ORIENTATION / LIFTING TECHNOLOGY
Manipulator, crane or chain hoist: Which is used for what?
There are various solutions for lifting and moving loads in production. Which one is right depends on the task, not just the price.
Zeilhofer Handhabungstechnik specializes in manipulators, lifting axes, and lifting aids. Cranes and chain hoists are not part of our product range. This overview is for informational purposes only and is not a sales pitch for any particular system.
COMPARISON OF THE SYSTEMS
THREE SOLUTIONS, THREE TASKS
Cranes, chain hoists, and manipulators solve different problems. The crucial difference lies in whether a load simply needs to be lifted or precisely handled during the process.
Crane & chain hoist
Cranes and chain hoists lift loads vertically and transport them over long distances. The load hangs from a rope or chain and can swing.
They are suitable when a load needs to be moved from point A to point B and the exact position at the destination is less critical. Advantages include high lifting heights, high load capacities, and a comparatively low purchase price.
Limitations become apparent when the load needs to be precisely positioned, rotated, or joined against resistance. A chain hoist cannot handle off-center loads or torques.
Manipulator Zeilhofer HHT
A manipulator guides the load using a rigid mechanism instead of a rope or chain. This prevents the load from swinging.
It can be positioned, rotated, tilted, and joined against defined resistance with millimeter precision. The manipulator can also handle off-center loads and torques.
The right choice when a component not only needs to be lifted but also handled precisely during the process: during insertion, joining, screwing, or alignment. This increases cycle time reliability and ergonomics.
LIFTING EQUIPMENT AT A GLANCE
HOIST OR MANIPULATOR?
Cranes and chain hoists are lifting equipment: they lift and transport. A manipulator additionally guides the load rigidly and positions it. This is how the most common types of hoists differ in practice:
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Electric chain hoist: Lifts loads vertically on a chain, usually mounted on a beam, track or crane. Robust and inexpensive for pure lifting, but the load swings and cannot be joined against resistance. A manipulator is the better choice when parts are inserted, rotated or bolted in the production cycle.
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Overhead and bridge cranes: Cover large hall areas and heavy loads and are ideal for transport over distance. For millimeter-precise positioning at the workstation they are too slow and too imprecise. Here a manipulator or the ZH90 lifting axis complements the crane directly at the assembly station.
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Pillar and wall-mounted jib cranes: Serve one workstation within their slewing radius, usually with a chain hoist. The load still hangs from a rope or chain. An articulated arm manipulator at the same spot takes over when rotating, tilting or off-center loads are required.
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Monorail hoist: Moves loads along a fixed line, for example between two stations, and is sufficient for simple transfers. If the load has to be joined precisely at the end of the line, a manipulator or lifting axis takes over.
DECISION AID
WHICH SYSTEM FOR WHICH TASK
A quick overview based on use case. In many companies, both systems are used in parallel.
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Simply lifting and transporting over a distance = CRANE / CHAIN HOIST
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Millimeter-precise positioning in the assembly process = MANIPULATOR
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Rotating, tilting or joining a load = MANIPULATOR
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Handling off-center loads or torques = MANIPULATOR
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Very high lifting heights with simple load handling = CRANE / CHAIN HOIST
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Swing-free, ergonomic handling in the production cycle = MANIPULATOR
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 What is the difference between a manipulator and a chain hoist?
A chain hoist lifts the load using a chain, which can swing during the process. A manipulator, on the other hand, guides the load via a rigid mechanism; it does not swing and can be positioned, rotated, and joined with millimeter precision. A manipulator can also handle off-center loads and torques, which a chain hoist cannot. Zeilhofer articulated arm manipulators handle loads up to 800 kg in this way.
02 When is a manipulator more worthwhile than a crane?
A manipulator is worthwhile when a component not only needs to be lifted but also handled precisely during the process, for example, during insertion, bolting, or alignment. If it's simply a matter of lifting and transporting over a distance, a crane is usually the more economical solution. Zeilhofer advises on this choice in the process analysis.
03 Can a manipulator replace a crane?
No, the two systems do different jobs. A crane transports loads over distance and height. A manipulator positions loads precisely in the assembly process. Many plants use both side by side. The Zeilhofer ZH90 lifting axis can also be integrated into an existing crane runway.
04 Does Zeilhofer also build cranes and chain hoists?
Zeilhofer Handhabungstechnik specializes in manipulators and lifting aids and does not offer standalone crane or chain hoist solutions. However, chain hoists are used as components, for example as lifting units within electric lifting axes.
05 Electric chain hoist or manipulator: which is better for assembly?
For assembly, usually the manipulator: it guides the load rigidly, so it does not swing and can be inserted, rotated and joined with millimeter precision. It also handles off-center loads and torques. An electric chain hoist is the cheaper choice when a load only needs to be lifted and set down vertically.
06 Can I combine a manipulator with my existing overhead crane?
Yes. The crane handles transport across the hall, the manipulator handles precise positioning at the workstation. The Zeilhofer ZH90 lifting axis can also be integrated into an existing crane runway and guides loads of up to 1,200 kg without swinging.
07 What is a monorail hoist and when is it enough?
A monorail is a single track along which a chain hoist or trolley moves loads on a fixed line. It is sufficient when loads are only transferred between fixed stations. If the load has to be joined precisely at the destination, a manipulator or lifting axis complements the monorail hoist.
08 What inspection rules apply to cranes, chain hoists and manipulators?
In Germany, cranes are inspected under DGUV Regulation 52, chain hoists and manipulators under DGUV Regulation 54: before first use and then at least once a year by a qualified person. Manipulators are expressly not cranes under Section 2 of DGUV Regulation 52, and the German Ordinance on Industrial Safety and Health (BetrSichV) applies to all three. Comparable rules apply elsewhere, such as LOLER in the UK and OSHA requirements in the US. The Zeilhofer guide to UVV inspection of lifting aids explains the procedure and intervals.