Seil-Manipulator ZH70 für Motorradbauteile
Seil-Manipulator ZH70 für Motorradbauteile
PRODUCT KNOWLEDGE - ROPE MANIPULATOR
ACER AND ZH70 ROPE MANIPULATORS: LIGHTWEIGHT ALUMINUM CONSTRUCTION UP TO 150 KG
The rope manipulator from Zeilhofer Handling Technology is available in two versions: Acer (up to 150 kg) and ZH70 (lightweight aluminum construction, up to 70 kg). Features include double rope technology, weight compensation, and intuitive handling.
CHAPTER 1
WHAT SETS THE ROPE MANIPULATOR APART
The rope manipulator guides the load in a straight line along two wire ropes. An integrated counterweight system makes the load feel almost weightless to the operator. The system is hand-operated, intuitive, and optimized for the rapid handling of medium loads.
Load capacity Acer up to 150 kg, ZH70 up to 70 kg
ZH70 in lightweight aluminum construction, low dead weight
Double rope technology with redundant load guidance
Weight compensation, load feels almost weightless
Large working radius up to 4 m
Intuitive hand guidance with natural movement
Can be used mobile or stationary
Gentle on load-bearing structures, straight pull direction
Deepen your understanding of the basics:
The general characteristics of a manipulator are explained in the guide " What is a manipulator ?". A comparison of the design to the articulated arm version can be found in the guide " Articulated or cable manipulators ". Technical data is available on the product page for cable manipulators .
CHAPTER 2
OVERVIEW OF THE MOST IMPORTANT AREAS OF APPLICATION
The rope manipulator is the right choice wherever medium loads need to be handled frequently and quickly. Six industries with particularly high prevalence:
01 Logistics & Warehousing
Quickly handle boxes, packages and components in order picking, packaging and shipping.
04 Automotive
Handle add-on parts, components and medium-sized parts in final assembly.
02 Food
To process and fill bags, drums and containers at a high rate.
05 Pharmaceuticals & Chemistry
Transfer containers, barrels and bags under cleanroom or hygiene requirements.
03 Mechanical Engineering
Loading and unloading workpieces on CNC machines and machining centers. Quick changeover between stations.
06 Packaging
Films, cardboard boxes, packing stations. Quick, repetitive movements with medium loads.
Other industries using rope manipulators include: wood and furniture industry, glass and windows, plastics and injection molding, semiconductors, toolmaking, construction industry, energy and utilities, research and development, aerospace, special machine construction, e-mobility, and foundries.
CHAPTER 3
PRACTICE: CARTON AND PACKAGING
Quickly handle cartons in order picking and shipping
In shipping, order picking, and packing stations, cartons weighing between 10 and 80 kg are handled. The pace is high, the location varies, and the strain on employees is considerable throughout the shift. Manual lifting leads to absences, and a forklift is too inflexible.
The rope manipulator with suction or clamping device lifts boxes almost weightlessly thanks to its counterweight system. The hand-operated controls adapt to the position of each box, and the double-rope technology keeps the load securely in place, even during movement.
Advantages of this application
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Fast handling at high clock speed
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Suction and clamping devices for different cardboard box sizes
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Reduced physical strain on employees
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Even unstable or lightweight cardboard boxes can be safely handled
CHAPTER 4
PRACTICE: WORKPIECES ON MACHINES
Quickly load and unload CNC machines
At CNC machining centers and machines, semi-finished products, blanks, and finished parts weighing between 30 and 150 kg are constantly being fed and removed. The machine's cycle time determines the loading rate. Manual solutions are strenuous, and cranes are too slow.
The Acer cable manipulator uses counterweights to move the workpiece almost weightlessly to the machine. The hand-held control allows for quick changes between workpiece handling, machine operation, and output storage. One operator can control multiple machines within the working radius using a single manipulator.
Advantages of this application
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Reduced machine downtime through fast loading
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Grippers and clamping devices can be custom-designed.
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One manipulator operates several machines within a radius of up to 4 m.
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High repeatability even with long shifts
CHAPTER 5
PRACTICE: BAGS AND CONTAINERS
Sacks, drums and containers in food and pharmaceutical production
In food, pharmaceutical, and chemical production, sacks, barrels, drums, and containers weighing between 20 and 100 kg are frequently moved: from storage to the mixer, to filling station, to processing line. The loads are often unstable, lifting them puts strain on the back and shoulders, and hygiene requirements limit the choice of solutions.
The rope manipulator with hook, clamp, or special device lifts the load using the counterweight. The lightweight aluminum construction allows for hygienic designs, and the double rope technology securely holds the load even during swaying.
Advantages of this application
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Hygienic design for the food and pharmaceutical industries
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Devices for shape-sensitive loads such as sacks are available.
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Reduced physical strain with frequent repositioning
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Quick switching between storage, mixer and bottling
CHAPTER 6
ACER OR ZH70: WHICH VERSION FITES?
Both rope manipulators utilize the same double-rope technology and operating principle. The difference lies in the maximum load capacity and typical application profile.
VARIANT 01
Acer 150 kg rope manipulator
Heavy-duty version. For somewhat larger and heavier components where the mobility of a rope manipulator is still required.
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Load capacity up to 150 kg
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Robust construction for higher loads
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Ideal for CNC feeding, heavy cardboard boxes, components up to 150 kg
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Available with extended features
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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.
VARIANT 02
Rope manipulator ZH70
Lightweight version. Optimized for maximum mobility and fast handling. Ideal for high cycle rates with medium loads.
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Load capacity up to 70 kg
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Especially lightweight aluminum profile
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Ideal for order picking, packing stations, and light workpieces.
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Maximum mobility for fast, repetitive movements
CHAPTER 7
DOUBLE ROPE TECHNOLOGY AND SAFETY
The double-rope technology is the key safety feature of the rope manipulator. Three functional levels ensure safe load handling in every operating phase.
01 Redundant rope routing
The load is supported by two parallel wire ropes. Should one rope fail, the second will hold the load securely. This redundancy meets the stringent safety requirements of industrial lifting equipment.
02 Straight direction of travel
The load is transferred in a straight line of pull. This relieves the load-bearing structure and reduces shear forces on hall columns and ceiling connections.
03 Pressure accumulator in case of power failure
An integrated pressure accumulator keeps the load securely in position even in the event of a compressed air failure. This reliably prevents uncontrolled lowering or swinging.
Optional safety features such as detents, locking mechanisms, and interrogations can be integrated. The rope manipulator is available with extended safety devices upon request and, like all lifting aids, is subject to annual safety inspections.
CHAPTER 8
ECONOMICAL USE
The rope manipulator is particularly advantageous where medium loads are handled frequently and at a high rate. Four levels of operation:
Clock speed
Intuitive manual guidance with weight compensation. Faster than manual operation, faster than a crane.
Sick days
Frequent repetitive movements without physical exertion. Significantly less back and shoulder pain.
Loss rate
Pendulum-free load guidance prevents impact damage to components and hall structures.
Occupancy
Mobile and movable with a pallet truck. One manipulator serves multiple workstations and stations.
In typical applications with high cycle rates, a rope manipulator pays for itself within 12 to 24 months through reduced sick days, higher throughput rates and avoided product damage.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
Frequently asked questions about the articulated arm manipulator up to 800 kg
01 What is a rope manipulator?
A rope manipulator is a rope-guided lifting aid where the load is lifted and guided by two wire ropes. An integrated counterweight makes the load feel almost weightless to the operator. This hand-held system enables fast, smooth, and precise movement of components, ideal for medium loads and frequently repeated handling tasks.
02 What is the load-bearing capacity of the Acer and ZH70 rope manipulators?
The Acer rope manipulator lifts loads up to 150 kg, while the ZH70 rope manipulator is designed for loads up to 70 kg. Both utilize the same double-rope technology. The ZH70 also features a lightweight aluminum construction. The choice of model depends on the load, cycle time, and required maneuverability.
03 What are the differences between Acer and ZH70?
The Acer is the heavy-duty version of the rope manipulator with a lifting capacity of up to 150 kg, suitable for somewhat larger and heavier components. The ZH70 is constructed of lightweight aluminum, designed for loads up to 70 kg, and optimized for high maneuverability and rapid handling. Both versions are identical in terms of operating principle and safety concept.
04 How does the double rope technology work?
The load is supported by two parallel wire ropes in the rope manipulator. This double-rope arrangement provides redundancy: should one rope fail, the second will hold the load securely. The load is guided in a straight line of pull, which reduces stress on the building structure. A pressure accumulator keeps the load securely in position even in the event of a power failure.
05 What devices can be attached to the rope manipulator?
The rope manipulator accommodates the complete ZHHT device program: gripping, suction, and hook devices, as well as customer-specific special solutions. Suction devices are used for cartons and packaging, grippers or clamping elements for workpieces, and clamping and hook solutions for sacks and containers. Complete solutions are designed specifically for each component.
06 Where is the rope manipulator typically used?
The cable manipulator is used wherever medium loads need to be handled frequently and quickly: in order picking and packing, machine loading, final assembly, food and pharmaceutical production, warehousing, and logistics. It can be used either mobile with a pallet truck or stationary on the ceiling or floor.
07 How does the rope manipulator differ from the articulated arm manipulator?
The cable manipulator guides the load via two counterweighted wire ropes and is designed for rapid handling: Acer up to 150 kg, ZH70 in lightweight aluminum construction up to 70 kg. The articulated arm manipulator guides the load rigidly via arms and joints, lifts up to 800 kg, and is designed for heavy-duty applications. Both designs complement each other. A detailed comparison can be found in the guide "Articulated or Cable Manipulator".