Hubachse ZH90 für PKW-Achsen
Hubachse ZH90 für PKW-Achsen
CATEGORY 04 / AUTOMOTIVE FINAL ASSEMBLY
LIFTING AIDS FOR AUTOMOTIVE FINAL ASSEMBLY
Automotive final assembly places the highest demands on lifting aids: centimeter-precise positioning in sync with the production cycle, heavy and bulky components, confined spaces, and the highest safety standards. Manipulators with pendulum-free load guidance have become the standard here – whether for doors, seats, cockpits, bumpers, or high-voltage batteries.
Zeilhofer HHT supplies OEMs and Tier 1 suppliers in the automotive industry with ZH90 lifting axes, articulated manipulators up to 800 kg, and special grippers. Each system is designed to suit the component, cycle time, and workstation – ISO 9001 and TISAX Level 2 certified with prototype protection. Made in Germany.
CHAPTER 1
WHAT IS AUTOMOTIVE FINAL ASSEMBLY?
Final assembly of automobiles is the last stage in vehicle production. Here, the completed body shell is assembled into a vehicle ready for delivery. Doors, cockpits, seats, engines, axles, wheels, bumpers, and high-voltage batteries are installed in a defined sequence.
The following are characteristic of the final assembly:
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High frequency — typically 60 to 90 seconds per station for car lines
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Changing components and variants within the same line
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Confined spaces in the individual stations
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Human workers remain at the center, even in automated systems.
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Highest quality requirements with joining tolerances ± 1 mm
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At the same time, final assembly is the area with the highest ergonomic demands. Many components are heavy and must be positioned precisely—a car door weighs 40 to 80 kg, a seat 25 to 50 kg, and a high-voltage battery between 300 and 700 kg. Lifting aids are not a luxury here, but a prerequisite for efficient production and employee health throughout the entire shift.
CHAPTER 2
REQUIREMENTS FOR LIFTING AIDS IN FINAL ASSEMBLY
OEMs and Tier 1 suppliers have very clear technical and procedural requirements for lifting aids used in final assembly. Five requirements are crucial in practice:
01 Non-oscillating load guidance
Unlike cranes or cable hoists, the load must not swing. Rigid, mechanically guided movement is mandatory—typical joining tolerances are ± 1 mm. This level of accuracy cannot be achieved with pendulum systems.
02 High clock speed capability
The movements must be integrated into the line cycle. Pneumatic drives enable rapid movements, programmable motion profiles, and defined end-position approach. The lifting axis synchronizes with the line PLC for precise assembly.
03 Sicherheitssteuerung
In critical applications such as high-voltage batteries or body parts, the load may only be released in the defined end position. End-position locks and two-hand operation protect against incorrect operation. Pneumatic lifting axes have safety valves to prevent pressure loss.
04 OEM Compliance
VDA 6.3 for process audits, IATF 16949 for quality management, and TISAX certification for information security are standard in the automotive industry. Manufacturers of lifting aids must meet these requirements; otherwise, they will not be qualified. Zeilhofer HHT is ISO 9001 and TISAX Level 2 certified with prototype protection.
05 Robustness in continuous operation
Final assembly lines typically run in 3 shifts, 5 to 7 days a week, often for 15 to 20 years. The design and materials must be appropriately robust. Zeilhofer systems from the early 2000s are still in daily use at customer sites with good maintenance practices.
CHAPTER 3
PRACTICE: DOOR INSTALLATION
Door installation is one of the classic applications for lifting aids in automotive final assembly. Depending on the model, a car door weighs between 25 kg (small car) and 80 kg (premium sedan). With electric cars, additional electronics and batteries often allow for weights of up to 100 kg.
Typical applications
Door hinge assembly after bodywork: Insertion into the hinges
Door removal for cockpit installation ("Doors Off" concept)
Door hinge assembly in final assembly
Door transport between stations
ZHHT solution
The articulated arm manipulator with component-specific mount lifts the door using suction or clamping grippers. In the "Doors Off" operating mode, the door is temporarily stored in a holding station and later reinstalled. The operator guides the door with minimal effort and positions it securely in the hinges.
Advantages of this application
The worker guides the door with minimal effort.
Pendulum-free positioning in the hinges
Swiveling around the vertical axis for an ergonomic mounting position
Safety control prevents unintentional release
Suction devices protect painted exterior surfaces
CHAPTER 4
PRACTICE: SEAT INSTALLATION
Vehicle seats are bulky, medium-weight components. A standard car seat weighs between 20 and 50 kg, while premium seats with massage functions can weigh up to 70 kg. They are inserted into the vehicle's interior through the door opening and bolted to the floor.
challenges
Bulky geometry with backrest, seat and upholstery
Entry through limited door opening
Fastening at four points in the floor plate
Sensitive surface made of leather, fabric or plastic
ZHHT solution
The ZH mobile lifting platform features a 48-volt battery and component-specific device. The platform is easily moved between stations, and its omniwheel chassis allows movement in all directions without repositioning. The device grips the seat at defined points without leaving pressure marks on the surface. The operator effortlessly guides the seat through the doorway and precisely positions it at the attachment points.
Advantages of this application
Wireless operation in confined spaces
Rapid movement even over long distances between stations
Swivel and rotate for ergonomic positioning
Reduces seat damage during transport
Over 8 hours of battery life, battery swap in under 30 seconds
CHAPTER 5
PRACTICE: COCKPIT AND INSTRUMENT PANEL INSTALLATION
The cockpit, also known as the instrument panel module, is one of the largest assemblies in final assembly. A modern cockpit module weighs between 30 and 60 kg and contains the steering wheel, steering column, air conditioning, airbag, display, and all electronic components.
The insertion into the bodywork is achieved through the windshield opening or the open door in the "Doors Off" concept. Fastening must be carried out at several points with defined torques.
ZHHT solution
The articulated arm manipulator or the ZH90 Flex-Arm lifting axis with special mounting. The mounting grips the cockpit at several points and secures it throughout the entire installation process. The ZH90 Flex-Arm lifting axis combines linear Z-guides with an articulated arm—ideal for movement through the body opening followed by precise positioning.
Advantages of this application
Non-oscillating load guidance protects electronic components
Rotation and swiveling for entry through the opening
High repeatability even in long shifts
Torque support for the screw connection can be integrated
Optionally available as a collaborative lifting axis for human-robot collaboration (HRC)
CHAPTER 6
PRACTICE: HIGH-VOLTAGE BATTERY UNDERBODY
High-voltage battery handling is the most demanding application in modern final assembly. A high-voltage battery weighs between 300 kg (small car) and over 1,000 kg (electric truck) and must be installed with the utmost precision and safety.
The high-voltage battery is typically inserted into the chassis from below (the so-called "underbody" process) and bolted in place at several points. The assembly tolerance is ± 1 mm.
Requirements
Load capacity up to 1,200 kg
Non-oscillating load handling — HV batteries must not be subjected to shocks
Safety control with release only in defined end position
VDA 6.3, IATF 16949 and TISAX compliance
Integration into line scheduling via PLC interfaces
ZHHT solution
The ZH90 lifting axis with project-specific gripping device. It is the most powerful lifting aid in the ZHHT portfolio and can carry loads up to 1,200 kg without swaying. The gripping device is custom-designed and precisely adapted to the geometry of the respective high-voltage battery. Multi-stage locking mechanisms secure the battery throughout the entire lifting process.
Advantages of this application
Highest load capacity up to 1,200 kg on the market
The pendulum-free Z-guide protects sensitive lithium-ion cells.
TISAX Level 2 certified manufacturing with prototype protection
Used in final assembly lines of leading OEMs (including VW ID series)
Interfaces to Profinet, EtherCAT, EtherNet/IP
Detailed guide to high-voltage battery handling: here
CHAPTER 7
PRACTICE: BUMPERS AND ATTACHMENTS
Bumpers, tailgates and other add-on parts are large, lightweight components weighing between 15 and 40 kg, which are attached in the rear area of final assembly.
challenges
Sensitive painted surfaces — no clamping grippers possible
Large-scale geometry with a width of 1.5 to 2 m
Precise positioning in the body mounts
High production volumes with frequent variants
ZHHT solution
The Acer or ZH70 cable manipulator with vacuum traverse. The vacuum traverse lifts the bumper above the painted top surface, thus protecting the finish. The cable manipulator is significantly lighter and more maneuverable than the articulated arm manipulator — ideal for the high cycle rates in final assembly.
Advantages of this application
Vacuum suction cups protect paints and surfaces
Fast handling for high clock speeds
Large working radius up to 4 m
Variant flexibility through adjustable suction plates
Lightweight aluminum construction in the ZH70 for extra fast handling
CHAPTER 8
COMPLETE SOLUTIONS FOR OEM LINES
Zeilhofer HHT provides OEMs and Tier 1 suppliers not only with individual lifting aids, but with complete solutions from a single source:
01 Component Analysis & Concept
Joint analysis of component, cycle time, workplace, and safety requirements. Concept including design, installation plan, and binding price indication. Free of charge and without obligation.
02 Design & Manufacturing
Engineering and manufacturing in Holzkirchen, Germany. In-house designers and technicians. ISO 9001 and TISAX Level 2 certified with prototype protection. Made in Germany.
03 Preliminary inspection in the showroom
Preliminary inspection with the original workpiece in the showroom in Holzkirchen, Germany, or digitally via video transmission. Customer approval before delivery.
04 Commissioning worldwide
Assembly on the production line, operator training and commissioning by our own technicians — worldwide in over 50 countries.
05 Service & Maintenance
Maintenance contracts, UVV testing according to DGUV regulation 54, original spare parts, technical hotline with remote support, plant relocation during factory moves.
References
Zeilhofer HHT has been supplying leading OEMs and Tier 1 suppliers in the automotive industry for years. Their systems are in daily use in final assembly lines for the VW ID series, at premium OEMs, and at several Tier 1 suppliers, among others.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 Which lifting aids are suitable for final assembly of automobiles?
For automotive final assembly, pendulum-free manipulators and lifting axes are standard. Depending on the component, articulated manipulators up to 800 kg (doors, cockpits), ZH90 lifting axes up to 1,200 kg (HV batteries), ZH lifting lifts with 48V batteries (seats), or Acer cable manipulators and ZH70 (bumpers) are used.
02 What loads can be handled during final assembly?
Load capacities range from 15 to 40 kg (bumpers) to 25 to 80 kg (doors, seats) up to 1,200 kg (high-voltage batteries). Zeilhofer HHT covers the entire range with its product portfolio — from rope manipulators and mobile lifting platforms to the high-performance ZH90 lifting axle.
03 Why is pendulum-free load guidance so important in final assembly?
Assembly tolerances in final assembly are often ± 1 mm. Swinging loads cannot be joined precisely and can become misaligned during insertion—leading to damage to the component and the vehicle body. Therefore, vibration-free load guidance via rigid mechanisms is the standard in the automotive industry.
04 What compliance requirements must lifting aids meet for OEMs?
OEMs typically require: CE conformity according to Machinery Directive 2006/42/EC, VDA 6.3 for process audits, IATF 16949 for quality management, and TISAX certification for information security. Zeilhofer HHT is ISO 9001 and TISAX Level 2 certified, offering prototype protection for confidential OEM projects.
05 How is safety ensured in high-voltage batteries?
High-voltage batteries may only be released in a defined end position. The safety control system detects the position via limit switches and only then releases the device. Additionally, multi-stage locking mechanisms prevent unintentional release of the gripping device. Pneumatic lifting axes have safety valves to protect against pressure loss.
06 What cycle times are possible with the lifting aids?
The cycle time depends on the component and the application. Typical values are 60 to 90 seconds per station for main assembly points. The lifting aids are coordinated with the line cycle time — with programmable motion profiles, defined acceleration, and end-position approach.
07 Can existing OEM lines be retrofitted with ZHHT systems?
Yes. During the initial consultation, Zeilhofer HHT analyzes the existing infrastructure—rail systems, pneumatics, electrical systems, and control systems—and adapts the lifting aid accordingly. Adapters and custom design solutions are included in the scope of delivery. Relocation of the system during factory moves is also possible.
08 Where are ZHHT systems manufactured for the automotive industry?
Design and manufacturing take place centrally in Holzkirchen, Germany. Commissioning is carried out worldwide at customer sites in over 50 countries. Made in Germany, ISO 9001 and TISAX Level 2 certified with prototype protection for confidential OEM projects.
READ MORE
FURTHER GUIDES ON THIS TOPIC
In-depth guides on related topics in handling technology.
E-MOBILITY
High-voltage battery handling
Non-sway lifting technology for high-voltage batteries up to 1,200 kg in automotive manufacturing. Modules, battery packs and pack housings.
COMPLIANCE
UVV inspection for lifting aids
Obligation, procedure and deadlines of the annual accident prevention inspection according to DGUV Regulation 54.
PRODUCT
ZH90 lifting axle in use
Swing-free lifting up to 1,200 kg. Practical applications from automotive, e-mobility, foundry and mechanical engineering.
NEXT STEP
WHICH COMPONENTS IN WHICH LINE?
Talk to our engineers about your automotive final assembly application. We analyze components, cycle times, and station requirements and develop a customized lifting technology comprising the lifting axis, gripping device, and control system—from concept to commissioning on your production line. Made in Germany.