GUIDE · AUTOMOTIVE INDUSTRY
ONE PARTNER FOR EVERY COMPONENT OF YOUR VEHICLE PRODUCTION
From delicate visible parts to 1,200-kilogram high-voltage batteries: Zeilhofer handles the entire spectrum of automotive components from a single source. Ergonomic, process-reliable, and custom-designed to your specific geometry.
CHAPTER 1
In vehicle assembly, every component presents a handling problem.
A windshield must not be scratched. A high-voltage battery weighs several hundred kilograms and must be inserted into the vehicle floor with millimeter precision. A front end is bulky and tilts when lifted. A cordless screwdriver puts strain on employees due to its own weight and reaction torque. Each of these parts has a different physical property to consider, and Zeilhofer has the right solution for each of these properties.
This is precisely the difference compared to specialized suppliers who only cover one segment, such as vacuum technology or lightweight construction. Zeilhofer supports the entire vehicle assembly process across the entire load range and designs every gripper and fixture as a custom-built solution tailored to the specific component geometry.
This guide does not arrange automotive components alphabetically, but rather according to their actual handling challenges. For each group, it specifies the realistic load class, explains the underlying technical principle, and provides concrete application examples drawn from more than 25 years of special-purpose machine construction.
The right solution for each load class
-
Hubachse ZH90 = 1,200 kg
-
Manipulator = 800 kg
-
Flex-Arm = 200 kg
-
Cable manipulator = 150 kg
-
Hebelift ZH = 100 kg
CHAPTER 2
Sensitive visible parts
Paint, glass, and visible surfaces cannot tolerate scratches or pressure marks. Here, the decisive factor is not the load-bearing capacity, but the type of grip. Form-fitting, component-specific grips with soft contact surfaces replace point-based suction technology, which reaches its limits with structured or curved visible parts.
Equally important is the vibration-free guidance: When installing a windshield, tight tolerances are crucial; a swinging component would touch the body. The balancer technology keeps the load steady and weightless in every position.
windshields
TAILGATE
GLASS ROOF
VEHICLE DOOR
CHAPTER 3
Heavy load up to 1,200 kg
High point loads, precisely guided: Depending on the vehicle model, a high-voltage battery weighs around 300 to 700 kg, with larger versions weighing even more. Axles, transmissions, and complete drive units are in a similar range. This is precisely where the advantage of the Hubachse ZH90, with a load capacity of up to 1,200 kg, lies: It guides heavy, compact components safely and with millimeter precision to their installation location.
If a particularly large battery exceeds the load-bearing limit, it is handled module- or cell-block-wise. The appropriate mounting is always custom-built.
HIGH-VOLTAGE BATTERY
TRANSMISSION
Guide in preparation
VEHICLE AXLE
BATTERY HOUSING
CHAPTER 4
Bulky add-on parts
Bulky components with a shifting center of gravity tend to tip over when lifted. Exhaust systems, front ends, bumpers, and trailer hitches therefore require less pure lifting power and more precise center of gravity control and a fixture that holds the component stably in position. Manipulators and cable manipulators guide such loads in a balanced and rotatable manner.
The direction of assembly also plays a role: springs and dampers are joined under defined preload, and the device must be able to safely absorb these forces.
EXHAUST SYSTEM
TOW BAR
BUMPER
SPRING & DAMPER
CHAPTER 5
Screwing and assembly technology
Not only components, but also the tools themselves need to be relieved of stress. An industrial screwdriver transmits a reaction torque to the operator when tightening, which leads to considerable strain over a workday. The Hubachse ZH90 supports screwdrivers and cockpit modules, bears their weight, and absorbs the reaction torque, while the operator only needs to guide the tool.
The effect is twofold: reduced physical strain and a repeatable, consistent screw-fastening quality in series assembly.
SCREW TECHNOLOGY
TIRES & WHEEL
COCKPIT MODULE
VEHICLE SEAT
CHAPTER 6
E-mobility: the most demanding handling in assembly
No area of vehicle production is changing handling procedures as drastically as electromobility. The high-voltage battery is the heaviest single component in the vehicle and is lifted into the floor of the vehicle from below, under tight tolerances and in a timed production line. Weight, precision, and workplace safety all converge here.
Zeilhofer has been involved in this transformation for years: from the ergonomic handling of individual battery modules to the gripper for the battery housing, all the way to the complete high-voltage battery on the Hubachse ZH90. Because each battery platform has a different geometry, the mounting is always custom-built, secured by TISAX Level 2 certified handling of prototypes.
Further practical examples:
BATTERY MODULE HANDLING IN E-MOBILITY
Hubachse ZH90 in the production of an electric SUV
CHAPTER 7
Why handling technology is increasingly becoming a necessity rather than an option
Musculoskeletal disorders are among the most frequent causes of sick days in production. Every lost workday costs money, and in mass production, this quickly adds up. Ergonomic handling technology is therefore not only a matter of occupational safety, but also a matter of business management.
In addition, there is the legal framework. In Germany, the Manual Handling Ordinance regulates the manual handling of loads, assessed using the key indicator method. From 2027, the EU Machinery Directive will further tighten the ergonomic requirements for machines and equipment. Those who invest in handling technology today will meet these requirements and future-proof their production.
Further reading:
EU MACHINERY REGULATION 2027
MUSCULAR DISEASES
CHAPTER 8
Four steps to the right solution for your component
The most suitable handling solution is determined by four questions. These also form the basis of every design consultation with our engineers.
01 WEIGHT
How heavy is the component? This determines the product line, from 100 kg lifting platform to 1,200 kg Hubachse ZH90.
03 Surface
Visible part or robust? Sensitive surfaces require form-fitting, scratch-free grippers instead of point-contact gripping.
02 Focus
Compact or bulky? Large parts with a shifting center of gravity require balanced center of gravity guidance.
04 cycle time
How often per shift? The frequency of movement determines ergonomics, degree of automation, and operating concept.
The most suitable handling solution is determined by four questions. These also form the basis of every design consultation with our engineers.
CHAPTER 9
No other company offers this range from a single source.
Other suppliers cover one segment: only lightweight construction, only vacuum technology, only one component. Zeilhofer designs every gripper and every fixture as a custom-built solution tailored to your component geometry and supports the entire vehicle assembly process, from 150 kg visible parts to 1,200 kg heavy loads.
Special construction
-
Each gripper is designed to fit the specific geometry; there is no catalog compromise.
ISO 9001 & TISAX L2
-
Certified quality and verified prototype protection for collaboration with OEMs.
Full load range
-
Five product lines seamlessly cover 100 to 1,200 kg, one contact person.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 Which components can be moved using handling technology?
Virtually every heavy or bulky component: high-voltage batteries and battery housings, vehicle axles and e-axles, transmissions, doors, front and rear hatches, windshields and glass roofs, seats and cockpit modules, tires and wheels, exhaust systems, bumpers, trailer hitches, as well as springs and dampers. A different characteristic is crucial for each component: weight, center of gravity, surface sensitivity, or cycle time. Zeilhofer builds the matching gripper for each component.
02 Up to what weight can a component be handled?
The Zeilhofer Hubachse ZH90 handles loads up to 1,200 kg, such as high-voltage batteries, axles, or gearboxes. Manipulators cover loads up to 800 kg, the flex arm up to 200 kg, the cable manipulator up to 150 kg, and the Hebelift ZH up to 100 kg. Large high-voltage batteries of some models can exceed the 1,200 kg limit and are then handled module by module or cell block by cell block.
03 How are sensitive visible parts handled without damage?
Component-specific grippers and fixtures ensure a scratch- and mark-free grip and guide the load without swinging. The crucial factor is not the load capacity, but rather defined gripping points, soft supports, and a balanced movement that prevents impact or tilting. This allows for the secure installation of windshields, glass roofs, and painted front and rear hatches. Zeilhofer designs these fixtures for each component.
04 How is a high-voltage battery safely installed in the vehicle floor?
The high-voltage battery is the heaviest single component in the electric vehicle and is lifted into the vehicle floor from below, under tight tolerances and in a timed production line. The Zeilhofer Hubachse ZH90 guides the battery, weighing up to 1,200 kg, to its installation location with millimeter precision, without any pendulum movement and with a defined mounting. Because each battery platform has a different geometry, the mounting is custom-made.
05 Is handling technology also suitable for screw and assembly technology?
Yes. The Zeilhofer Hubachse ZH90 accommodates screwdrivers and fastening technology and positions them ergonomically and with repeatable accuracy at the joining point. This relieves employees of the weight and reaction torque of the tool and ensures consistent fastening quality in series assembly.
06 What does a handling solution for automotive production cost?
The price depends on component weight, gripper geometry, working area, and degree of automation, as each solution is custom-built. Economically, the amortization is more crucial than the purchase price: A handling solution reduces absenteeism due to musculoskeletal disorders, accelerates cycle times, and minimizes component damage. In many cases, it pays for itself within just a few years. Zeilhofer quotes a fixed price after the process analysis.
07 How does the development of a component-specific device proceed?
The process begins with the component geometry, including weight, center of gravity, and gripping points. From this, Zeilhofer engineers design, construct, manufacture, and commission grippers and fixtures, all under one roof. Handling prototypes is secured through TISAX Level 2 testing, which is particularly important in the early development phase with automotive manufacturers.
08 What legal requirements apply to manual handling of loads in production?
In Germany, the Manual Handling Ordinance regulates the manual handling of loads, assessed using the key indicator method. From 2027, the EU Machinery Regulation will tighten the ergonomic requirements for machinery and equipment. Zeilhofer handling technology demonstrably reduces physical strain and helps to meet these requirements.
09 Where are the handling devices manufactured?
Zeilhofer develops, designs, and manufactures all handling equipment in Germany. From there, the systems are delivered to over 50 countries and are used in the automotive industry as well as in foundries, logistics, and special-purpose machinery manufacturing. Design, fixture construction, and commissioning are all provided by a single source.
10 What distinguishes Zeilhofer from other suppliers of handling technology?
Zeilhofer has been manufacturing special-purpose machinery since 1999, covering the entire spectrum of automotive components from a single source, from 150 kg visible parts to 1,200 kg heavy-duty applications. Every gripper and fixture is custom-designed to fit the specific component geometry. Zeilhofer is ISO 9001 certified and TISAX Level 2 audited with prototype protection, supplying all major automotive manufacturers in over 50 countries.