers" also describes how strenuous manual handling of rollers without aids can be.
Switch flexibly instead of undertaking costly conversions.
The core of the solution is the interchangeable spreading mandrel. It can be replaced in just a few steps, thus enabling the use of rollers with different core diameters, without having to change the entire fixture.
Instead of maintaining multiple manipulators or undertaking complex conversions, a quick change of the expanding mandrel is sufficient. This saves setup time and simultaneously increases flexibility in everyday production, especially with frequently changing roll formats. The expanding mandrel is one of the holding devices that we individually design as part of the overall system; you can find more information on the page Devices, Grippers, Suction Cups & Magnets .
This is how the spreading mandrel is changed.
The replacement process itself takes place in a few clearly defined steps and usually requires no special tools:
Detach the roller and move the manipulator into the changeover position.
Release the locking mechanism of the current expanding mandrel.
Remove the expanding mandrel and attach the appropriate mandrel for the new core diameter.
Close the lock and perform a function test.
Pick up the next role and continue working
This transforms a setup process that previously required tools and several minutes of downtime into a single step during operation.
Safe roll handling for a wide variety of applications
Safely handling and precisely moving heavy rolls requires reliable handling technology. The manipulator takes on almost all of the roll's weight, enabling controlled movement with minimal effort. This reduces strain on employees and improves workplace safety. At the same time, rolls can be positioned precisely, for example, on production machines, winding systems, or packaging lines.
Depending on the system, our articulated manipulators move loads up to 800 kg, and the ZH90 lifting axis even up to 1,200 kg, all with zero oscillation and precision. The article "Manipulators for Heavy Rolls of Different Sizes" describes the general advantages of a manipulator over a crane or chain hoist for handling rolls.
Interchangeable spreading mandrel compared to other solutions
There are three common approaches to roller insertion. A comparison shows where the interchangeable spreading mandrel demonstrates its strengths:
One fixed device per roll size: very quick changeover, but high investment and storage costs, as a separate system must be available for each core diameter.
Modification of the existing equipment: lower investment, but long setup times, tool usage and system downtime with each change
Interchangeable spreading mandrel: one basic device with multiple mandrels, changeover in minutes without special tools, low investment with high flexibility
Custom-designed for your roles
Not every role is the same. That's why each handling solution is individually tailored to the specific application. During the planning phase, we clarify, among other things:
roller weight
roller diameter
Core diameter
Roll width
Material properties
Work processes
ergonomic requirements
Based on this, a tailor-made solution is created that can be optimally integrated into the existing production process.
Improved ergonomics and higher productivity
A manipulator with an interchangeable expanding mandrel not only improves workplace ergonomics but also ensures more efficient processes. The quick mandrel change allows for handling different roll formats without lengthy interruptions. This reduces setup times, increases system availability, and improves material flow, especially with frequently changing production orders. A similar principle also proves beneficial for other cylindrical components such as tube bundles; see Tube Bundle Handling with Manipulators .
Areas of application
A manipulator with an interchangeable spreading mandrel is suitable for numerous industries, including:
Paper industry
Film production
Plastics processing
Packaging industry
printing industry
textile industry
Logistics and material flow
Wherever rollers with different core diameters need to be moved safely, the interchangeable spreading mandrel ensures maximum flexibility. For flexible locations without permanent installation, mobile solutions are also available, as described in the article "Mobile Lifting Aid for Handling Rollers" .
Process: From consultation to commissioning
Consulting: Initial technical consultation, analysis of roller range, core diameters and work processes
Concept: Individual concept including device, control system and quotation with price indication
Manufacturing: Design and manufacturing in Holzkirchen, Germany, in-house technicians, ISO 9001 and TISAX Level 2 certified.
Commissioning: On-site assembly, training and commissioning, worldwide, optionally with a maintenance contract
Individual handling technology is our strength.
Every production process places different demands on roll handling. That's why Zeilhofer Handling Technology develops customized manipulators and holding devices precisely tailored to the specific workflows. The interchangeable spreading mandrel demonstrates how intelligent design and practical solutions can be combined, similar to the manipulator with interchangeable gripper system for flexible production processes . The result is ergonomic workstations, safe processes, and cost-effective handling of a wide variety of roll formats.
Frequently asked questions about the manipulator with interchangeable spreading mandrel
What is a replaceable spreading mandrel?
An interchangeable spreading mandrel is a replaceable mount on the manipulator that allows for the use of rolls with different core diameters. The mandrel can be changed in just a few steps, eliminating the need for a complete fixture change.
How long does it take to replace the spreading mandrel?
The replacement process typically takes only a few minutes and requires no special tools. The exact duration depends on the specific design and locking mechanism, which we tailor to each individual case.
What core diameters can be covered with an interchangeable expanding mandrel?
That depends on the individual design. Since each solution is designed specifically for the project, we determine the covered core diameters together with the customer during the initial consultation.
What advantages does an interchangeable spreading mandrel offer compared to several individual devices?
Instead of maintaining multiple manipulators or fixtures, simply changing the spreading mandrel is sufficient. This reduces investment costs, saves storage space, and shortens setup times in daily production.
Can an existing manipulator be retrofitted with an interchangeable spreading mandrel?
In many cases, yes. Whether a retrofit is possible depends on the existing model and the recording interface. We would be happy to check this using your existing system.
Up to what weight can rollers be handled?
The articulated manipulator handles rollers up to 800 kg, and the ZH90 lifting axis up to 1,200 kg, each with zero oscillation and precision. The exact load capacity depends on the roller weight, diameter, and application.
For which industries is this solution suitable?
Especially for the paper industry, film manufacturing, plastics processing, packaging industry, printing industry, textile industry and logistics, anywhere where rolls with different core diameters need to be moved.
Further topics from the blog and guide
You can find more in-depth information about roller handling and manipulators in these articles:
How to handle your roles flexibly and ergonomically?
Do you process different types of rolls and are looking for a holder that covers multiple core diameters? Our engineers will be happy to advise you and design a customized solution for you, Made in Germany, from a single source.
Our guide to roller lifters and roller handling offers more in-depth information on roller lifters, variants and selection criteria.
