Gelenk-Manipulator für Wasserstofftanks
Gelenk-Manipulator für Wasserstofftanks
PRODUCT KNOWLEDGE - ARTICULATED ARM MANIPULATOR
ARTICULATED ARM MANIPULATOR UP TO 800 KG: HEAVY DUTY WITH REACH
The articulated arm manipulator from Zeilhofer Handling Technology moves loads up to 800 kg without pendulum movement over a working radius of up to 4.5 m. Pneumatically driven, available in four mounting variants, ergonomic in every position.
CHAPTER 1
WHAT SETS THE JOINT ARM MANIPULATOR APART
The articulated arm manipulator moves, positions, and handles loads using arms and joints. The operator guides the load without having to carry it. From a fixed position, it covers a large working area.
Load capacity up to 800 kg
Working radius up to 4.5 m from one position
Swing-free load guidance via arms and joints
Pneumatic drive with weight compensation
Four mounting options: floor- and ceiling-mounted or mobile
Sensitive positioning for assembly and parts insertion
Can also be used overhead and in hard-to-reach places.
Can be combined with lifting axes, rotary modules and swivel arms
Deepen your understanding of the basics:
What generally defines a manipulator is explained in the guide " What is a manipulator ?". A comparison to cable-guided designs can be found in the guide " Articulated or cable manipulators ". Technical data is available on the product page "Articulated manipulator ".
CHAPTER 2
OVERVIEW OF THE MOST IMPORTANT AREAS OF APPLICATION
The articulated arm manipulator is the right choice wherever heavy loads need to be handled precisely within a larger work area. Six industries with particularly high adoption rates:
01 Automotive
Precisely position assemblies, axles, cockpit modules, and seating sets. Handle heavy loads up to 800 kg without swaying.
04 Aerospace
Handling engine modules, structural components and large-area components in pre-assembly and final assembly.
02 Mechanical Engineering
Handle tools, clamping devices and large components from a fixed workstation. Large working radius saves travel distances.
05 Glass and windows
Large-format panes and frames can be moved without swinging. Suction cups are integrated directly into the arm.
03 Foundry
Remove hot castings from the mold and transfer them safely. Joint kinematics reach awkwardly positioned locations.
06 Food industry
Handling of bags, drums and containers up to 800 kg. Hygienic design possible.
Other industries that use articulated arm manipulators include: semiconductors, toolmaking, special machine construction, packaging, construction industry, energy and utilities, research and development, furniture industry, pharmaceuticals, e-mobility, and logistics.
CHAPTER 3
PRACTICE: ROLLERS AND PIPES
Handling cylindrical loads without pendulum motion
Paper rolls, film rolls, steel pipes, aluminum pipes, and wire spools are cylindrical, often heavy, and must be positioned precisely in fixtures, machines, or storage areas. Manual handling is no longer feasible above 50 kg, and conventional cranes cause the load to swing, which leads to collisions with large-diameter rolls.
The articulated arm manipulator picks up cylindrical loads using specialized devices: mandrel grippers engage the inside of the coil, clamping grippers grasp pipes on the outside, and magnetic devices lift ferromagnetic steel pipes. The pendulum-free mechanism guides the load precisely into position, even with large diameters.
Advantages of this application
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Specialized mounts for indoor and outdoor handles
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Rollers up to 800 kg, precisely rotatable and positionable
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Protection of sensitive surfaces, such as coated pipes and film rolls
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High-bay racking operation across the full working radius height
CHAPTER 4
PRACTICE: RECORDS AND DISCS
Safely implement large-format, flat components
Glass panes, metal sheets, solar panels, wood-based panels, and aluminum sandwich panels are large, fragile, and unwieldy due to their geometry. Their surfaces are often highly finished and must not be damaged. Manual lifting is impossible with large formats, and a forklift would scratch or tilt the load.
The articulated arm manipulator with suction or vacuum traverse lifts the plate above the surface without mechanical contact at the edge. The load can be positioned horizontally via the working radius and, with a swivel mechanism, also rotated from horizontal to vertical.
Advantages of this application
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Suction and vacuum devices protect sensitive surfaces
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Swivel up to 90° for vertical mounting possible
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Pendulum-free load guidance protects large-format components.
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Handle transparent and coated materials such as glass safely.
CHAPTER 5
PRACTICE: BODY PARTS
Body and structural components in vehicle manufacturing
In car body manufacturing, doors, hoods, fenders, floor panels, and structural components are assembled in several steps. The components are large, form-fitting, and delicate, requiring extremely tight positioning. Manual handling is ergonomically unacceptable, while forklifts or cranes are too imprecise to achieve the required accuracy.
The articulated arm manipulator guides the body panel over a component-specific fixture. Suction devices, clamping grippers, or shaping fixtures hold the part securely and in a stable position. The working radius covers multiple stations or docking positions without requiring the manipulator to be repositioned.
Advantages of this application
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Component-specific recordings without risk of damage
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Precise positioning in the millimeter range
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Multiple component variants can be handled with one device
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Direct screwing via integrated screw systems is possible.
CHAPTER 6
FOUR ASSEMBLY OPTIONS FOR EVERY HALL STRUCTURE
Depending on the load, workflow and structural requirements, the articulated arm manipulator is designed in one of four assembly variants.
01 FLOOR INPATIENT
Permanently mounted to the hall floor. Maximum stability, ideal for the heaviest loads and continuous operation at the same workstation.
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Maximum load capacity up to 800 kg
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Installation radius around the column
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No intervention in the hall ceiling is necessary.
03 Floor-movable
Can be moved on a rail or trolley. Extends the working radius linearly and allows use at multiple workstations.
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Linear travel distance in addition to the working radius
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Multiple stations can be operated with one manipulator.
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Rail as standard profile or embedding
02 Ceiling-mounted
Mounted on the hall ceiling or a steel structure. Keeps the hall floor clear and allows free movement space under the manipulator.
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Floor completely clear for forklifts and workers
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Ideal for cramped workspaces
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Load-bearing ceiling or steel structure required
04 Ceiling-mounted
Suspended from a crane track, freely movable within the hall. Maximum freedom of movement with full heavy-duty load-bearing capacity.
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Movement space across the entire hall
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Compatible with existing crane runways
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Floor completely free for other processes
CHAPTER 7
COMBINATION WITH OTHER ZHHT SYSTEMS
The articulated arm manipulator is part of the modular system and can be expanded with other Zeilhofer components to create complex movement sequences.
01 + Hub axle ZH90
The arm handles the horizontal movement, while the lifting axis provides the precise vertical stroke. Ideal for tasks requiring long vertical travel distances.
02 + Drehmodul Arm ZH3
An additional pivot point at the arm end allows the load to rotate during movement. This is necessary for components that are mounted in multiple layers.
03 + swivel mechanism
Swiveling the load around an additional axis. This also allows the handling of workpieces that need to be rotated within the installation space.
The devices also include grippers, suction cups, magnets, hooks, as well as integrated screwdrivers and screw spindles. This allows for the handling of virtually all industrial tasks up to 800 kg.
CHAPTER 8
ECONOMICALITY IN HEAVY DUTY USE
The articulated arm manipulator is particularly advantageous where heavy loads are frequently handled. Four levels of operation:
Investment savings
Heavy loads are no longer lifted manually. Fewer back problems and absences.
Clock speed
A skilled operator can handle 800 kg faster than a forklift. Higher throughput time per shift.
Loss rate
Pendulum-free load guidance prevents impact damage to components and hall structures.
Occupancy
A mobile version serves multiple workstations. The purchase pays for itself faster.
In typical heavy-duty applications, an articulated arm manipulator pays for itself within 18 to 30 months, based on lost productivity, breakdown rates, and cycle time. The exact payback period depends on load frequency, component value, and previous costs.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
Frequently asked questions about the articulated arm manipulator up to 800 kg
01 What is an articulated arm manipulator and what is it used for?
An articulated arm manipulator is a pneumatic lifting aid that moves, positions, and handles loads via arms and joints. The operator guides the load but does not have to carry it themselves. The articulated arm manipulator covers a large working area from a fixed position and is used in automotive, mechanical engineering, foundries, aerospace, and many other industries.
02 What is the maximum load capacity of an articulated arm manipulator?
The articulated arm manipulator from Zeilhofer Handling Technology lifts loads up to 800 kg without swaying. This makes it suitable for heavy-duty applications, from assemblies and axles to tools and large components. The exact configuration depends on the load, lever arm, and application.
03 What working radius is possible with the articulated arm manipulator?
The working radius is up to 4.5 m. This means that the articulated arm manipulator covers a large working area from a fixed position and can reach even distant or awkwardly located areas without having to move the entire manipulator.
04 What mounting options are available for the articulated arm manipulator?
The articulated arm manipulator is available in four mounting options: floor-mounted for maximum stability, ceiling-mounted for unobstructed floor space, floor-movable on rails or trolleys for flexible applications, and ceiling-mounted on a crane track for maximum maneuverability. The choice depends on the component weight, workflow, and building structure.
05 What devices can be attached to the articulated arm manipulator?
The articulated arm manipulator accommodates the complete ZHHT fixture program: gripping, suction, magnetic, and hook devices, as well as integrated screwdrivers and screw spindles. Mandrel and clamping fixtures are used for rollers and tubes, suction and vacuum traverses for plates and discs, and component-specific form fixtures for body parts. Fixtures are custom-designed and tailored to the specific component.
06 How does the articulated arm manipulator differ from the rope manipulator?
The articulated arm manipulator rigidly guides the load via arms and joints, lifts up to 800 kg, and is designed for heavy-duty applications. The rope manipulator guides the load via two counterweighted wire ropes, is lightweight, and designed for fast handling of loads up to 150 kg. Both designs complement each other; a detailed comparison can be found in the guide "Articulated or Rope Manipulator."
07 Can the articulated arm manipulator be combined with other systems?
Yes. The articulated arm manipulator is part of the modular ZHHT system and can be combined with the ZH90 lifting axis, the ZH3 rotary arm module, and swivel mechanisms. This allows for complex motion sequences that could not be achieved with a single system.