KNOWLEDGE FROM PRACTICE
GUIDE TO HANDLING TECHNOLOGY
Objective guidance on lifting technology, selection and use of manipulators and lifting aids. The guides from Zeilhofer Handhabungstechnik in Holzkirchen answer the most frequently asked questions from practical experience, without sales pressure. Zeilhofer designs and manufactures manipulators up to 800 kg, the Hubachse ZH90 up to 1,200 kg, cable manipulators up to 150 kg, and the ZH mobile lifting platform up to 100 kg, with over 2,500 units delivered since 1999.
TOPICS
GOOD STARTING POINTS
COSTS
How much does a manipulator cost?
Price range, the 7 biggest cost drivers and price guidance for all four system types.
SELECTION
Which Zeilhofer system is suitable?
Lifting axis, manipulator or lifting platform: find the right system for your component in a few steps.
CLASSIFICATION
Automation without robots
Robot, cobot, exoskeleton or handling technology: which solution really pays off for your task.
CATEGORY 01
SYSTEM AND SELECTION
Selecting the right lifting aid depends on load capacity, drive type, and level of automation. This guide compares manipulators, lifting axes, hoists, cranes, and chain hoists for loads up to 1,200 kg and explains when pneumatic, electric, or manual drives are economical and how to identify a suitable manipulator manufacturer.
ORIENTATION
Manipulator, crane or chain hoist
TECHNOLOGY
Pneumatic or electric lifting
Advantages and disadvantages of the three drive concepts for lifting aids in comparison.
BASICS
What is a lifting axis?
COMPARISON
Manipulator or cobot?
When a classic manipulator is worthwhile, when a cobot is, and how the ZH90 collaboratively combines both.
FUNDAMENTALS
Lifting off-center loads safely
Calculate the tilting moment, find the center of gravity and choose lifting technology that absorbs the moment.
AUTOMATION LEVEL
Manual, semi-automated, or robot?
Which level of automation suits your task and why semi-automated handling is often the most economical option for heavy loads. Includes an interactive selection tool.
COMPARISON
Robot gripper or custom device?
Standard gripper or custom-made device in direct comparison, including decision support for your component.
CLASSIFICATION
Automation without robots
Not every automation requires a robot: Industrial robots, cobots, exoskeletons and handling technology in a factual overview.
SELECTION
Which Zeilhofer system is suitable?
Lifting axis, manipulator or lifting platform, tailored to the load and application.
BASICS
What is a manipulator?
Industrial manipulators explained: Function, types, and comparison to cranes and chain hoists. For loads up to 800 kg.
ORIENTATION
Articulated or cable manipulator?
ALTERNATIVE
Hose lifter or device?
When a device with rigid load guidance is the better alternative to a vacuum tube lifter. With comparison and interactive finder.
SUPPLIER SELECTION
Select manipulator manufacturer
The 7 criteria for choosing the right supplier: certification, vertical integration, and service. How to recognize a manufacturer that will truly solve your problem.
SELECTION
Select lifting axis
The 5 criteria for choosing the right lifting axis: load capacity, drive, and design. Includes market comparison and interactive quick check.
COMPARISON
AGV or lifting axis?
Moving parts from A to B without handover: when a rail-mounted lifting axis replaces an AGV with two robots.
CATEGORY 02
SAFETY AND APPLICATIONS
The safe operation of lifting aids requires workplace ergonomics and an annual safety inspection. These guides explain how to reduce physical strain when lifting, what requirements apply to handling high-voltage batteries, and how the obligation, procedure, and deadlines for accident prevention inspections of lifting aids are regulated.
OCCUPATIONAL SAFETY
Ergonomics at the assembly workstation
E-MOBILITY
Handling high-voltage batteries safely
FOOD INDUSTRY
Hygienic design for handling technology
EHEDG, HACCP, IFS Food: Standards and requirements for hygienic manipulators and lifting axes up to 1,200 kg.
TESTING OBLIGATION
The UVV inspection for lifting aids
Obligation, procedure and deadlines for the annual accident prevention inspection.
SCREWDRIVING TECHNOLOGY
Reaction torque in screwdriving
How the lifting axis absorbs the reaction torque and why a catalogue Nm value does not reflect the real screwdriving application.
CATEGORY 03
PRODUCT KNOWLEDGE ZEILHOFER
Zeilhofer Handhabungstechnik manufactures lifting axes, manipulators, and lifting platforms for loads up to 1,200 kg. This guide presents the Hubachse ZH90, the articulated manipulator (up to 800 kg), the cable manipulator (up to 150 kg), and the battery-powered lifting platform (up to 100 kg), including information on drive systems, load capacities, operating limits, and economic lifespan.
PRODUCT
Hubachse ZH90 in use
Non-oscillating up to 1,200 kg, lightweight aluminum construction, practical applications.
PRODUCT
Articulated arm manipulator up to 800 kg
PRODUCT
Lifespan of manipulators
What ensures 15 to 20 years of economical operation: an overview of maintenance, operating conditions and drive type, including tips for extending service life.
PRODUCT
Lifting platform: When is it the right choice?
Function, drive and limits of the mobile lifting platform, with the 150 kg turning point and interactive finder.
PRODUCT
Hebelift ZH without compressed air
PRODUCT
Acer cable manipulator and ZH70
PRODUCT
Hub-Drehvorrichtung ZH
Lifting and rotating up to 4,000 kg: pneumatic, electric, or customized solutions compared. Includes component adapters and loading/unloading technology as a complete solution.
CATEGORY 04
APPLICATIONS & INDUSTRY SOLUTIONS
Industrial lifting aids are used in production, logistics, automotive manufacturing, and heavy industry. These guides showcase applications ranging from tire and rim handling to engine and transmission assembly, as well as forging and casting, supplemented by roller lifters, carton handling, and customized solutions for loads up to 1,200 kg.
AUTOMOTIVE
Handling technology for the automotive industry
From visible components to 1,200 kg high-voltage batteries: the right handling solution for every component in your vehicle production.
LIFTING AIDS FOR CARTON
Solutions for logistics, shipping and order picking
Manipulators with surface suction cups or mechanical grippers for cartons. Ideal for logistics, shipping, and order picking.
APPLICATION LIFTING AID
Lifting aids in automotive final assembly
Special solution
Special machine construction and special solutions
HEAVY INDUSTRY
Forged and cast parts handling
Non-oscillating lifting axes for hot, heavy workpieces up to 1,500 kg. Heat-resistant, high load capacity, for forges and foundries.
LASER CUTTING
Inserting and removing sheet metal from laser cutting machines
Insert the solid plate, safely remove the perforated remaining grid. Manipulator up to 800 kg and Hubachse ZH90 up to 1,200 kg.
CONTROL CABINET CONSTRUCTION
Lifting aids in control cabinet construction
DEFENSE & ARMORY
Handling technology for the defense industry
Lifting armor steel plates, armor and structural components without pendulum movement during ramp-up, with system selection up to 4,000 kg, ATEX and TISAX.
APPLICATION LIFTING AID
For production, industry, warehousing and logistics up to 1,200 kg
The complete guide to industrial lifting aids. Types, applications and selection criteria at a glance.
Roller lifter
Films, paper & heavy rolls up to 800 kg
Industrial lifting aids for cylindrical loads. Function, variants and selection criteria at a glance.
LOGISTICS
Lifting aids in logistics
AUTOMOTIVE
Tire and rim handling
Lifting aids for tire mounting, balancing, and order picking in automotive manufacturing. From final assembly manipulators to warehouse lifts.
AUTOMOTIVE / MECHANICAL ENGINEERING
Engine & gearbox assembly handling
Non-sway lifting aids for engines, transmissions and drive trains up to 1,200 kg from car final assembly to the truck assembly line.
AGRICULTURAL AND CONSTRUCTION MACHINERY
Manipulators for agricultural and construction machinery
Ergonomically handle gearbox, attachment and body parts up to 1,200 kg, from tractors to excavators.
GLASS AND WINDOWS
Manipulator for glass panes and windows
Calculate glass weight, suction or gripping, rotating, tilting and glazing, with manipulator up to 800 kg or Hubachse ZH90 up to 1,200 kg.
TOOL CHANGE
Lifting aid for tool changes
Change injection moulds, stamping and press tools safely: manipulator, lifting axis or Hebelift for tools up to 200 kg and more.
CATEGORY 05
HEAT TREATMENT AND HARDENING
Heat-resistant lifting aids enable the swing-free handling of hot batches in hardening and heat treatment shops. These guides explain how to safely load and unload charging racks and annealing baskets weighing up to 1,200 kg, how to reduce the risk of burns and distortion, and how contract hardening shops can increase their throughput without additional personnel.
HARDENING APPLICATION
Handling charging racks and glow baskets
Heat-resistant lifting aids for heat treatment. Load charging racks up to 1,200 kg without pendulum movement, remove from the furnace and quench.
SAFETY & QUALITY HARDENING
Handle hot workpieces safely
Heat protection, burn protection and distortion prevention when handling hot batches. Heat-resistant lifting aids for heat treatment up to 1,200 kg.
ECONOMIC HARDENERY
Increase throughput without adding staff
How contract heat treatment plants can increase batch sizes, alleviate staff shortages, and improve ergonomics with lifting aids. Manipulators and lifting axes up to 1,200 kg.
CATEGORY 06
COSTS AND EFFICIENCY
The cost of a lifting aid ranges from around €10,000 for simple cable manipulators to €150,000 for complex lifting axis solutions. This guide explains the biggest cost drivers, from load capacity to degree of automation, financing options such as leasing and hire purchase, and the amortization calculation, which balances the investment against sick days, cycle time losses, and scrap.
COST
How much does a manipulator cost?
Honestly explained: the price range of around 10,000 to 150,000 euros, the 7 biggest cost drivers, running costs and a price guide for all four system types.
FINANCING
Leasing and financing lifting aids
Leasing for 24, 36 or 48 months or hire purchase from 12 months via Würth Leasing: which option suits you best, how the process works and what you should pay attention to when comparing.