Gelenk-Manipulator

Gelenk-Manipulator mit Greifvorrichtung für Motormontage

Gelenk-Manipulator

Gelenk-Manipulator mit Greifvorrichtung für Motormontage

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CATEGORY 06 / AUTOMOTIVE

MECHANICAL ENGINEERING ENGINE AND GEARBOX ASSEMBLY AND HANDLING

Engines and transmissions are the heaviest individual components in automotive and mechanical engineering assembly. A modern internal combustion engine weighs between 80 and 250 kg, a truck engine reaches 400 to 800 kg, a passenger car transmission weighs 40 to 100 kg, and a truck transmission up to 250 kg. During powertrain assembly, the engine and transmission are joined. The total weight of a completed powertrain ranges from 150 to 600 kg.

Manually handling these loads is not only unreasonable, but also prohibited in Germany according to DGUV regulations. A sway-free lifting aid is mandatory here. Zeilhofer Handling Technology from Holzkirchen has been developing manipulators and lifting axes for engine and transmission assembly for over 20 years, from final assembly of passenger cars to truck and off-highway component lines.

CHAPTER 1
WHAT IS AN AGGREGATE MANIPULATOR?

An engine or transmission manipulator is a lifting aid designed for handling complete engine or transmission units. Three types are established: firstly, the lifting axis for pendulum-free lifting with a high load capacity of up to 1,200 kg and precise positioning on the vehicle body; secondly, the articulated manipulator with a large working radius for supplying multiple assembly stations; and thirdly, the turning device with a rotary axis for 360-degree rotation of the engine or transmission unit during assembly.

Special grippers are designed specifically for each engine or transmission model. They typically feature multiple contact points on the engine block and a redundant locking mechanism to prevent unintentional release. The interface with the vehicle body must be precise, accurate to within millimeters; therefore, the manipulators utilize force-feedback sensors and an auto-positioning function.

CHAPTER 2
WHEN IS AN AGGREGATE LIFTING AID WORTH IT?

Engine and transmission assembly is among the most demanding areas of automotive manufacturing. Four indicators show when a pendulum-free lifting axis with force feedback sensors becomes economically and safety-wise essential.

01 Aggregate weights over 30 kg

Engines, transmissions, and attachments such as axles, differentials, or clutches regularly exceed the DGUV load recommendations. Technical lifting assistance is mandatory here, both legally and economically.

02 Cycle times under 90 seconds per vehicle

Modern final assembly lines operate at 90-second cycle times. Manual component assembly is impossible here. A pendulum-free lifting axis with precise positioning is standard.

03 Variety of engine or transmission variants

With a variety of 5 to 15 different motor or gearbox types in a single line, the lifting aid must be quick to reconfigure. Quick-change grippers and format memory in the control system are essential.

04 High-precision positioning on the car body

Components are connected to the body with tolerances in the millimeter range. Force feedback sensors and an auto-positioning function save assembly time and reduce the risk of damage.

CHAPTER 3
PRACTICE: ENGINE MANIPULATOR ON THE CAR FINAL ASSEMBLY LINE

The following four practical applications cover the most common areas of use in powertrain handling. They range from final assembly of passenger cars to assembly of truck powertrains and the electric drive line.

Requirements:

Engines weigh 80 to 250 kg per unit
Variety of variants: 8 to 12 engine types
Cycle time 60 to 90 seconds per vehicle
Precise connection to the body with a tolerance of less than 2 mm
High safety requirements according to EN ISO 10218

ZHHT solution

A heavy-duty ZH90 lifting axis with a component-specific motor gripper transfers the engine unit from the engine supply line to the car body. The gripper has multiple contact points on the engine block and features redundant locking. Force feedback sensors guide the engine into the car body. The control system detects when the engine reaches its limit and automatically stops the lowering movement. A format recognition system adjusts the gripper position to the specific variant.

Advantages of this application

Swing-free lifting even with a 250 kg aggregate load
Auto-positioning with force feedback saves assembly time.
Format recognition for 12 engine variants
Secure locking mechanism to prevent accidental release
Line frequency maintained at 100% without any ergonomic compromises

CHAPTER 4
PRACTICE: GEARBOX MANIPULATOR WITH REVERSING DEVICE

Each solution is implemented with component-specific special grippers and PLC integration into the line cycle.

Requirements:

Gearboxes weigh between 40 and 250 kg, depending on the vehicle class.
Turn for screw mounting from both sides
Variety of manual and automatic transmissions
Precise positioning on the engine block
Switching between front-wheel and rear-wheel drive variants

ZHHT solution

A lifting axis with an integrated rotary axis allows for 360-degree rotation of the gearbox without repositioning the gripper. The component-specific gripper has contact points on the gearbox housing and the bell housing. The rotating device turns the gearbox for screw mounting from either side. A quick-change interface allows for switching between grippers for manual and automatic transmissions in under 60 seconds.

Advantages of this application

Turning without repositioning. Productive workflow.
Quick changeover between manual and automatic grippers
High variant flexibility through format storage
Precise positioning with force feedback
Scalable to multiple assembly stations

CHAPTER 5
PRACTICE: TRUCK UNIT ASSEMBLY WITH UP TO 800 KG

Force feedback sensors achieve connection tolerances of less than one millimeter.

Requirements:

Truck engines 400 to 800 kg per unit
Long travel distances through the hall
Several operators involved in the assembly process
Safety requirements for heavy goods
Precise connection to truck frame

ZHHT solution

A special lifting axle with a 1,000 kg load capacity and a large working radius handles the truck assemblies. Movement is achieved via a traversing bridge across the hall, with multi-axis control for precise positioning. Safety light curtains and floor sensors protect the operating personnel inside the hall. For multiple operators, zone control is available, enabling or disabling movements depending on the operator's position.

Advantages of this application

Swing-free lifting up to 1,000 kg, unique in the market
Zone control for multiple operators
Long travel distances through the hall
Force feedback for precise connection positions
Scalable to parallel aggregate assembly stations

CHAPTER 6
PRACTICE: ELECTRICAL UNIT ASSEMBLY (E-MOBILITY)

The result is lifting aids that operate reliably for decades under the toughest conditions.

Requirements

Electric motor with gearbox unit 60 to 180 kg
Highly sensitive electronics and sensors
Changing modules depending on the vehicle variant
Sterile workspace in the pre-assembly area
Force feedback requirements for precise positioning

ZHHT solution

A ZH90 lifting axis with force feedback sensors and a collaborative variant handles the electrical components for connection to the vehicle body. The gripper is equipped with ESD-dissipating pads to prevent damage to sensitive electronics from electrostatic discharge. Movement is slow and smooth, with continuous force feedback to the operator. A format recognition system adjusts the gripper position to the specific electric drive variant.

Advantages of this application

ESD-dissipating pads protect electronics
Slow, pendulum-free lifting for sensitive components
Force feedback to operator
Format recognition for high-variety production
Compliance with ISO/TS 15066 (collaborative robotics)

CHAPTER 7
ENGINEERING PROCESS STEP BY STEP

An aggregate manipulator is developed through a clearly structured engineering process. Six steps lead from the initial consultation to commissioning. A lifting aid for machinery is developed through a structured engineering process. Zeilhofer HHT works according to VDI guidelines and provides everything from initial consultation to commissioning from a single source.

01 Initial consultation and generator specification

What types of engines and transmissions, what weights, what variety of variants? Inspection of the assembly line, including recording of the interfaces to the line's PLC and recording of the body geometry.

02 Concept and gripper selection

Selection of the lifting aid design (lifting axis, joint, turning device), load capacity design, component-specific special gripper with multiple support points. Binding price indication.

03 Detail Engineering

3D CAD design, FEM calculation, safety analysis according to EN ISO 13849 PL d and EN ISO 10218, pneumatic design and PLC programming, format programming for variant flexibility.

04 Manufacturing in Germany

Mechanical manufacturing in our own Holzkirchen plant, welding construction, painting, assembly and factory acceptance testing with original units or equivalent dummies.

05 Preliminary inspection in the showroom

Customer acceptance testing in the Zeilhofer showroom with customer-provided sample units or line acceptance testing at the customer's site. Safety check, functional test, final adjustments before delivery.

06 Commissioning and training

Service technicians travel worldwide for commissioning, integration into the line PLC, training operators and maintenance personnel, and handing over operating documentation.

CHAPTER 8
REFERENCES: 25 YEARS OF CUSTOM SOLUTIONS

Over twenty years of experience in engine and gearbox assembly make Zeilhofer HHT a proven supplier to the automotive industry in Germany, France, Italy, Poland and the Czech Republic.

Engine and transmission assembly is one of Zeilhofer HHT's oldest fields of application. We supply automotive manufacturers and suppliers in Germany, France, Italy, Poland, the Czech Republic, and the USA. Typical projects include:

Typical projects

Final assembly of passenger cars: Engine manipulators at German and European OEMs
Truck axle lifting axles up to 1,000 kg load capacity
Gear reversing devices for manual and automatic transmissions
E-drive manipulators with ESD protection for e-mobility
Aggregate pre-assembly in axle and transmission plants
Off-highway power unit assembly at agricultural and construction machinery manufacturers

What distinguishes Zeilhofer solutions?

ISO 9001 certified quality management since 2008
TISAX Level 2 with prototype protection for confidential OEM projects
Special lifting axles with a load capacity of up to 1,000 kg are available.
Format memory for up to 16 aggregate variants
Collaborative variants according to ISO/TS 15066 are available.

FAQ / Q&A
FREQUENTLY ASKED QUESTIONS

01 What is the maximum possible aggregate load?

Zeilhofer's standard product range includes lifting axles up to 1,200 kg. For truck and off-highway units up to 1,000 kg, a special lifting axle is standard. For extremely heavy units, a combination with an overhead crane is typically used; the lifting aid ensures precise positioning.

02 How precise is the positioning?

With force feedback sensors and an auto-positioning function, we achieve tolerances of less than 1 mm when positioning the connection to the vehicle body. The sensors detect stops and automatically halt the movement, preventing any damage.

03 Is the lifting aid collaborative according to ISO/TS 15066?

Yes. For sensitive e-mobility applications, we offer collaborative versions of the lifting axis with force limitation, reduced speed, and force feedback sensors. Safe operation without a safety fence according to ISO/TS 15066 is possible.

04 How many variants can the controller store?

By default, the PLC stores up to 16 aggregate variants with their respective gripper positions and motion parameters. Expansion to 32 or 64 variants is possible upon request. The Zeilhofer compact controller delivers similar performance at a lower acquisition cost.

05 Welche Sicherheits-Funktionen sind enthalten?

Emergency stop, two-hand operation, end-position locking, safety light curtain, and floor sensors are included as standard. All functions are certified according to PL d according to EN ISO 13849. Collaborative versions also include force limitation according to ISO/TS 15066.

06 How much does an aggregate manipulator cost?

Standard motorized lifting axes with pneumatic grippers start at around €45,000. Fully equipped unit manipulators with a reversing device, force feedback, and PLC integration range from €75,000 to €150,000. Special lifting axes with a lifting capacity of up to 1,000 kg cost between €110,000 and €220,000, depending on complexity.