Hebelift ZH mit Greifvorrichtung für PKW-Reifen
Hebelift ZH mit Greifvorrichtung für PKW-Reifen
CATEGORY 01
AUTOMOTIVE TIRE AND RIM HANDLING IN AUTOMOTIVE MANUFACTURING
A mid-range car tire weighs between 8 and 15 kg, while a complete SUV wheel with an aluminum rim can easily reach 25 kg. Four wheels are needed per vehicle during final assembly. With a cycle time of 60 seconds, this equates to 240 tire movements per hour. This is precisely where an ergonomic lifting aid comes in: it relieves the worker of the load without reducing speed.
Zeilhofer Handling Technology from Holzkirchen develops tire manipulators that are precisely designed for the geometry of current passenger car and commercial vehicle wheels, from premium tire factories to quick-change workshops.
CHAPTER 1
WHAT IS A TIRE MANIPULATOR?
A tire manipulator is a pneumatically or electrically operated lifting aid with a component-specific gripper for wheels. Unlike standard manipulators, the gripper is shaped to securely handle both passenger car tires from 13 to 22 inches and van and SUV wheels up to 25 inches.
Three designs dominate in practice: firstly, the vacuum gripper with a large suction plate for the tread; secondly, the mechanical gripper with two pneumatic clamping jaws that grip the inside or outside of the tire; and thirdly, the combination gripper for complete wheels with rims. The manipulator itself is based on a lifting axis, articulated manipulator, or cable balancer, depending on the stroke, reach, and freedom of movement.
The tactile feedback to the worker is important: The load must feel like 2 to 3 kg instead of the actual 15 to 25 kg.
CHAPTER 2
WHEN IS A TIRE LIFT WORTH IT?
Not every tire handling application immediately justifies a lifting aid. However, four clear indicators show when the investment makes economic and ergonomic sense.
01 Over 50 tire movements per shift
From this point onward, musculoskeletal strain increases measurably. Occupational accident insurance institutions and health insurance companies recommend technical support. Herniated discs and shoulder problems cause the most sick days in automotive final assembly.
02 Tire weights over 15 kg per unit
SUV wheels, van wheels, and commercial vehicle tires significantly exceed the DGUV recommendations for men (15 kg) and women (10 kg). A lifting aid reduces the load to practically zero.
03 High cycle rates over 100 tires per hour
In the final assembly of large premium tire factories, up to 240 tires per hour are installed on a single line. Manual handling slows down the cycle time. A well-designed lifting aid maintains the cycle time, without oscillation and with a quick-change gripper.
04 Premium wheels with sensitive rim surface
Polished aluminum rims or painted high-end rims cannot tolerate clamping marks. Vacuum clamping solutions with soft pads are essential here; otherwise, rework and customer complaints will result.
CHAPTER 3
PRACTICE: TIRE MANIPULATOR IN CAR FINAL ASSEMBLY
The following four practical applications cover the most common areas of application in tire and rim handling. From final assembly of passenger cars and balancing to order picking in the warehouse.
Requirements:
Cycle time under 60 seconds per vehicle
4 wheels per vehicle, 8 to 25 kg per wheel
Swivel range of roller conveyor to vehicle
Pendulum-free positioning on the wheel bolt image
Quick change between different tire sizes
ZHHT solution
A ZH90 lifting axis with a pneumatic tire gripper picks up each wheel directly from the tire supply line. The operator guides the manipulator to the vehicle, positions it securely in front of the bolts, and releases the gripper with the push of a button. The tire is then seated, followed by bolt assembly at the downstream workstation. The manipulator automatically returns to its picking position.
Advantages of this application
Cycle time maintained at 100% without any ergonomic compromises.
Sick days due to back/shoulder problems reduced by over 60 percent
Gentle handling protects painted and polished rims.
Quick-change grippers for 13 to 22 inches in under 30 seconds
Scalable to 4 manipulators per line cycle
CHAPTER 4
PRACTICE: RIM HANDLING IN THE BALANCE AREA
They each show typical requirements, the appropriate ZHHT solution and the specific advantages for your business.
Requirements:
Rims without tires, often polished aluminum surfaces
Transport between balancing machine and assembly station
Rotation for visual inspection
Damage-free recording is mandatory
A wide variety of options, from steel to forged rims
ZHHT solution
A jointed manipulator with a vacuum rim gripper and soft silicone suction cups picks up each rim centrally. The suction force is monitored by sensors; the movement stops immediately if pressure is lost. An additional rotating axis allows for 360-degree visual inspection without repositioning the gripper. For premium rims, FDA-compliant white suction cups are used that leave no marks.
Advantages of this application
No clamping marks on polished surfaces
Sensory pressure monitoring prevents rim crashes.
The rotary axis saves a complete repositioning process.
Variant flexibility without tool changes
Reduced rework in final inspection
CHAPTER 5
PRACTICE: TIRE PICKING IN THE SPARE PARTS WAREHOUSE
Each application is combined with a component-specific gripper solution.
Requirements:
High-bay racking with tires on 4 to 6 levels
Order picking from swap frames or tire trolleys
Operators of different heights
Repetitive movements across the entire layer
Quick change between individual tires and complete wheels
ZHHT solution
A mobile lifting platform with a tire clamp gripper can safely handle both individual tires and complete wheels with rims. Its lifting height of 0 to 1,800 mm covers all high-bay racking levels, and the lifting position is electrically adjustable. The operator guides the platform like a pallet truck using two handles. Load, lifting, and lowering are intuitively controlled via force feedback sensors.
Advantages of this application
One person can pick orders for an entire shift without getting tired.
High-bay racking levels up to 1.8 m reachable without climbing aids
Gripper for individual tires and complete wheels (alternating)
Mobile and usable between different storage aisles
Battery operation without compressed air connection
CHAPTER 6
PRACTICE: SUMMER/WINTER TIRE CHANGE IN WORKSHOPS
The result is a lifting aid that fits seamlessly into your existing production or workshop workflow.
Requirements
4 wheels per vehicle, change in under 15 minutes
Workshop floor with lifting platform and narrow aisles
Multiple elevation changes per vehicle
Operation by different mechanics on a rotating basis
Dirty and wet tires under real-world conditions
ZHHT solution
The ZH lifting platform, in a compact workshop version with IP-protected controls, is installed between a car lift and tire storage rack. The platform is robust against dirt and salt residue, and the controls are water jet resistant. Operating elements are ergonomically positioned, and the learning curve for new mechanics is less than 10 minutes.
Advantages of this application
Tire change time per vehicle reduced by 15 to 25 percent
Robust against workshop conditions IP54 or better
Quickly learnable for different operators
Reduces strain during peak seasons in spring/autumn
Low maintenance, no sensitive electronic components
CHAPTER 7
ENGINEERING PROCESS STEP BY STEP
A custom-designed tire lifting aid is created through a clearly structured engineering process. Six steps lead from the initial consultation to commissioning.
A custom-designed tire lifting aid 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 requirements recording
What tire sizes, rim types, weights, and cycle times? Photographs or CAD drawings of typical wheels, a site visit to the production line or workshop, documentation of interfaces, compressed air, electricity, and control system connections. Result: a documented requirements specification.
02 Concept and gripper selection
Selection between vacuum, clamping, or combination grippers; design of the lifting axis or articulated manipulator; installation plan with collision analysis. Binding price indication and delivery time, free of charge.
03 Design and CE Engineering
3D CAD design, FEM calculation, safety analysis according to EN ISO 13849, pneumatics and control design, circuit diagram creation and PLC programming.
04 Manufacturing in Germany
Mechanical manufacturing in our own Holzkirchen plant, welding construction, painting, assembly and factory acceptance testing with original tires or dummy.
05 Preliminary inspection in the Holzkirchen showroom
Customer acceptance inspection in the Zeilhofer showroom with their own tire samples, prior to delivery. Safety check, functional test, final adjustments.
06 Commissioning worldwide and training
Assembly in factory or workshop, PLC integration, operator training and handover protocol.
CHAPTER 8
REFERENCES: 25 YEARS OF CUSTOM SOLUTIONS
Over twenty years of experience in tire and rim handling have made Zeilhofer HHT an established partner of the automotive manufacturing and workshop sectors. Tire and rim handling is one of the oldest application areas for Zeilhofer lifting aids. For over 20 years, we have supplied the automotive manufacturing and workshop sectors. Typical projects include:
Typical projects
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Passenger car final assembly lines of German and European OEMs
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SUV and van wheel assemblies with loads up to 35 kg
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Premium wheel balancing areas for sensitive aluminum rims
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Tire logistics in distribution centers of tire manufacturers
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Quick-change workshops with high seasonal workloads
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Tire retailers and distribution centers with order picking lifts
What distinguishes Zeilhofer solutions?
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ISO 9001 certified quality management since 2008
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TISAX Level 2 with prototype protection for confidential OEM projects
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Engineering, manufacturing and service from a single source in Holzkirchen
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Tire grippers for 13 to 25 inch wheels in the range of variants
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Lifetime spare parts supply for delivered systems
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 What tire sizes can a Zeilhofer lifting aid handle?
Standard sizes range from 13 to 22 inches for cars and SUVs, with optional sizes up to 25 inches for vans and smaller commercial vehicles. Larger truck and off-highway wheels are available as special orders. Quick-change grippers typically cover 4 to 6 sizes without tools.
02 How quickly can a lifting aid be timed?
With proper design, a tire manipulator achieves cycle times of 8 to 12 seconds per pick-up-move-place cycle. This makes line cycles of 240 tires per hour per manipulator realistic. For higher cycle rates, 2 or 4 manipulators are operated in parallel.
03 Do the grippers leave marks on polished aluminum rims?
No, if the correct gripper is chosen. FDA-compliant silicone suction cups or white EPDM suction cups are used for premium rims. Harder PU pads are sufficient for steel rims. A pressure regulator prevents excessive clamping force.
04 How much does a tire manipulator cost?
Standard solutions for passenger car tires start at around €12,000 for a workshop-based version. Final assembly manipulators with quick-change grippers and PLC integration range from €25,000 to €45,000. You will receive a specific price estimate free of charge after an initial consultation.
05 What maintenance does a tire manipulator require?
Annual safety inspections according to DGUV Regulation 54 are mandatory. Pneumatic components require visual and functional testing every six months. Suction cups are replaced every 6 to 24 months, depending on usage. Zeilhofer offers maintenance contracts with annual service visits.
06 Is subsequent integration into existing lines possible?
Yes. We analyze the line interface (Profinet, EtherCAT, EtherNet/IP, or classic I/O), adapt the controller, and perform commissioning in the ongoing production environment. For many projects, line integration is even possible at night without affecting daytime production.
READ MORE
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NEXT STEP
YOUR INDIVIDUAL SPECIAL SOLUTION
Talk to our engineers about your tire handling needs. We analyze tire sizes, cycle times, and workplace conditions and develop a suitable lifting aid for your final assembly line, balancing area, order picking, or workshop. The consultation is free and without obligation. Made in Germany, ISO 9001 certified.