2x Hubachse ZH90 als Wendevorrichtung
2x Hubachse ZH90 als Wendevorrichtung
SPECIAL MACHINERY CONSTRUCTION AND SPECIAL SOLUTIONS
Standard solutions handle 80 percent of all handling tasks in industry. The remaining 20 percent—those with unusual geometries, extreme loads, the highest accuracy requirements, or confidential components—require special-purpose machines. This is precisely where the engineering team at Zeilhofer HHT comes in: We develop customized manipulators, special grippers, and custom control systems that are precisely tailored to your component, cycle time, and workstation.
From initial concept to worldwide commissioning, everything comes from a single source in Holzkirchen, Germany. ISO 9001 certified, TISAX Level 2 compliant with prototype protection — for confidential OEM projects and customer-specific special tasks.
CHAPTER 1
WHAT ARE SPECIAL MACHINES AND SPECIAL SOLUTIONS?
Special-purpose machines are individually designed systems built for a specific application—as opposed to series-produced or standard machines. In the handling sector, this typically applies to:
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Special gripper with component-specific mounting
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Special devices for complex 3D geometries
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Special control system with customer-specific PLC integration
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Special mechanics with higher load capacity, larger working radius or unusual axes
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Special security technology for critical components (HV batteries, confidential prototypes)
A custom solution is always an engineering project: It begins with gathering the customer's requirements, goes through concept and design development, and ends with preliminary acceptance testing in the showroom and commissioning at the installation site. Unlike standard manipulators, each custom solution is unique, with its own documentation, CE declaration of conformity, and customer-specific operating instructions.
CHAPTER 2
WHEN IS A CUSTOM SOLUTION WORTH IT?
Four indicators point to a special machine rather than a standard lifting aid:
01 Geometry does not conform to any standard
If the component is non-circular, hollow, asymmetrical, or has undercuts, a standard gripper often cannot pick it up securely. Examples include body parts with creases, cockpit modules with attachments, and hydrogen tanks with connections. In these cases, the gripping area is precisely recreated—usually using 3D scans or CAD data provided by the customer.
02 Load range exceeds standard series
Standard manipulators cover lifting capacities up to 800 kg. The ZH90 lifting axis lifts up to 1,200 kg. For higher capacities—up to 2,000 kg or with unusual lifting strokes—a custom mechanism is available. Zeilhofer has supplied special lifting axes with a 1.5 t lifting capacity and a 3 m lifting stroke.
03 Highest security and compliance requirements
High-voltage batteries, explosives, confidential prototypes or hygiene-critical pharmaceutical components require special control systems with certified safety functions, redundant end-position locking mechanisms and special material versions (stainless steel, ESD, ATEX Zone 2).
04 Confidential OEM Prototypes
For prototype components prior to series production, the highest level of confidentiality applies. TISAX Level 2 with prototype protection is mandatory here. Zeilhofer's special projects for OEMs are conducted under NDA, with separate rooms, documented access control, and contractually guaranteed confidentiality.
CHAPTER 3
PRACTICE: SPECIAL GRIPS FOR COMPLEX GEOMETRICES
The most frequent need for custom solutions lies with the gripper. Standard vacuum lifters only work on flat surfaces, and standard clamping grippers require parallel contact surfaces. For complex components, a component-specific fixture is the only solution.
Typical applications
Body parts with creases, paintwork and crash structures
Cockpit modules with electronic components and air intakes
Bumpers and spoilers with curved surfaces
Hydrogen tanks and pressure vessels with connections
Glass body panels and photovoltaic modules
ZHHT solution
Based on CAD data or a 3D scan of the component, our engineers develop a custom-fit gripper. The gripper engages at several defined points, protects sensitive surfaces with special material pads (felt, foam, PTFE), and secures the component against unintentional release via a multi-stage locking mechanism. Standardized interfaces allow for mounting on the ZH90 lifting axis or articulated manipulator.
Advantages of this application
The image is precisely adapted to the component geometry.
Gentle pads prevent damage to painted surfaces.
Multi-stage locking mechanism secures component against being dropped.
Quick-change interface for variant flexibility
Documented design and CE declaration of conformity
CHAPTER 4
PRACTICE: SPECIAL DEVICES FOR SENSITIVE COMPONENTS
Sensitive components — painted body parts, polished stainless steel surfaces, optical components or electronic modules — require special devices to prevent damage.
Challenge
Painted surfaces cannot tolerate pinch or scratch marks.
Suction cups must not leave pressure marks on body panels.
Electronic components cannot tolerate vibrations or shocks.
Sterile components (pharmaceutical, medical) require stainless steel and cleanroom-compliant materials.
ZHHT solution
Vacuum suction cups with pressure control and soft pads (silicone, EPDM, foam) distribute the holding force over a large area and gently. Pressure sensors continuously monitor the suction force—movement stops immediately if pressure is lost. Stainless steel versions with FDA-compliant pads are used for sterile applications, while electrically conductive materials are used for ESD areas.
Advantages of this application
Pressure regulation prevents suction cup marks.
Soft pads protect painted and polished surfaces.
Sensory monitoring detects loss of holding immediately.
Special materials available for sterile and ESD applications
Pendulum-free movement protects electronic components
CHAPTER 5
PRACTICE: SPECIAL CONTROL AND PLC INTEGRATION
Modern production lines operate on a cycle-controlled schedule via central PLC controllers. A lifting aid must integrate seamlessly into this control environment — with defined interfaces, visual feedback signals, and safety functions.
Typical interfaces
Profinet (Siemens-dominated industries)
EtherCAT (high-speed automation industries)
EtherNet/IP (Allen-Bradley / Rockwell world)
OPC UA for Industry 4.0-compliant data connectivity
Classic I/O wiring for simple applications
ZHHT solution
Our design team offers custom control systems using Siemens S7-1500, Beckhoff TwinCAT, or Allen-Bradley CompactLogix. The control system communicates with the line PLC at precise synchronization, handles motion enable signals via photoelectric sensors, and provides feedback when end positions are reached. Safety functions (emergency stop, two-hand operation, end position interlock) are certified to PL d according to EN ISO 13849.
Advantages of this application
Precise integration into existing line PLCs
Movement release via safety light curtain and two-hand control
End-position locking prevents premature release.
CHAPTER 6
PRACTICE: HYBRID HUMAN-ROBOT COLLABORATION (HRC)
Human-robot collaboration is the trend in modern production lines. Instead of the classic separation of worker and robot, both work together — the worker guides the component intuitively, the lifting aid takes over the load and ensures safety.
Requirements
Sensory safety without a safety fence
Force limitation in case of collision according to ISO/TS 15066
Intuitive hand guidance with force feedback
Non-oscillating load guidance for precise positioning
Compliance with DIN EN ISO 10218 (Robotics Safety)
ZHHT solution
The ZH90 lifting axis, a collaborative variant with force limitation, tactile sensors, and reduced speed, enables safe operation without a safety fence. The operator guides the lifting axis by hand, and it bears the load weight. In the event of a collision with the operator or workpiece, the movement stops in less than 0.1 seconds. Force feedback sensors detect whether the operator is pulling or pushing—the control system reacts intuitively.
Advantages of this application
Safe working without a safety fence according to ISO/TS 15066
Intuitive hand guidance with force feedback
Workers and lifting aids work as a team
Pendulum-free load guidance protects the component and the worker.
Scalable from 50 kg to 1,200 kg load capacity
CHAPTER 7
ENGINEERING PROCESS STEP BY STEP
A custom-built machine is developed through a structured engineering process. Zeilhofer HHT works according to VDI guidelines and provides everything from initial consultation to commissioning from a single source.
01 Initial consultation and requirements gathering
Joint analysis on-site or digitally: Which component, which loads, which cycle time, which workplace situation, which compliance requirements? Documentation of interfaces — pneumatics, electrical systems, IT, safety. Result: documented specifications and concept sketch.
02 Concept and binding price indication
Design of the lifting aid (manipulator, lifting axis, hoist) and selection of the gripping device. Concept including installation plan, collision analysis, and motion simulation. Binding price indication and delivery time. Free of charge and without obligation.
03 Design and Detail Engineering
3D CAD design in SOLIDWORKS or NX. FEM calculation of load-bearing capacity, dynamic motion simulation, safety analysis according to EN ISO 13849. Creation of mechanical drawings, circuit diagrams, and PLC programming.
04 Confidential OEM Prototypes
Mechanical manufacturing takes place in our own workshop in Holzkirchen, Germany. This includes welding, machining, painting, and assembly. Pneumatics and electrical systems are integrated in parallel. Factory functional testing is performed using the original component or a dummy with the same geometry.
05 Preliminary inspection in the Holzkirchen showroom
The customer inspects the system in our showroom in Holzkirchen or follows the pre-acceptance inspection via video transmission. Testing with original workpieces, safety check, and functional validation are performed. The system is only delivered after customer approval.
06 Commissioning worldwide and training
Our own service technicians travel worldwide for commissioning – to over 50 countries. This includes on-site installation, PLC integration into the line control system, training of operators and maintenance personnel, and handover protocol and operating documentation.
CHAPTER 8
REFERENCES: 25 YEARS OF CUSTOM SOLUTIONS
Since 1999, Zeilhofer HHT has been developing special-purpose machines for German and international industry. Over 18 industries rely on our engineering expertise from Holzkirchen:
Typical special projects
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Automotive final assembly: Special grippers for cockpit installation, doors, high-voltage batteries
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E-Mobility: Lifting axles for high-voltage battery handling up to 1,200 kg
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Mechanical engineering: Lifting aids for engines, gearboxes, forged parts
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Glass/PV industry: Special vacuum trusses for solar modules and architectural glass
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Pharmaceuticals/Medical: Stainless steel manipulators for cleanroom applications
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Packaging and food: hygiene-compliant special solutions
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Workshop logistics: mobile lifting platforms for spare parts picking
What distinguishes Zeilhofer's special solutions?
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ISO 9001 certified quality management since 2008
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TISAX Level 2 with prototype protection for confidential OEM projects
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Engineering, manufacturing and service from a single source in Holzkirchen
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Customer support by our own engineers — no outsourcing chains
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Lifetime spare parts supply for delivered systems
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Plant relocation possible during factory moves worldwide
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 What does a custom solution cost compared to a standard lifting aid?
A custom solution typically costs 20 to 50 percent more than a standard manipulator with comparable load capacity. However, the additional cost is usually offset by shorter cycle times, improved ergonomics, and the prevention of damage to sensitive components. You will receive a specific price estimate free of charge after an initial consultation.
02 How long does it take to develop a special-purpose machine?
From initial consultation to commissioning, typically 4 to 9 months — depending on complexity. Concept and price indication in 1 to 3 weeks, design 6 to 12 weeks, manufacturing 8 to 16 weeks, preliminary acceptance and commissioning 2 to 4 weeks. Acceleration is possible for time-critical projects.
03 Which industries are supplied with special solutions?
Automotive and e-mobility industries, mechanical engineering, hydrogen and fuel cell industries, glass and PV industries, pharmaceuticals and medical technology, food and packaging, forging and foundry, heavy machinery manufacturing, and over 12 other sectors. A total of 18 sectors across 50 countries.
04 How is confidentiality ensured in prototype projects?
Zeilhofer HHT is TISAX Level 2 certified with prototype protection. Confidential projects are conducted under NDAs, with documented access control, separate workspaces, and contractually guaranteed confidentiality. This certification is mandatory for many OEM prototype contracts.
05 Which interfaces do Zeilhofer special control systems support?
Profinet, EtherCAT, EtherNet/IP, OPC UA and classic I/O interfaces. Siemens S7-1500 PLCs, and others upon request.
06 Who is responsible for CE conformity and documentation?
Zeilhofer HHT — as the manufacturer of the special-purpose machine. We prepare the CE declaration of conformity, risk assessment according to Machinery Directive 2006/42/EC, operating instructions in the customer's language, technical documentation, and maintenance instructions. For systems integrated with other machines, we coordinate the overall CE marking.
07 What service and maintenance services are included?
Commissioning worldwide by our own technicians, operator training, maintenance contracts with annual safety inspections according to DGUV Regulation 54, original spare parts even 15+ years after delivery, technical hotline with remote support, plant relocation during factory moves.
08 Where are Zeilhofer special machines manufactured?
Design and manufacturing take place centrally in Holzkirchen, Germany. Commissioning takes place worldwide at customer sites in over 50 countries. Made in Germany, ISO 9001 certified and TISAX Level 2 with prototype protection.
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.
PRODUCT
ZH90 lifting axle in use
Swing-free lifting up to 1,200 kg. Practical applications from automotive, e-mobility, foundry and mechanical engineering.
BASICS
What is a manipulator?
Industrial manipulators explained: Function, types and comparison to cranes and chain hoists.
NEXT STEP
YOUR INDIVIDUAL SPECIAL SOLUTION
Talk to our engineers about your specific requirements. We analyze the component, cycle time, and workstation, and develop a customized special-purpose machine—from concept and design to manufacturing and commissioning worldwide. Made in Germany, ISO 9001 and TISAX Level 2 certified.