Gelenk-Manipulator für den Verbau von PKW-Türen
Gelenk-Manipulator für den Verbau von PKW-Türen
GUIDE: INDUSTRIAL LIFTING AIDS
LIFTING AIDS
Short answer
Lifting aids are industrial devices that take over the weight of a load, allowing the employee to guide it smoothly instead of carrying it. Zeilhofer Handling Technology from Holzkirchen manufactures four systems for this purpose: the Zeilhofer Manipulator (up to 800 kg), the Zeilhofer Lifting Axis ZH90 (up to 1,200 kg), the Zeilhofer Rope Manipulator (ZH70 and Acer) (up to 150 kg), and the mobile Zeilhofer Lift ZH with a 48-volt battery (up to 100 kg).
The Zeilhofer rule of thumb
Heavy loads or precise joining: Manipulator or lifting axis ZH90
Quickly repositioning light parts with a long reach: rope manipulator
Changing workstations without compressed air: Lifting platform ZH
Over 2,500 Zeilhofer systems delivered since 1999 in 18 industries
CHAPTER 1
WHAT IS A LIFTING AID?
A lifting aid is an industrial tool for the ergonomic handling of loads. It supports employees in lifting, moving, rotating, and positioning components, thus relieving strain on the body during repetitive tasks.
Industrial lifting aids are used wherever loads are too heavy for manual handling or where the frequency is so high that repeated strain would harm employees. They reduce sick leave, the risk of injury, and downtime , while simultaneously increasing productivity and quality in manufacturing.
The term lifting aid is often used synonymously with: manipulator, handling device, load manipulator, ergonomic lifting aid, or pneumatic lifting aid. Zeilhofer has been developing customized solutions for loads up to 1,200 kg since 1999.
Within the lifting aid family, several designs are distinguished: articulated arm manipulators (also known as articulated boom or jointed arm manipulators ), parallelogram manipulators , lifting columns (also known as lifting arms ), rope balancers ( pneumatic rope manipulators ), vacuum lifters , and tube lifters. Each design has its own strengths. More information can be found in the comprehensive Zeilhofer guides on the individual systems.
CHAPTER 2
TYPES OF LIFTING AIDS
Industrial lifting aids can be divided into four main categories . Each category has its own strengths and is ideal for specific applications. The selection depends on the load, movement sequence, location, and frequency of use.
01 Manipulator up to 800 kg
Stationary lifting aid with rigid, pendulum-free load guidance via rods, axles, and joints. Pneumatically or electrically operated. Highest precision for repetitive tasks.
02 Lifting axis up to 1,200 kg
Linear Z-axis with pneumatic drive, ideal for purely vertical lifting with maximum load capacity. Patented aluminum profile on the ZH90 for minimal maintenance.
03 Lifting platform up to 100 kg
Mobile lifting aid with battery operation and omniwheel chassis. Maximum mobility for flexible use at changing workstations in warehousing and logistics.
04 Rope manipulator up to 150
Pneumatic lifting aid with cable pull for flexible, fast movements. The ZH70 and Acer are particularly suitable for light to medium loads with a long reach and free load positioning.
CHAPTER 3
WHEN IS A LIFTING AID NECESSARY?
The need for lifting assistance arises from the interplay of load weight, lifting frequency, and occupational safety. The German Ordinance on Manual Handling of Loads (LasthandhabV) obligates employers to avoid or reduce manual handling of loads if the strain on employees poses a risk.
Investments in lifting aids typically pay for themselves within 12 to 24 months: through reduced sick leave, fewer employee absences, higher productivity, less component damage and guaranteed quality.
As a rough guideline, around 25 kg for men and 15 kg for women is considered the threshold at which lifting assistance becomes advisable; for frequent lifting, significantly lower weights may be appropriate. There is no fixed legal weight limit; the decisive factor is a risk assessment based on the BAuA's key indicator method. The guide "How much weight can you lift? Limit values and key indicator method" explains in detail how this assessment is carried out and what obligations arise from it. Zeilhofer solutions cover the entire range from 5 to 1,200 kg.
CHAPTER 4
LIFTING AIDS IN PRODUCTION
In production, lifting aids are the daily tools for assembly workstations, machine loading, and ergonomic manufacturing. They ensure consistently high quality in repetitive handling tasks.
01 Production: Stationary manipulators as standard
In production, stationary manipulators mounted on columns, ceiling brackets, or wall supports are dominant. They guide the load without swinging and enable positioning accurate to the centimeter. Typical applications include car body construction, battery module handling, engine assembly, tool holding, and machine loading.
CHAPTER 5
LIFTING AIDS IN INDUSTRY
Industry is the broadest field of application: from mechanical engineering and special-purpose machinery to chemical and metal processing. All types of lifting aids are used here, often combined in a single system.
02 Industry: Maximum flexibility for diverse tasks
Industrial applications often require combined solutions: a lifting axis for vertical lifting, a manipulator for positioning, and a vacuum lifter for handling. Zeilhofer HHT designs such combined systems as multi-axis machines with programmable controls.
CHAPTER 6
LIFTING AIDS IN WAREHOUSES AND LOGISTICS
Mobile lifting aids dominate in warehousing and logistics. Changing workstations, varying loads, and short distances make flexibility more important than sheer lifting capacity.
Warehouse: Mobile lifting platforms as the ideal solution
The Zeilhofer ZH lifting platform is designed for receiving, order picking, and shipping. It is battery-powered at 48 volts and equipped with an omniwheel chassis for quick maneuverability. For particularly heavy or frequent tasks, stationary manipulators at fixed packing and sorting stations are available.
Fast loading and unloading with mobile devices
In logistics, handling, loading and unloading, and sorting are key processes. Mobile lifting devices and manipulators with suction cups for smooth packaging such as cardboard boxes and foil pallets are standard solutions. For high throughput and fixed stations, stationary manipulators are also a worthwhile investment.
CHAPTER 7
SELECTION CRITERIA
The right lifting aid is determined by a systematic analysis of the load, movement, environment, and safety. Zeilhofer clarifies these points during the initial consultation:
01 Load and Geometry
Maximum weight, dimensions, material properties, gripping points, and center of gravity of the load. These factors determine the choice of the appropriate lifting aid category.
01 Movement sequence
What movements are required? Pure lifting, rotating, turning, swiveling, or moving over long distances? The axis configuration is determined by this.
03 Deployment location and mobility
Fixed workstation or flexible deployment? Hall size, ceiling and floor conditions, existing connections. Stationary or mobile solution?
04 Frequency and shift operation
How often is lifting performed per shift? Is it a single shift or continuous operation? This entails requirements for robustness, maintenance, and availability.
05 Work environment
Cleanroom, ATEX zone, outdoor area, temperature, dirt, chemicals? These factors determine the protection class, material selection, and surface treatment.
06 Control and Safety
Manual operation, collaborative use or fully automatic operation? CE conformity, machinery directive and safety concept are integrated into the planning.
CHAPTER 8
FROM CONCEPT TO DELIVERY
Every lifting aid project with Zeilhofer follows a structured process, from the initial consultation to worldwide commissioning.
01 Consultation
Analysis of requirements on-site or via video call: load, movements, environment, security.
03 Manufacturing
Design and manufacturing in Holzkirchen, Bavaria. In-house technicians, ISO 9001 and TISAX Level 2 certified.
02 Concept
Individual concept including setup plan, equipment, control system and binding price indication.
04 Commissioning
On-site assembly, training, and commissioning, worldwide. Optional maintenance contract.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
The most frequently asked questions about lifting aids, types, areas of application and the selection of the appropriate solution.
01 What is a lifting aid?
A lifting aid is an industrial tool for the ergonomic handling of loads. It assists employees in lifting, moving, rotating, and positioning components, relieving strain on the body during repetitive tasks. Zeilhofer manufactures manipulators, lifting axes, cable manipulators, and mobile lifting systems for production, industry, warehousing, and logistics.
02 What types of lifting aids are there?
The most important types of industrial lifting aids are: pneumatic manipulators with grippers for precise lifting and positioning, lifting axes as linear axes with high load capacity, cable manipulators for quickly moving light parts, and mobile, battery-powered lifting platforms. Zeilhofer offers the manipulator (up to 800 kg), the ZH90 lifting axis (up to 1,200 kg), the cable manipulator (ZH70 and Acer) (up to 150 kg), and the ZH lifting platform (up to 100 kg). The selection depends on the load, the movement sequence, and the application location.
03 When does a company need lifting aids?
Lifting aids are required if employees regularly lift loads over 25 kg or if loads under 25 kg are moved very frequently per shift. The German Ordinance on Manual Handling of Loads (LasthandhabV) obligates employers to avoid manual handling of loads. The guide "How many kg can you lift?" explains in detail how the limits are determined. Lifting aids reduce sick leave, the risk of injury, and downtime.
04 What loads can lifting aids handle?
Industrial lifting aids handle loads from a few kilograms up to 1,200 kg. Zeilhofer's manipulator (up to 800 kg), the ZH90 lifting axis (up to 1,200 kg), the rope manipulator (up to 150 kg), and the ZH lifting lift (up to 100 kg) cover the entire range. Zeilhofer develops the appropriate device for each load, ensuring the gripper is precisely matched to the component.
05 What distinguishes a lifting aid from a crane?
An industrial lifting aid, such as a manipulator, has a rigid, pendulum-free load guidance system. Unlike a crane, where the load swings on a cable, a lifting aid allows loads to be positioned, rotated, and swiveled with centimeter precision. This makes lifting aids ideal for assembly workstations and machine loading.
06 Which lifting aids are suitable for production?
For production, stationary manipulators with column or ceiling mounting are suitable, such as the Zeilhofer manipulator with a capacity of up to 800 kg. They are pendulum-free, precise, and fast. Common applications include assembly workstations, machine loading, tool holding, car body construction, and battery module handling. The fixture is individually tailored to the component, using mechanical grippers, vacuum, or expanding mandrels.
07 Which lifting aids are suitable for warehousing and logistics?
Mobile lifting aids like the Zeilhofer ZH lifting platform are ideal for warehousing and logistics. It is battery-powered (48 volts), mobile, and can be used flexibly at various workstations. Typical applications include inbound and outbound goods handling, order picking, and machine loading. Stationary manipulators complement mobile devices at fixed packing and sorting stations.
08 What is the LasthandhabV in manufacturing?
The German Ordinance on Manual Handling of Loads (LasthandhabV) obliges employers to avoid or reduce manual handling of loads in manufacturing, for example at assembly workstations. Lifting aids such as manipulators and lifting axes are one of the most effective measures to fulfill this obligation.
SELECTION
WHEN A MANIPULATOR IS THE RIGHT CHOICE
Manipulators are useful when loads are regularly positioned manually, when precision is required, when ergonomic requirements according to DIN EN 1005 must be met, or when a crane would be too slow or too inaccurate.
Manipulators are now standard in automotive final assembly, the handling of high-voltage batteries, and the assembly of large glass and window elements.
Zeilhofer manufactures manipulators for loads up to 800 kg. The devices are pendulum-free, readily available, and currently serve 18 industrial sectors.