Gelenk-Manipulator für Türeneinbau bei Porsche
Gelenk-Manipulator für Türeneinbau bei Porsche
SYSTEM AND SELECTION
WHAT IS A MANIPULATOR
Definition, construction, and function of industrial manipulators. Plus: How manipulators, cranes, and chain hoists differ in practice.
A manipulator is an industrial handling device that assists in manually moving, positioning, and joining heavy loads. Unlike a crane, the operator actively guides the load; the manipulator takes the weight off the operator's shoulders and provides full control over the movement.
In industrial handling technology, manipulators have become the standard solution when loads between 5 kg and 800 kg need to be moved precisely, ergonomically, and safely. Typical applications include assembly lines, foundries, the glass and window industry, logistics, and special-purpose machine construction.
CONSTRUCTION
CONSTRUCTION OF A MANIPULATOR
A manipulator essentially consists of three modules, which are combined differently depending on the application and load range.
01 Supporting structure
The supporting structure transfers the load forces to the floor or ceiling. It can be designed as a column, wall arm, ceiling mount, or mobile console.
02 Lifting system
The lifting system raises and lowers the load. Depending on the design, pneumatic, electromechanical, or hydraulic systems are used.
03 Load handling
The load-bearing device is adapted to the specific application. Grippers, vacuum lifters, magnetic lifters, or special tools take over the load and guide it to the workpiece.
CONSTRUCTION
CONSTRUCTION OF A MANIPULATOR
A manipulator essentially consists of three modules, which are combined differently depending on the application and load range.
COMPACT
MANIPULATOR AT A GLANCE
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Load range from 5 kg to 800 kg
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Oscillation-free, precise load guidance
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Lightweight aluminum construction, optional 48-volt battery
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Deployment in 18 industrial sectors
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UVV inspection required according to DGUV Regulation 54
FUNCTION
HOW IT WORKS
The operator moves the load by hand using the load-bearing device or the integrated control handle. The manipulator compensates for the weight, allowing loads of 200 kg or more to be moved with minimal effort. In pendulum-free systems, lateral oscillation of the load is also suppressed, enabling precision work that would be impossible with a crane.
CONSTRUCTION
MANIPULATOR, CRANE AND CHAIN WHEEL COMPARED
A direct comparison clearly shows the different strengths of the three lifting aid classes.
01 Chain hoist
It lifts loads vertically, but allows them to swing freely. This is imprecise and ergonomically unfavorable for heavy workpieces.
02 Crane
Designed for transporting loads over longer distances. Less suitable for precision positioning at the assembly site.
03 manipulator
Optimized for the workplace. Guides the load rigidly, without pendulum movement, with high repeatability and ergonomic operation.
TYPES
MANIPULATOR TYPES AT A GLANCE
Industrial manipulators can be divided into four main types based on their design and range of motion. The most suitable type depends on the workspace, load capacity, and required range of motion.
01 Articulated arm manipulator
The articulated arm manipulator uses swivel axes for maximum mobility within the work area. Ideal for complex movement sequences in assembly, such as the installation of doors, cockpits, or seats. Load capacity up to 800 kg.
03 Rope manipulator
The rope manipulator uses a steel cable for flexible load handling. Suitable for light to medium loads with a long reach and free load positioning. Available from ZHHT as the ZH70 or Acer, up to 150 kg.
02 Hubaches (linear manipulator
The lifting axis operates purely vertically as a pneumatic linear axis. It is the highest-capacity variant and ideal for pure lifting with high repeatability. At Zeilhofer HHT, it's suitable for loads up to 1,200 kg with the ZH90.
04 articulated arm manipulator
The articulated arm manipulator combines multiple swivel joints for maximum flexibility. It reaches areas inaccessible with other designs. Typical for special-purpose machines and individual handling tasks.
SELECTION
WHEN A MANIPULATOR IS THE RIGHT CHOICE
Manipulators are useful when loads are regularly positioned manually, when precision is required, when ergonomic requirements according to DIN EN 1005 must be met, or when a crane would be too slow or too inaccurate.
Manipulators are now standard in automotive final assembly, the handling of high-voltage batteries, and the assembly of large glass and window elements.
Zeilhofer manufactures manipulators for loads up to 800 kg. The devices are pendulum-free, readily available, and currently serve 18 industrial sectors.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 What is the difference between a manipulator and a crane?
A manipulator guides the load rigidly and without pendulum motion directly at the workstation, while a crane transports freely swinging loads over greater distances. Manipulators are optimized for precision positioning.
02 What loads can a manipulator move?
Industrial manipulators move loads from a few kilograms to over 500 kg. Zeilhofer manipulators are designed for loads up to 800 kg.
03 Can a manipulator replace a crane?
Not generally, but in many applications, yes. A manipulator is always the better choice when loads need to be precisely positioned, rotated, or joined. For simple transport over long distances or very heavy loads exceeding 1,200 kg, the crane remains the first choice. In assembly, manufacturing, and machine setup, manipulators have largely replaced the crane.
04 In which industries are manipulators used?
Manipulators are used in automotive final assembly, foundries, the glass and window industry, logistics, special-purpose machinery manufacturing, and numerous other sectors. Zeilhofer currently supplies 18 industries.
05 Are manipulators subject to mandatory testing?
Yes. Manipulators are subject to annual safety inspections according to DGUV Regulation 54. The inspection must be carried out and documented by a qualified person.
06 What types of manipulators are there?
Industrial manipulators can be divided into four main types: articulated arm manipulators for complex movements, pneumatic linear axes with lifting axes up to 1,200 kg, rope manipulators for flexible load handling up to 150 kg, and articulated arm manipulators for maximum reach. The choice depends on the load, workspace, and movement sequence.
07 Where can I find manipulator manufacturers in Germany?
Zeilhofer HHT develops and manufactures manipulators in Holzkirchen, Bavaria. Since 1999, they have been producing customized lifting aids for 18 industries, ranging from the automotive and mechanical engineering sectors to glass and window production. All manipulators are designed and manufactured in Germany.
07 Where can I find manipulator manufacturers in Germany?
Zeilhofer HHT develops and manufactures manipulators in Holzkirchen, Bavaria. Since 1999, they have been producing customized lifting aids for 18 industries, ranging from the automotive and mechanical engineering sectors to glass and window production. All manipulators are designed and manufactured in Germany.
SELECTION
WHEN A MANIPULATOR IS THE RIGHT CHOICE
Manipulators are useful when loads are regularly positioned manually, when precision is required, when ergonomic requirements according to DIN EN 1005 must be met, or when a crane would be too slow or too inaccurate.
Manipulators are now standard in automotive final assembly, the handling of high-voltage batteries, and the assembly of large glass and window elements.
Zeilhofer manufactures manipulators for loads up to 800 kg. The devices are pendulum-free, readily available, and currently serve 18 industrial sectors.