Lifting Axis ZH90

Lifting Axis ZH90 for batteries

Lifting Axis ZH90

Lifting Axis ZH90 for batteries

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E-MOBILITY / battery assembly
SAFE HANDLING OF HIGH-VOLTAGE BATTERY IN E-MOBILITY PRODUCTION

High-voltage batteries are among the most demanding components in vehicle assembly. They are heavy, sensitive, and safety-critical. Handling them places special demands on lifting technology.

This guide explains the requirements for handling high-voltage batteries. Zeilhofer Handling Technology uses lifting axes and fixtures for battery assembly in the automotive industry.

THE CHALLENGE
WHY HV STORAGE IS SPECIAL

A vehicle battery weighs several hundred kilograms, but it must be installed in the vehicle body with millimeter precision and without vibration. Impacts or tilting can damage the cells.

At the same time, strict occupational safety requirements apply. The high-voltage battery must be guided securely and protected against uncontrolled movement throughout the entire handling process. Lifting equipment that only supports the weight is insufficient for this task.

High load capacity

Safe handling of loads up to the four-figure kilogram range.

Precise joining

Insertion with millimeter precision, without impact and without damaging the cells.

Pendulum-free guidance

Rigid load guidance instead of a cable, so that the storage unit does not swing or tilt.

Safe device

Gripping device with defined load securing, precisely designed for the storage type.

A vehicle battery weighs several hundred kilograms, but it must be installed in the vehicle body with millimeter precision and without vibration. Impacts or tilting can damage the cells.

At the same time, strict occupational safety requirements apply. The high-voltage battery must be guided securely and protected against uncontrolled movement throughout the entire handling process. Lifting equipment that only supports the weight is insufficient for this task.

THE CHALLENGE
WHY HV STORAGE IS SPECIAL

A vehicle battery weighs several hundred kilograms, but it must be installed in the vehicle body with millimeter precision and without vibration. Impacts or tilting can damage the cells.

At the same time, strict occupational safety requirements apply. The high-voltage battery must be guided securely and protected against uncontrolled movement throughout the entire handling process. Lifting equipment that only supports the weight is insufficient for this task.

01 PKW (Kompakt- und Mittelklasse)

E-Kleinwagen, Plug-in-Hybride und Mittelklasse-EVs. Akkupacks sind meist Flachbauweise und werden von unten in die Karosserie eingesetzt. Standardanwendung für Hubachsen mit pendelfreier Z-Führung.

Lastbereich: 150–500 kg

03 Bus, LKW und Nutzfahrzeuge

Electric buses, distribution trucks, and electric tractor units. Modular packing systems with multiple individual packs or a single large central module. Challenging handling due to size and weight.

Load range: 800–1,200 kg

02 Passenger cars (Premium and SUV)

Premium-EVs, große SUVs und Performance-Modelle mit längeren Reichweiten. Größere Pack-Geometrie, höhere Energiedichte. Hubachse ZH90 mit Doppelhub im Standardeinsatz.

Lastbereich: 500–800 kg

04 Industrie und stationäre Speicher

Stationäre Energiespeicher, Gabelstapler-Batterien, Bahn- und Schiffsantriebe. Lastbereich stark anwendungsabhängig. Häufig kombinierte Hub- und Schwenkbewegungen über die Hubachse ZH90 Flex-Arm.

Lastbereich: 200–1.200 kg+

A vehicle battery weighs several hundred kilograms, but it must be installed in the vehicle body with millimeter precision and without vibration. Impacts or tilting can damage the cells.

At the same time, strict occupational safety requirements apply. The high-voltage battery must be guided securely and protected against uncontrolled movement throughout the entire handling process. Lifting equipment that only supports the weight is insufficient for this task.

THE CHALLENGE
WHY HV STORAGE IS SPECIAL

A vehicle battery weighs several hundred kilograms, but it must be installed in the vehicle body with millimeter precision and without vibration. Impacts or tilting can damage the cells.

At the same time, strict occupational safety requirements apply. The high-voltage battery must be guided securely and protected against uncontrolled movement throughout the entire handling process. Lifting equipment that only supports the weight is insufficient for this task.

01 MODUL

Battery module handling

Individual battery modules are inserted into the pack cassette. High frequency, short cycle times, medium load. Often with a cable manipulator or lightweight lifting axis plus a standardized quick-change gripper.

Load capacity: 20–80 kg · Tolerance: ± 1 mm

02 PACK

Akkupack-Handling

Komplette Hochvoltbatterie wird in die Karosserie gefügt – meist von unten in den Underbody. Pendelfreie Z-Führung, präzise Endlage, sanftes Absetzen. Standardanwendung der Hubachse ZH90 mit projektspezifischer Greifvorrichtung.

Traglast: 200–1.200 kg · Toleranz: ± 1 mm

03 FRAME

Pack, case and frame handling

Empty pack housing or welded battery frame before module assembly. Bulky geometry, low load compared to a fully loaded pack. Often uses a vacuum gripper or mechanical four-point mounting.

Load capacity: 30–150 kg · Tolerance: ± 2 mm

A vehicle battery weighs several hundred kilograms, but it must be installed in the vehicle body with millimeter precision and without vibration. Impacts or tilting can damage the cells.

At the same time, strict occupational safety requirements apply. The high-voltage battery must be guided securely and protected against uncontrolled movement throughout the entire handling process. Lifting equipment that only supports the weight is insufficient for this task.

THE CHALLENGE
WHY HV STORAGE IS SPECIAL

A vehicle battery weighs several hundred kilograms, but it must be installed in the vehicle body with millimeter precision and without vibration. Impacts or tilting can damage the cells.

At the same time, strict occupational safety requirements apply. The high-voltage battery must be guided securely and protected against uncontrolled movement throughout the entire handling process. Lifting equipment that only supports the weight is insufficient for this task.

01 PRÄZISION

Precision & Accuracy

Repeatability below ± 1 mm, smooth insertion with electronically damped end position. Mechanically rigid Z-guide, no oscillation. Optional servo support for millimeter-precise end positioning.

02 TIMES

Geschwindigkeit & Taktzeit

Lifting speed synchronized with the line cycle time. Programmable motion profiles with defined acceleration and end-position approach. Interface to the line PLC for synchronous operation.

03 CONNECTION

Anschluss & Umgebung

Druckluft, 24-V-Steuerstrom und SPS-Schnittstelle (Profinet, EtherCAT, EtherNet/IP). Auf Wunsch ESD-konforme Ausführung und Reinraumtauglichkeit für Zellfertigung. Wartungszugänge ohne Linienstillstand.

A vehicle battery weighs several hundred kilograms, but it must be installed in the vehicle body with millimeter precision and without vibration. Impacts or tilting can damage the cells.

At the same time, strict occupational safety requirements apply. The high-voltage battery must be guided securely and protected against uncontrolled movement throughout the entire handling process. Lifting equipment that only supports the weight is insufficient for this task.

CHAPTER 06 / INDUSTRIES
INDUSTRIES AND AREAS OF APPLICATION

Lifting axes are used in virtually all industrial sectors where heavy loads need to be moved precisely vertically. Zeilhofer HHT supplies OEMs and Tier 1 suppliers in 18 industries and over 50 countries – with customized designs from load cells to control systems.

OEM PKW

Endmontage von E-Autos und Plug-in-Hybriden in den großen Automobilwerken. Hochfrequente Pack-Montage in die Karosserie.

Zellfertigung

Lithium-Ionen-Zellenproduktion mit höchsten Reinraum-Anforderungen. ESD-Schutz, Partikelfreiheit, vollelektrische Antriebe ohne Druckluft.

Service und Reparatur

After-Sales-Service in Werkstätten und Service-Centern. Ein- und Ausbau einzelner Packs oder Module zur Diagnose, Reparatur oder zum Austausch.

Nutzfahrzeuge

E-Busse, Verteiler-LKW, E-Trucks und elektrische Sattelzugmaschinen. Häufig modulare Pack-Systeme mit Mehrfach-Handling pro Fahrzeug.

Stationäre Energiespeicher

Large-scale storage systems for power grids, solar and wind energy storage, UPS systems. Very heavy packs, often modularly scaled to MWh levels.

Recycling and Second Life

Demontage von End-of-Life-Batterien, Modulauslese für Second-Life-Anwendungen, Vorbereitung der Zellen für stoffliches Recycling.

Tier-1-Zulieferer

Batteriesystem-Hersteller, die komplette HV-Packs an OEMs liefern. Zell-zu-Modul-, Modul-zu-Pack- und Pack-Endmontage in einer Produktionsstätte.

Bahn und Marine

Hybrid and fully electric drives for trains, ferries and special-purpose vessels. Large packs with specific classification and safety requirements.

Industry not listed? Special assignments in foundries, the wood and furniture industry, waste management, or the textile industry are also possible. → Request a consultation

CHAPTER 06 / INDUSTRIES
INDUSTRIES AND AREAS OF APPLICATION

Lifting axes are used in virtually all industrial sectors where heavy loads need to be moved precisely vertically. Zeilhofer HHT supplies OEMs and Tier 1 suppliers in 18 industries and over 50 countries – with customized designs from load cells to control systems.

01 Bauteil und Lastfall

Module, pack, or frame? What load type, weight, and dimensions? These factors determine the design of the lifting axis and the gripping principle of the device.

02 Fügetoleranz

How tight are the joining tolerances in car body construction? What end-position accuracy does the design require? Repeatability and end-position damping are dimensioned accordingly.

03 Taktzeit und Frequenz

How many pack assemblies per hour, per shift, per year? This determines the drive concept, maintenance intervals, and requirements for quick-change chucks.

04 Anschluss und Schnittstellen

Compressed air supply, PLC interface, line integration. Profinet, EtherCAT, EtherNet/IP or completely stand-alone operation? Line synchronization must be considered from the outset.

05 Sicherheit und Lastsicherung

Welche Sicherheitsstufe nach Maschinenrichtlinie? Lastsicherung bei Druckabfall, Notabschaltung, Endlagenbegrenzung. Bei OEM-Linien zusätzlich VDA 6.3 und TISAX.

06 Work environment

Reinraum, ESD-Zone, klassische Montagehalle? Daraus ergeben sich Materialwahl, Oberflächenbehandlung, Schutzart und elektrische Ausführung.

CHAPTER 06 / INDUSTRIES
INDUSTRIES AND AREAS OF APPLICATION

Lifting axes are used in virtually all industrial sectors where heavy loads need to be moved precisely vertically. Zeilhofer HHT supplies OEMs and Tier 1 suppliers in 18 industries and over 50 countries – with customized designs from load cells to control systems.

01 Technische Erstberatung

Analysis of component, load case, joining tolerance, cycle time, and line integration. Clarification of safety and compliance requirements with OEM specifications. Free of charge and without obligation.

02 Individuelles Konzept

Konstruktionskonzept inklusive Hubachsen-Auslegung, projektspezifischer Greifvorrichtung, Steuerung und SPS-Schnittstelle. Verbindliches Angebot mit Liefertermin und Inbetriebnahme-Bedingungen.

03 Konstruktion und Fertigung

Engineering und Fertigung in Holzkirchen, Deutschland. Eigene Konstrukteure und Techniker. ISO 9001 und TISAX Level 2 zertifiziert mit Prototypenschutz. Made in Germany.

04 Assembly and commissioning

Montage an der Produktionslinie, Schulung der Bediener und Inbetriebnahme durch eigene Techniker – weltweit in über 50 Ländern. Optional Wartungsvertrag und Ersatzteilversorgung über die gesamte Lebensdauer.

FAQ / Q&A
FREQUENTLY ASKED QUESTIONS

01 How heavy is a car battery?

Depending on the vehicle class, a high-voltage battery weighs several hundred kilograms, and in larger vehicles up to the four-digit kilogram range.

02 Why is non-commuting leadership important here?

A vibrating storage unit cannot be precisely fitted and can become misaligned during insertion. A rigid, pendulum-free load guide prevents this and protects the sensitive cells.

03 Which Zeilhofer system is suitable for this?

The ZH90 lifting axis with project-specific gripping fixture. It can carry up to 1,200 kg, guides the load without pendulum movement and positions it with millimeter precision.

04 Is the gripping device individually developed?

Yes. The device is designed precisely for the respective storage type and the assembly process and is supplied as a complete solution from a single source.

04 Is the gripping device individually developed?

Yes. The device is designed precisely for the respective storage type and the assembly process and is supplied as a complete solution from a single source.

04 Is the gripping device individually developed?

Yes. The device is designed precisely for the respective storage type and the assembly process and is supplied as a complete solution from a single source.

04 Is the gripping device individually developed?

Yes. The device is designed precisely for the respective storage type and the assembly process and is supplied as a complete solution from a single source.

04 Is the gripping fixture individually developed?

Yes. The device is designed precisely for the respective storage type and the assembly process and is supplied as a complete solution from a single source.