Lifting Axis ZH90 for batteries
Lifting Axis ZH90 for batteries
E-MOBILITY / BATTERY INSTALLATION
Handling high-voltage batteries: Manipulator and lifting axis for battery assembly
Short answer
Automotive plants handle high-voltage batteries with rigidly guided lifting axes and manipulators with battery-specific gripping devices, not with cranes, winches, or by hand. The Zeilhofer ZH90 lifting axis rigidly lifts complete HV battery packs weighing up to 1,200 kg, inserts them into the vehicle body from below with a repeatability of less than ± 1 mm, and securely holds the load in the event of a pressure drop. For battery modules and empty pack housings, Zeilhofer uses lighter manipulators with rotary and swivel functions. Design and manufacturing take place in Holzkirchen, certified according to ISO 9001 and TISAX Level 2 with prototype protection.
The most important points in brief
Complete HV battery packs weigh between 150 and over 1,000 kg, depending on the vehicle; modules weigh between 20 and 80 kg.
For installation of the pack in the underbody, a rigid, pendulum-free guide is mandatory; a crane or cable winch will swing.
Zeilhofer lifting axis ZH90: up to 1,200 kg, repeatability below ± 1 mm, load securing in case of pressure drop.
The gripping device or the Zeilhofer lifting and rotating device ZH takes over the rotation and tilting of the load carrier into the installation position.
Connection to the line PLC via Profinet, EtherCAT or EtherNet/IP.
CE compliant according to the Machinery Directive, annual UVV testing according to DGUV Regulation 54, TISAX Level 2 for confidential OEM projects.
CHAPTER 01 / Assembly
Typical assembly situations in an automotive plant
A high-voltage battery undergoes multiple movements in the automotive plant: from the load carrier to the assembly station, rotated into the correct position, and finally inserted into the car body from below. Each of these situations places specific demands on the lifting technology. Zeilhofer therefore always designs the solution for the specific work step.
Pack installation
Add the battery pack to the body from below.
The complete assembly is positioned under the body and joined vertically. The Zeilhofer ZH90 lifting axis guides the assembly rigidly along the Z-axis, electronically dampens the end position, and achieves the required joining tolerance of less than ± 1 mm.
Module assembly
Insert modules into the packing cassette
Battery modules weighing between 20 and 80 kg are inserted into the cassette at a steady pace. A lightweight manipulator, such as the Zeilhofer rope manipulator (up to 150 kg), with a quick-change gripper, is used for this purpose.
Rotate and tilt
From the load carrier to the installation position
Packs and housings are often not positioned correctly on the load carrier. A gripping device with a rotary or tilting unit, or the Zeilhofer ZH lifting and rotating device, brings the component into the correct position without repositioning the gripper.
Housing
Grip the pack case, turn and swivel it
Empty housings are lightweight but bulky and are moved frequently. A Zeilhofer gripper with rotating and swiveling functions makes every side accessible without the operator having to hold the component.
Practical example
Zeilhofer ZH90 lifting axle for battery modules up to 800 kg in passenger car manufacturing
In the vehicle production line of an automotive manufacturer, a Zeilhofer ZH90 lifting axis with a project-specific gripping device moves battery modules weighing up to 800 kg without any swaying. A single operator guides the load and positions it precisely. Learn more in the article "Battery Module Handling in E-Mobility" .
CHAPTER 02 / SECURITY
SAFETY REQUIREMENTS FOR LIFTING TECHNOLOGY
Handling a high-voltage battery is subject to stricter regulations than any other component class in automotive assembly. Three risks are paramount: thermal damage to the cells due to impacts, mechanical deformation of the pack housing, and personal safety in the event of a high-voltage arc flash. The lifting technology must eliminate these risks through its design, not merely mitigate them.
01 Non-oscillating load guidance
Rigid, mechanically guided movement instead of cable-guided vibration. No tilting during insertion, no lateral impacts on the packaging housing. A prerequisite for the required joining tolerance of less than ± 1 mm.
03 Load securing and securing against loosening
Zeilhofer pneumatic lifting axes are equipped with safety valves that prevent unintentional lowering in the event of a pressure drop. A multi-stage locking mechanism prevents the gripping device from unintentionally releasing the package.
02 Shock and vibration freedom
Load handling and release without acceleration peaks. The shock sensitivity of the lithium-ion cells requires gentle, controlled lowering with electronically damped end positions.
04 Compliance and Certification
CE compliant according to Machinery Directive 2006/42/EC. Annual safety inspection according to DGUV Regulation 54. For OEM lines, additional audits according to VDA 6.3 and TISAX. Documentation and traceability throughout the entire service life.
Detailed compliance overview in the guide "UVV testing for lifting aids" .
CHAPTER 03 / LOAD AREAS
LOAD RATES BY VEHICLE TYPE
The weight of a high-voltage battery scales with vehicle class and range. From the battery pack of a small car to the high-voltage storage system of an electric truck, the spectrum ranges from 150 kg to well over 1,000 kg. The design of the lifting equipment is based on the highest expected load plus a safety margin.
01 Passenger cars (compact and mid-size)
Small electric cars, plug-in hybrids, and mid-size EVs. Battery packs are usually flat and inserted into the body from below. Standard application for lifting axes with pendulum-free Z-axis guidance.
Load range: 150 to 500 kg
03 Buses, trucks and commercial vehicles
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, large SUVs, and performance models with longer ranges. Larger pack geometry, higher energy density. ZH90 lifting axle with double stroke as standard.
Load range: 500 to 800 kg
04 Industrial and stationary storage
Stationary energy storage systems, forklift batteries, rail and marine propulsion systems. Load range is highly application-dependent. Frequently combined lifting and swiveling movements via the ZH90 Flex-Arm lifting axis.
Load range: 200–1,200 kg+
More about the most powerful solution in the Zeilhofer program: ZH90 lifting axle , Load capacity up to 1,200 kg, pendulum-free Z-guide, Made in Germany.
CHAPTER 04 / HANDLING TYPES
COMPONENT HANDLING TYPES IN DETAIL
Battery assembly involves three clearly distinguishable handling tasks, each with its own lifting technology requirements. The selection of the lifting axis, gripping principle, and fixture depends on component size, joining tolerance, and cycle time. Modern lines often operate several types of components in parallel.
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
2 PACK
Battery pack handling
The complete high-voltage battery is inserted into the body, usually from below into the underbody. It features a pendulum-free Z-axis guide, precise end positioning, and gentle lowering. The ZH90 lifting axis is used as standard with a project-specific gripping device.
Load capacity: 200–1,200 kg · Tolerance: ± 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
For combined lifting and swiveling movements, we recommend the ZH90 Flex-Arm lifting axis : Linear Z-guide combined with articulated arm for complex joining situations.
CHAPTER 5 / COMPARISON
Lifting axis, manipulator, vacuum lifter, lifting table or crane?
Various types of equipment are used on the market for handling high-voltage batteries. The crucial factors are whether the load is rigidly guided, whether it can be gripped off-center, and whether the movement needs to be integrated into the line cycle.
Lifting axle
Rigidly guided, oscillation-free, even for off-center loads. The Zeilhofer ZH90 lifting axle carries up to 1,200 kg and is suitable for installation in the underbody.
Battery-powered lifting table
Proven in workshops and service for installation and removal. In series production, guided positioning in synchronized cycles and PLC integration are usually lacking.
Joint manipulator
Rigid articulated arm with a working radius of up to 4.5 m. The Zeilhofer articulated manipulator can support up to 800 kg and is suitable for modules, housings and movements with a swiveling component.
crane and chain hoist
High load-bearing capacity, but the load swings on the rope. Unsuitable for joint tolerances below ± 1 mm and shock-sensitive cells.
Vacuum tube lifter
Fast with smooth, lightweight parts. However, with heavy packs that have uneven surfaces and off-center centers of gravity, the rigid guide for precise assembly is lacking.
robot
Useful for fully automated lines with very high production volumes. For a wide variety of product variants and operator guidance, a manipulator is usually more economical.
More information can be found in the guides "Tube lifter or device?" and "Automation without robots" .
CHAPTER 06 / TECHNOLOGY
TECHNICAL REQUIREMENTS FOR LIFTING TECHNOLOGY
High-voltage batteries place demands on lifting aids that go far beyond their standard requirements. Three dimensions are critical: precision in assembly, speed in cycle operation, and compatibility with the OEM's line infrastructure.
01 PRECISION
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
Speed & Cycle Time
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
Connection & Environment
Compressed air, 24 V control power, and PLC interface (Profinet, EtherCAT, EtherNet/IP). ESD-compliant design and cleanroom suitability for cell manufacturing available upon request. Maintenance access without line downtime.
Detailed comparison of drive concepts: pneumatic or electric lifting . More on the most powerful lifting axis: ZH90 lifting axis .
CHAPTER 07 / INDUSTRIES
INDUSTRIES AND AREAS OF APPLICATION
E-mobility is the driving force behind high-voltage battery handling, but by no means the only one. Zeilhofer supplies OEMs, Tier 1 suppliers, and stationary energy storage manufacturers worldwide. Each market segment has its own requirements regarding load, cycle time, and compliance.
OEM passenger cars
Final assembly of electric cars and plug-in hybrids in large automotive plants. High-frequency packing assembly into the body.
Cell manufacturing
Lithium-ion cell production with the highest cleanroom requirements. ESD protection, particle-free environment, fully electric drives without compressed air.
Service and repair
After-sales service in workshops and service centers. Installation and removal of individual packs or modules for diagnosis, repair, or replacement.
Commercial vehicles
Electric buses, distribution trucks, electric trucks and electric tractor units. Often modular packing systems with multiple handling units per vehicle.
Stationary energy storage
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
Dismantling of end-of-life batteries, module selection for second-life applications, preparation of cells for material recycling.
Tier 1 supplier
Battery system manufacturers that supply complete high-voltage packs to OEMs. Cell-to-module, module-to-pack, and final pack assembly in one production facility.
Rail and Navy
Hybrid and fully electric drives for trains, ferries and special-purpose vessels. Large packs with specific classification and safety requirements.
Your industry isn't listed? We also offer specialized projects in research and development, test bench construction, or special-purpose machine manufacturing. → Request a consultation
CHAPTER 8 / SELECTION
SELECTION CRITERIA
The right lifting technology for handling high-voltage batteries is determined by six systematic selection criteria. Zeilhofer clarifies these criteria during the initial consultation and delivers a coordinated concept comprising the lifting axis, gripping device, and control system.
01 Component and load case
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 Joining tolerance
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 Cycle time and frequency
How many pack assemblies per hour, per shift, per year? This determines the drive concept, maintenance intervals, and requirements for quick-change chucks.
04 Connection and interfaces
Compressed air supply, PLC interface, line integration. Profinet, EtherCAT, EtherNet/IP or completely autonomous operation? Line synchronization must be considered from the outset.
05 Safety and load securing
Which safety level according to the Machinery Directive? Load protection in case of pressure drop, emergency shutdown, end position limitation. For OEM lines, additionally VDA 6.3 and TISAX.
06 Work environment
Cleanroom, ESD zone, classic assembly hall? This determines the choice of materials, surface treatment, protection class and electrical design.
CHAPTER 09 / PROJECT PROCESS
FROM CONCEPT TO DELIVERY
Every high-voltage battery project with Zeilhofer follows a structured process, from the initial technical consultation to commissioning on the production line. Design and manufacturing take place centrally in Holzkirchen, Germany, while commissioning is carried out at the customer's site worldwide.
01 Initial Technical Consultation
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 Individual concept
Design concept including lifting axis layout, project-specific gripping device, control system and PLC interface. Binding offer with delivery date and commissioning conditions.
03 Design and 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.
04 Assembly and commissioning
Installation on the production line, operator training, and commissioning by our own technicians, worldwide in over 50 countries. Optional maintenance contract and spare parts supply for the entire product lifespan.
CHAPTER 10 / COSTS
COSTS AND FINANCING
A lifting axis solution for high-voltage battery assembly is designed for the specific pack, joining process, and production line. Complex lifting axis solutions with customized gripping devices and automation components can cost up to approximately €150,000. You will receive a fixed price quote after the process analysis. The pricing logic is explained in the guide "What does a manipulator cost?" , and information on leasing and hire purchase through Würth Leasing is available in the guide "Leasing and financing lifting aids" .
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 What lifting technology do automotive plants use for high-voltage batteries?
For complete battery packs, the system uses pendulum-free lifting axes with battery-specific gripping devices; for modules and housings, lighter manipulators are used. The Zeilhofer ZH90 lifting axis lifts high-voltage battery packs up to 1,200 kg and inserts them into the vehicle body with a repeatability of less than ± 1 mm.
02 How heavy is a car battery?
Depending on the vehicle class, a high-voltage battery weighs between 150 and 500 kg in a compact car, 500 to 800 kg in a premium SUV, and 800 to 1,200 kg in buses and trucks. Individual modules weigh between 20 and 80 kg.
03 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.
04 Which Zeilhofer system is suitable for this?
The ZH90 lifting axis with project-specific gripping device. It can carry up to 1,200 kg, guides the load without pendulum movement and positions it with millimeter precision.
05 Can the battery be rotated or tilted during handling?
Yes. The gripping device is equipped with a rotary or tilting unit as needed. For heavy components, Zeilhofer uses the ZH lifting and rotating device, which moves the package or housing from the load carrier into the installation position.
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.
07 What safety requirements apply to handling high-voltage batteries?
Lifting equipment for high-voltage batteries must be CE compliant according to Machinery Directive 2006/42/EC, subject to annual safety inspections according to DGUV Regulation 54, and, for OEM lines, additionally comply with VDA 6.3 and TISAX. Zeilhofer is certified according to ISO 9001 and TISAX Level 2 with prototype protection.
08 Which interfaces to the line PLC are possible?
Standard features include Profinet, EtherCAT, and EtherNet/IP. Profibus, CC-Link IE, or customer-specific protocols are available upon request. The lifting axis is synchronized with the line control system for precise, cycle-accurate pack assembly.
09 Is the ZH90 lifting axis also suitable for cell manufacturing?
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.
10. Where are Zeilhofer solutions for HV battery handling manufactured?
Design and manufacturing take place in Holzkirchen, Germany. Commissioning worldwide at customer sites in over 50 countries. Made in Germany, ISO 9001 and TISAX Level 2 certified.
TERMS
SYNTHEMS AND RELATED TERMS
In technical terminology, a high-voltage battery is also referred to as a high-voltage storage device, HV storage device, HV battery, traction battery, battery pack, or battery module (for the smaller assembly). Special types include removable batteries and range extender batteries.
Related components include the pack housing (also called battery frame or battery tray), the battery cell as the smallest unit, and the BMS (Battery Management System) as the electronic control unit. Commonly referred to as high-voltage battery, HV battery, traction battery, battery pack, or EV battery in English-speaking countries.
READ MORE
FURTHER GUIDES ON THIS TOPIC
BASICS
What is a lifting axle?
APPLICATION
Lifting aids for automotive final assembly
Doors, seats, cockpits, battery modules: typical applications in vehicle production.
