Gelenk-Manipulator mit Greifvorrichtung für unterschiedliche Stahlringe
Gelenk-Manipulator mit Greifvorrichtung für unterschiedliche Stahlringe
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 Workpieces over 25 kg in repetitive handling
Forged and cast parts regularly exceed the DGUV load recommendations. Without technical lifting aids, chronic back problems are almost inevitable. Trade associations in the metal industry often support investments in lifting aids with funding programs.
02 Hot workpieces above 100 °C at the mounting
Standard grippers are unsuitable as soon as the workpiece comes out of the press or mold warm. Heat-resistant supports, temperature-resistant sensors, and thermal shielding of the pneumatics are mandatory.
03 High cycle rates of over 100 workpieces per hour
Modern forging presses produce 200 to 600 workpieces per hour. Manual loading and unloading slows down the line. A pendulum-free lifting axis with a heavy-duty gripper can achieve cycle times of 6 to 10 seconds.
04 Unusual geometry without standard grippers
Crankshafts, axle housings, connecting rods, and pressed parts have unique geometries. A component-specific custom gripper based on 3D scans or CAD data is significantly more productive than any standard clamping gripper and reduces the risk of damage to a minimum.
CHAPTER 3
PRACTICE: BLACKSMITH MANIPULATOR AT THE PRESS
The following four practical applications cover the most common areas of use in forging and casting handling. They range from the forging press and cleaning to the loading of heavy workpieces.
Requirements:
Workpieces 50 to 400 kg, temperature 300 to 600 °C
Loading and unloading in under 10 seconds cycle time
Pendulum-free method over a 2 to 4 meter line
Heat protection for operator and camera
Robust construction to withstand vibrations and sparks
ZHHT solution
A heavy-duty ZH90 lifting axis with a heat-resistant gripper made of heat-resistant steel picks up the forged blanks directly from the press. A water-cooled protective wall shields the operator from radiant heat. The gripper opens and closes pneumatically via clear, thermally insulated flow control valves. The pneumatic system itself uses heat-resistant PTFE hoses.
Advantages of this application
Operator distance of 2 to 3 meters to the heat source
Swing-free lifting even with a workpiece weight of 400 kg
Heat-resistant mounting up to 600 °C permanently
Resistant to vibrations and sparks
Maintenance-free pneumatics thanks to heat-resistant hoses
CHAPTER 4
PRACTICE: CASTING PARTS HANDLING IN THE FOUNDRY
Each application is combined with heat-resistant mounting, robust mechanics and fail-safe sensors.
Requirements:
Sand-cast or die-cast workpieces weighing 100 to 800 kg
Demolding from casting mold with residual heat of 200 to 400 °C
methods for cleaning or processing
Delicate contours, no damage permitted
Dusty environment with molding and cleaning dust
ZHHT solution
A long-reach articulated manipulator with a working radius of 3.5 meters serves multiple workstations in the plastering shop. The special gripper is component-specific, designed for each casting, and features soft, high-temperature pads made of aramid or silicate felt. Compressed air and electrical connections are dustproof (IP65). A compressed air flush of the sensors prevents malfunctions caused by plaster dust.
Advantages of this application
Multiple workstations operated with one manipulator
Component-specific gripper protects sensitive contours
Dustproof and vibration-resistant for foundry conditions
Heat resistant up to 400 °C at the point of application
Reduced sick days due to the elimination of manual handling of loads
CHAPTER 5
PRACTICE: CRANKSHAFT AND CONNECTING ROD HANDLING
The solutions have proven successful in heavy industry plants throughout Europe.
Requirements:
Workpieces weighing 25 to 120 kg, wide variety of options
High-quality finished surfaces, no scratches
Loading of machining centers and hardening furnaces
Turn and rotate for inspection
Multiple variants in one line
ZHHT solution
A ZH90 lifting axis with a rotary gripper enables 360-degree rotation of the shaft without repositioning. A component-specific gripper with a soft polyurethane pad grips centrally on the connecting rod housing or the main bearing journal. A quick-change interface allows for the exchange of grippers for different shaft types in under a minute. The control system stores the position of up to 16 gripper variants.
Advantages of this application
360-degree rotation without repositioning saves a work step
Quick-change grippers for a wide variety of variants
Gentle handling protects processed surfaces
Memory for up to 16 gripper variants in the control system
Scalable to multiple machining centers
CHAPTER 6
PRACTICE: HANDLING AND LOADING LOADS UP TO 1,500 KG
The result is lifting aids that operate reliably for decades under the toughest conditions.
Requirements
Workpieces weighing 500 to 1,500 kg, e.g. axle housings, crankshaft castings
Loading onto pallets, transport racks or direct delivery
Long travel distances of up to 8 meters across the hall
Precise placement without pendulum action
Several operators simultaneously in the hall within the safety area
ZHHT solution
A special lifting axis with a 1,500 kg lifting capacity and a 3-meter stroke is used on a traversing bridge running across the hall. Pendulum-free lifting is ensured by redundant end-position locking, and precise positioning is achieved via multi-axis control. Safety light curtains and floor sensors detect people in the travel area and stop the movement. Force feedback sensors detect when the workpiece makes contact with the floor and automatically reduce the lowering rate.
Advantages of this application
Swing-free lifting up to 1,500 kg, unique in the market
Safety light curtains protect people in the hall
Force feedback prevents hard landings
Long travel distances up to 8 meters across the overhead crane bridge
Scalable to multiple stations with central control
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.
01 Initial consultation on site
Inspection of the forge or foundry, recording of workpieces, temperatures, cycle times and interfaces. Assessment of the hall layout and safety requirements.
02 Concept and specifications
Determination of the lifting aid design, calculation of the load capacity, selection of heat-resistant grippers and safety features. Binding price indication, free of charge.
03 Detailed Engineering and Safety
3D CAD design, FEM calculation, safety analysis according to EN ISO 13849 PL d, pneumatic design with heat protection, circuit diagram and PLC programming.
04 Production in Germany
Mechanical manufacturing with heat-resistant materials, welded construction, painting with heat-resistant paint, assembly and factory acceptance testing with dummy.
05 Preliminary inspection in the showroom
Preliminary inspection in the Zeilhofer showroom or via video transmission. Safety check, functional test, final adjustments before delivery.
06 Commissioning and training
Our own service technicians travel worldwide for commissioning, integration into the PLC control system of the forge or foundry, and training operators and maintenance personnel.
CHAPTER 8
REFERENCES: 25 YEARS OF CUSTOM SOLUTIONS
More than two and a half decades of experience in heavy industry make Zeilhofer HHT a proven partner for forges and foundries in Germany and Europe.
The forging and casting industry is one of Zeilhofer HHT's oldest application areas. For over 25 years, we have supplied forges, foundries, and heavy industry plants in Germany and Europe. Typical projects include:
Typical projects
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Forging manipulators on presses for crankshafts and connecting rods
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Casting parts handling for truck axle housings and gearbox housings
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Cleaning manipulators with a range of up to 4 meters
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Special lifting axles with a 1,500 kg load capacity for heavy cast parts
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Hot part manipulators with protection up to 600 °C
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Turning devices for machining centers in the forge
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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Heat-resistant components up to 600 °C in the standard range
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Special lifting axles with a load capacity of up to 1,500 kg are available.
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Engineering and service from Holzkirchen, no outsourcing chains
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 What is the maximum possible load capacity?
Zeilhofer's standard product range includes lifting axes with capacities up to 1,200 kg. Custom solutions with capacities up to 1,500 kg are also available. For heavier loads, an overhead crane is typically used. The lifting aid then handles the final few meters to the processing station.
02 How hot can a workpiece get?
Standard grippers are designed for temperatures up to 80 °C. With high-temperature coatings made of aramid or silicate, continuous operation at temperatures of 200 to 400 °C is possible. For workpieces exceeding 500 °C, special stainless steel grippers with water cooling are used.
03 How free from pendulum action does a lifting axle operate under a 1,500 kg load?
The ZH90 lifting axis in the heavy-duty version features redundant end-position locking and three pendulum-free guide axes. In practice, residual pendulum motion is less than 5 mm with a workpiece load of 1,500 kg and a travel distance of 2 meters.
04 What maintenance cycles are typical in a forging environment?
Annual safety inspections according to DGUV Regulation 54 are mandatory. Due to vibrations and heat, we recommend visual and functional inspections every six months. The heat-resistant pneumatic hoses are replaced every 24 to 36 months.
05 Is integration into existing forging presses possible?
Yes. We analyze the press's PLC (typically Siemens S7-1500 or Beckhoff), develop the communication interface, and carry out the commissioning in the ongoing production environment. The downtime for integration is usually less than one shift.
06 Are ATEX areas also served?
Yes. For potentially explosive atmospheres such as aluminum forges or magnesium foundries, Zeilhofer offers special manipulators in ATEX Zone 2 and Zone 22 versions. These feature pneumatic instead of electric operation, conductive materials, and documented conformity according to ATEX Directive 2014/34/EU.
READ MORE
FURTHER GUIDES ON THIS TOPIC
In-depth guides on related topics in handling technology.
PRODUCT
ZH90 lifting axle in use
Swing-free lifting up to 1,200 kg. Practical applications from forges, foundries and heavy industry.
SPECIAL SOLUTIONS
Special machine construction and special solutions
Engineering projects from concept to commissioning. Special grippers, special controls and special devices.
PRODUCT
Joint manipulator
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.