ZH90 lifting axis with vacuum device lifting a glass pane in production
ZH90 lifting axis with vacuum device lifting a glass pane in production
Guide · Glass and Windows
Manipulator for glass panes and windows
Glass manipulator and lifting aid for glass: Safely lift, rotate, tilt and glaze glass panes, insulating glass and window elements in production.
Short answer
For glass panes and windows in production, manipulators, also called glass manipulators or glass lifting aids, with vacuum, gripping, or combined devices are suitable. A Zeilhofer articulated manipulator lifts up to 800 kg, while the ZH90 lifting axis lifts up to 1,200 kg. The rigid guide prevents oscillation, allowing panes to be positioned, rotated, tilted, and glazed with millimeter precision. Glass weighs approximately 2.5 kg per square meter and millimeter of thickness. This guide shows you how to calculate the weight, choose the right system, and properly design the safety features.
The guide "Vacuum Tube Lifter Alternative" explains in detail how vacuum safety works.
The most important points in brief
This refers to solutions for production, window manufacturing and insulating glass, not vacuum lifters for construction sites.
Glass weighs approximately 2.5 kg per m² and mm thickness; insulating glass 4/4/4 with 2.0 × 1.5 m weighs around 90 kg.
Lifting lift ZH up to 100 kg (mobile), rope manipulator up to 150 kg, articulated manipulator up to 800 kg, lifting axis ZH90 up to 1,200 kg, each including device.
Suction, gripping, or a combination of both; the combination offers maximum safety.
Rotating, swiveling, tilting and glazing are implemented according to customer requirements.
Two separate vacuum circuits and pressure monitoring keep the disc in place even in the event of a fault.
CHAPTER 1
Why glass handling is a special challenge
A pane of glass behaves differently than a steel component of the same mass. It has a large surface area, breaks under point loads or edge impacts, and has surfaces that are susceptible to damage from coatings, films, or solar control layers. At the same time, its weight increases with every millimeter of thickness and with each additional pane in the structure.
Manually moving large panes of glass, insulating glass units, or finished window elements requires two to four people, risks glass breakage, and puts strain on the back and shoulders. A manipulator transforms this team task into a single-person job: the load is guided almost weightlessly, and the operator determines its position and orientation with minimal effort. This guide focuses on solutions for production, window manufacturing, and insulating glass production, not vacuum lifters for construction sites.
CHAPTER 2
Calculating glass weight: the rule of thumb
Float glass has a density of approximately 2,500 kg per m³. This results in a simple rule of thumb: Weight in kg = Width in m × Height in m × Glass thickness in mm × 2.5. For insulating glass, only the glass thickness matters, not the space between the panes.
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Triple insulating glass 4/4/4, 2.0 × 1.5 m: 3.0 m² × 12 mm × 2.5 = approx. 90 kg
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Large format insulating glass 6/6/6, 4.0 × 2.5 m: 10 m² × 18 mm × 2.5 = approx. 450 kg
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Architectural glass LSG 2 × 10 mm, 3.21 × 2.5 m: 8.0 m² × 20 mm × 2.5 = approx. 400 kg
The design doesn't just depend on the glass. The load-bearing capacity of a manipulator always applies to the component plus the fixture. Include the frame, fittings, and the weight of the suction or gripping device, and plan for the heaviest format that will be manufactured in the future.
CHAPTER 3
Which system is suitable for which glass weight?
The choice of basic system depends primarily on the overall weight, the reach, and the required movements. Zeilhofer offers four systems for glass and windows, each with its own individual device:
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Lifting platform ZH up to 100 kg: mobile movement of smaller glass plates, battery-operated, without crane and without compressed air
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Cable manipulator up to 150 kg: smaller panes and window sashes, predominantly vertical lifting
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Articulated manipulator up to 800 kg: insulating glass, window elements and architectural glass, rigidly guided with rotation and tilting.
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Lifting axis ZH90 up to 1,200 kg: very large glass elements and doors, linearly guided and integrable into lines
Which system for which glass weight:
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Which system is suitable in each individual case also depends on working height, cycle time, and available space. Mounting options and the reach of the articulated arm are shown in the guide "Articulated Arm Manipulators up to 800 kg ," while the mobile solution is described in the article "Mobile Lifting Aid for Panels ." What to consider when choosing a manufacturer is explained in the guide "Selecting a Manipulator Manufacturer ."
CHAPTER 4
Suction, grasping, or a combination of both?
The device determines whether glass is picked up safely and gently. Zeilhofer designs them individually for each component. The article "What is a suction device?" explains how a vacuum is maintained in principle.
Innengriff und Dorn
Hülsen, Rohre und Hohlkörper werden von innen gespannt, die Außenfläche bleibt frei für Bearbeitung und Prüfung.
Magnet
Stahl- und Panzerstahlplatten werden flächig über Magnete aufgenommen, ohne Bohrungen oder Anschlagpunkte.
Außengriff und Prisma
Geschosskörper und Wellen werden formschlüssig von außen gehalten, Prismen zentrieren runde Teile sicher.
Vakuum
Gehäuse, Abdeckungen und lackierte Flächen werden schonend gesaugt, mit Drucküberwachung und redundanten Kreisen.
Combined: For large and heavy elements, tilting, and glazing, Zeilhofer combines both principles. The vacuum holds the pane, while the gripper provides additional form-fitting security. This ensures the load remains secure even if the vacuum is lost.
CHAPTER 5
Rotating, swiveling, tilting and glazing
In glass and window production, simply lifting is rarely sufficient. All movements are implemented according to customer requirements, either manually guided or motorized.
Manipulator
Führung
Starr geführt, das Bauteil pendelt nicht
Positionieren
Millimetergenau, auch beim Einlegen in Maschinen
Außermittige Lasten
Werden momentfrei aufgenommen
Personal
Eine Person statt zwei
Geeignet für
Feste Arbeitsplätze, Takt und Serie
Kran oder Kettenzug
Führung
Hängt an Seil oder Kette und pendelt
Positionieren
Braucht Zeit und oft eine zweite Person
Außermittige Lasten
Neigen zum Schiefhängen
Verfügbarkeit
Kran wird oft von mehreren Stationen geteilt
Geeignet für
Seltene, sehr schwere Hübe
In glass and window production, simply lifting is rarely sufficient. All movements are implemented according to customer requirements, either manually guided or motorized.
CHAPTER 6
Safety: What a glass manipulator must be able to do
When glass is placed near or above people, safety is of paramount importance. Zeilhofer vacuum devices are therefore equipped with multi-stage safety features:
01 Starre Lastführung
Das Bauteil pendelt nicht und schlägt nicht an. Das schützt Werker und Funktionsflächen
03 Redundante Lastsicherung
Bei Vakuum zwei getrennte Kreise mit Drucküberwachung, bei Greifern mechanische Endlagenverriegelung.
02 Sicherheitstechnik nach EN ISO 13849
Je nach Anwendung bis Performance Level d, mit Not-Halt und Absetzen nur in definierter Endlage.
04 Explosionsschutz
Sondermanipulatoren für ATEX Zone 2 und Zone 22, ausgelegt nach der Zoneneinteilung des Betreibers.
The guide "Vacuum Tube Lifter Alternative" explains why a guided manipulator with a vacuum device has advantages in terms of safety and positioning accuracy compared to the classic vacuum tube lifter.
CHAPTER 7
Manipulator or vacuum lifter on the crane.
Many companies lift glass using a vacuum lifter attached to a chain hoist or crane. This works, but reaches its limits in mass production. The difference lies in the way the load is guided.
CHAPTER 8
Applications in the glass and window industry
Glass is not only used in window construction. Typical tasks for which Zeilhofer has implemented solutions include:
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Window construction: Glazing, moving and stacking on transport racks of plastic and wooden windows, house, balcony, sliding and patio doors as well as prefabricated elements
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Insulating glass: Insert panes into the edge seal and form stacks.
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Architectural and facade glass: Handling large formats up to 6 m in length before and after cutting, grinding and coating systems
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Photovoltaics: Transferring modules weighing 18 to 35 kg between the laminator, frame and junction box station
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Mirrors and furniture glass: moving sensitive surfaces without leaving marks
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Vehicle glazing: Installation of windshields, glass roofs and train windows
Selected practical examples:
An overview of all 18 industries can be found under Applications .
1
Einzelplatz entlasten
Schwerster Arbeitsplatz zuerst: eine Person statt zwei
2
Stationen verbinden
Ein System bedient mehrere Maschinen oder Prüfplätze
3
Takt absichern
Pendelfrei und reproduzierbar, unabhängig vom Werker
4
Linie ausbauen
Teilautomatisiert mit synchronisierten Achsen
Glass is not only used in window construction. Typical tasks for which Zeilhofer has implemented solutions include:
-
Window construction: Glazing, moving and stacking on transport racks of plastic and wooden windows, house, balcony, sliding and patio doors as well as prefabricated elements
-
Insulating glass: Insert panes into the edge seal and form stacks.
-
Architectural and facade glass: Handling large formats up to 6 m in length before and after cutting, grinding and coating systems
-
Photovoltaics: Transferring modules weighing 18 to 35 kg between the laminator, frame and junction box station
-
Mirrors and furniture glass: moving sensitive surfaces without leaving marks
-
Vehicle glazing: Installation of windshields, glass roofs and train windows
Selected practical examples:
An overview of all 18 industries can be found under Applications .
CHAPTER 9
Practical example: 13 solutions for a leading window manufacturer
Zeilhofer has been collaborating with a leading window manufacturer since 2008. During this time, 13 customized handling solutions have been developed, ranging from glazing and moving finished window elements to loading transport racks. At these stations, a single person now lifts where previously a team was needed. You can read the detailed practical example in the article "Lifting Aids for Window Production ."
CHAPTER 10
Costs and financing
The price comprises the basic system and the attachment. A simple cable manipulator starts at approximately €10,000, excluding installation and commissioning. Solutions for glass with vacuum or combined attachments, tilting and rotating functions cost more, depending on the requirements; complex lifting axis solutions can reach up to approximately €150,000. The cost drivers are explained in the guide "What does a manipulator cost?" . Instead of a one-time payment, leasing and hire purchase are possible through Würth Leasing; all details can be found in the guide "Leasing and financing lifting aids" .
CHAPTER 11
Checklist: Your request needs this information
With this information, you will receive a reliable assessment and a fixed-price offer more quickly:
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Largest and smallest format as well as glass construction or glass thickness
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Maximum weight including frame and fittings
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Surface: Float glass, coated, foiled or framed
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Storage and placement: lying down, standing up, rack, frame or roller conveyor
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Required movements: rotating, swiveling, tilting, glazing
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Working heights, reach and available space
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Quantity per shift as well as photos or drawings of component and workplace
FAQ / Q&A
Frequently asked questions about glass manipulators
01 Was ist Handhabungstechnik für die Rüstungsindustrie?
Handhabungstechnik für die Rüstungsindustrie umfasst Manipulatoren, Hubachsen und Hebehilfen, die schwere Bauteile in der Fertigung von Munitionskomponenten, Fahrzeugen und Systemen pendelfrei heben, drehen und positionieren. Sie entlastet Mitarbeiter im Produktionshochlauf und sorgt für reproduzierbare Abläufe.
02 Welche Bauteile werden in der Rüstungsfertigung mit Manipulatoren gehandhabt?
Typisch sind Geschosskörper und Hülsen, Stahl- und Panzerstahlplatten, Rohre, Laufwerks- und Getriebeteile, Fahrzeug- und Strukturbaugruppen, Elektronikmodule sowie Behälter und Kisten. Ein 155-mm-Artilleriegeschoss wiegt bereits über 40 kg.
03 Welches System eignet sich für welches Gewicht?
Der Hebelift ZH hebt mobil bis 100 kg, der Seil-Manipulator bis 150 kg, der Gelenk-Manipulator bis 800 kg und die Hubachse ZH90 bis 1.200 kg, jeweils inklusive Vorrichtung. Zum Heben und Wenden großer Baugruppen gibt es die Hub-Drehvorrichtung ZH elektrisch bis 4.000 kg.
04 Wie schwer ist eine Stahl- oder Panzerstahlplatte?
Stahl wiegt rund 7,85 kg pro Quadratmeter und Millimeter Dicke. Eine Platte mit 2,0 × 1,0 m und 20 mm Dicke wiegt damit etwa 314 kg, die Vorrichtung kommt hinzu.
05 Gibt es Manipulatoren für explosionsgefährdete Bereiche?
Ja. Zeilhofer realisiert Sondermanipulatoren für ATEX Zone 2 und Zone 22. Die Zoneneinteilung legt der Betreiber fest, die Anlage wird danach ausgelegt.
06 Wie wird die Vertraulichkeit sichergestellt?
Zeilhofer ist nach TISAX Level 2 mit Prototypenschutz und nach ISO 9001 zertifiziert. Projekte laufen unter Geheimhaltungsvereinbarung mit dokumentierter Zugriffskontrolle und getrennten Arbeitsbereichen.
07 Stellt Zeilhofer Rüstungsgüter her?
Nein. Zeilhofer entwickelt und fertigt ausschließlich Handhabungstechnik, also die Anlagen, mit denen Mitarbeiter schwere Bauteile in der Produktion sicher bewegen.
08 Lässt sich Handhabungstechnik stufenweise einführen?
Ja. Üblich ist der Start am schwersten Arbeitsplatz, danach folgen weitere Stationen bis zur teilautomatisierten Linie mit synchronisierten Achsen, passend zum Auftragsvolumen.
09 Was kostet ein Manipulator für die Rüstungsfertigung?
Einfache Seil-Manipulatoren beginnen bei ca. 10.000 € ohne Montage, komplexe Hubachsen-Lösungen liegen bei bis zu ca. 150.000 €. Leasing und Mietkauf sind über Würth Leasing möglich.
10 Wo kann man Zeilhofer persönlich treffen?
Zeilhofer stellt auf der DSEI Germany vom 9. bis 12. März 2027 in Hannover aus. Anfragen beantwortet das Team werktags innerhalb von 24 Stunden.
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