CATEGORY 02
HEAVY INDUSTRY FORGED PARTS AND CASTINGS HANDLING IN HEAVY INDUSTRY
Forged and cast parts represent the toughest application area in handling technology. These parts are often heavy, hot, sharp-edged, and have unique geometries. A crankshaft weighs between 25 and 120 kg, a sand-cast truck axle housing can weigh between 150 and 400 kg, and a forging die blank can emerge from the press at 500 °C.
A lifting aid in this environment must meet three requirements simultaneously: It must guide loads from 50 to 1,500 kg without swaying, it must withstand temperatures up to 600 °C, and it must operate reliably for decades in a factory hall with dust, sparks, and vibrations. Zeilhofer Handling Technology from Holzkirchen has been supplying precisely these custom solutions for forges and foundries throughout Europe for 25 years.
CHAPTER 1
WHAT IS A FORGE MANIPULATOR?
A forging or casting manipulator is a specialized lifting aid for heavy industry. Three designs have become established: firstly, the lifting axis for linear, pendulum-free lifting with a high load capacity of up to 1,500 kg; secondly, the articulated manipulator with a large working radius of up to 4 meters for loading and unloading presses; and thirdly, the cable manipulator for maximum reach across multiple workstations.
All three are designed for forging and casting applications, featuring heat-resistant grippers, vibration-resistant pneumatics, and dustproof end positions. Special grippers often utilize special materials such as temperature-resistant steel 1.4828 for holders that are in direct contact with workpieces heated to 400-500 °C.
CHAPTER 2
WHEN IS A SPECIAL LIFTING AID WORTH InvestING IN FORGES AND FOUNDRIES?
Forges and foundries are among the most demanding environments for lifting aids. Four indicators reveal when a standard solution is no longer sufficient and a custom lifting aid becomes economically viable.
01 Accelerate feeding
Positioning the load in front of the oven without pendulum movement, without setting it down or readjusting, shortens each loading process.
02 Decouple personnel
One person operates the line instead of two. Freed-up capacity goes into testing, equipment, or a second line.
03 Operating multiple ovens
A manipulator with a large radius or a movable lifting axis covers several stations.
04 Avoiding failures
Less physical strain reduces musculoskeletal disorders and stabilizes shift staffing.
CHAPTER 3
PRACTICE: BLACKSMITH MANIPULATOR AT THE PRESS
The bill:
The payback period results from three factors: saved personnel time per batch, avoided downtime due to improved ergonomics, and increased revenue from higher throughput. In many hardening plants, the payback period is between 12 and 30 months.
Calculation example (illustrative)
Time saved on personnel: 1 fewer person on the furnace line per shift
Reduced sick days due to lower physical strain
Higher throughput: more batches per shift without new hires
Funding: Employers' liability insurance associations often support ergonomics investments.
Zeilhofer prepares an individual economic analysis for every request, including your batch numbers and labor costs, free of charge.
CHAPTER 4
PRACTICE: CASTING PARTS HANDLING IN THE FOUNDRY
Overhead crane
It lifts heavy loads, but it wobbles and is slow at precise positioning. Unsuitable for repetitive furnace loading because every cycle requires readjustment.
Hub axle ZH90
Linear, pendulum-free lifting up to 1,200 kg. Ideal for fast, precise loading on a fixed furnace line.
Joint or cable manipulator
Large working radius, serves multiple furnaces and stations. Ideal when a lifting aid needs to cover several process steps.
CHAPTER 5
PRACTICE: CRANKSHAFT AND CONNECTING ROD HANDLING
Forges and foundries are among the most demanding environments for lifting aids. Four indicators reveal when a standard solution is no longer sufficient and a custom lifting aid becomes economically viable.
CHAPTER 6
PRACTICE: HANDLING AND LOADING LOADS UP TO 1,500 KG
01 On-site analysis
Recording batches, cycle times, furnace layout and bottlenecks in your hardening shop.
03 Engineering
3D-CAD, FEM, safety according to EN ISO 13849, heat-resistant design, manufacturing in Germany.
02 Concept and specifications
Individual analysis using your figures. Binding price indication, free of charge.
04 Commissioning
Integration into your production line, training, worldwide service by our own technicians.
CHAPTER 7
ENGINEERING PROCESS STEP BY STEP
A custom lifting aid for a forge or foundry is developed through a clearly structured engineering process. Six steps lead from the initial consultation to commissioning.
A custom-built machine for a forge or foundry 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.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 How does a lifting aid increase throughput in the hardening shop?
Sie verkürzt das Be- und Entladen, weil Chargiergestelle pendelfrei ohne Absetzen positioniert werden. Eine Person genügt statt zwei, der Engpass Ofenbeschickung wird vom Personal entkoppelt.
02 Is a lifting aid worthwhile in case of staff shortages?
Yes. It relieves the burden on existing staff, makes demanding jobs more widely available, and reduces absences due to musculoskeletal disorders.
03 When does a lifting aid pay for itself?
Usually between 12 and 30 months, depending on the number of batches, shift pattern, and labor costs. Zeilhofer prepares an individual assessment.
04 Manipulator or crane for furnace loading?
The crane oscillates and is slow in positioning. A manipulator or lifting axis guides the load smoothly, quickly and precisely, clearly superior for repetitive loading.
05 Can one lifting aid operate multiple ovens?
Yes. A large-radius articulated or cable manipulator or a movable lifting axis covers several furnaces and stations.
06 How quickly can a special lifting aid be delivered?
Designed according to specifications and manufactured in Germany, typically taking a few months. Initial consultation and price indication are free of charge.
READ MORE
FURTHER GUIDES ON THIS TOPIC
In-depth guides on related topics in handling technology.
HEAT TREATMENT
Handling charging racks and glow baskets
Swing-free lifting up to 1,200 kg. Practical applications from forges, foundries and heavy industry.
PRODUCTS
ZH90 lifting axle in use
Engineering projects from concept to commissioning. Special grippers, special controls and special devices.
HEAVY INDUSTRY
Forged and cast parts handling
Articulated arm manipulator with a load capacity of up to 800 kg for forges and foundries with a large working radius.
NEXT STEP
YOUR INDIVIDUAL SPECIAL SOLUTION
Talk to our engineers about your forging or casting handling requirements. We analyze workpieces, temperatures, cycle times, and your production hall layout. From this, we develop a custom machine that perfectly fits your production environment. Made in Germany, ISO 9001 and TISAX Level 2 certified, free consultation.