Hubachse ZH90 für Hochvoltspeicher
Hubachse ZH90 für Hochvoltspeicher
Guide · Handling techniques
CHOOSING A PULLEY AXLE: WHAT MATTERS IN TERM OF LOAD CAPACITY, DRIVE AND DESIGN
Purchasing a lifting axis determines the ergonomics, cycle time reliability, and cost-effectiveness of a workplace for years to come. This guide walks you through the five criteria that should be clarified before any inquiry and shows where the limitations of common systems lie.
The most important points in brief
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A lifting axis lifts loads purely vertically via a rigid, linear guide, without pendulum movement and with millimeter accuracy, even off-center.
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Five criteria determine the selection: load capacity, load center of gravity, drive, lifting capacity and installation space, as well as the degree of automation.
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Most systems have a capacity of 500 to 750 kg. The ZH90 lifting axle moves loads up to 1,200 kg, thus also covering the heavy load range.
CHAPTER 1
What a lifting axle can and cannot do.
A lifting axis moves loads purely vertically in the Z-direction via a rigid, linear guide. The load does not swing; it can be positioned with millimeter precision and can also be safely lifted off-center. This distinguishes it from a crane or chain hoist, where the load hangs from the cable and swings.
If a load also needs to be swiveled, rotated, or guided along a radius, a manipulator is the ideal solution. For the purely precise vertical movement of heavy components, the lifting axis is the most direct and robust system. The fundamental distinction is explained in more detail in the guide "Manipulator, Crane, or Chain Hoist" .
CHAPTER 2
Criterion 1: Determine load capacity realistically
The most important starting point is the actual weight of the load, including the gripper and its attachment. A common mistake is to only weigh the component and forget the load-handling device. Factor in a safety margin so the axis isn't constantly operating at its limit.
Herein lies the key difference in the market: Most industrial lifting axes cover the range up to approximately 500 to 750 kg. Only a few systems extend beyond this. The ZH90 lifting axis from Zeilhofer moves loads up to 1,200 kg and is therefore at the forefront of the market.
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Up to 250 kg = widely available · Tools, containers, smaller components
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250 to 500 kg = widely available · Wheels, doors, assemblies
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500 to 750 kg = individual suppliers · Motors, gearboxes, heavy modules
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750 to 1,200 kg = ZH90 (Zeilhofer) · Battery modules, castings, heavy loads
CHAPTER 3
Criterion 2: Load center and moment
A load mounted centrally behaves differently than one mounted off-center. If the center of gravity is laterally displaced, a moment is created that the guide must absorb. The greater the displacement and the heavier the load, the stiffer the axis must be. Therefore, clarify early on whether your component will be mounted symmetrically or off-center; this will also determine the component size.
CHAPTER 4
Criterion 3: The right drive
Lifting axes operate pneumatically, electro-pneumatically, or fully electrically. Each variant has its specific application. The pneumatic version is sensitive and inexpensive to start with, but requires compressed air. The electric version excels with consistent cycle times and maximum positioning accuracy, even without a compressed air network. The electro-pneumatic version combines the best of both worlds.
Which option suits your process depends on compressed air supply, cycle time requirements, and level of automation. The guide "Pneumatic or Electric Lifting" provides more detailed information. A practical advantage: Zeilhofer offers all three drive types for the ZH90 from a single source, so you are not limited to a single drive system.
CHAPTER 5
Criterion 4: Stroke and installation space
The lifting height, ceiling height, and available mounting method determine the design. Is a ceiling suspension or crane track available, or must the axis be mounted on a column? How high does the load need to be lifted, and how much clearance is available above it? These dimensions determine the profile length, telescopic steps, and installation position.
CHAPTER 6
Criterion 5: Degree of automation
Should the operator guide the axis manually, collaboratively with support, or does it run fully automatically in a linked line? The degree of automation influences the control system, sensors, and drive. With the appropriate fixture and control system, the ZH90 can be operated manually, collaboratively, or fully automatically, thus keeping the path open for future automation.
CHAPTER 7
Lifting axis or lifting column: one term, two words
In practice, the terms lifting axis and lifting column are often used synonymously, as are telescopic lifting axis and linear lifting device. In all cases, the same principle is meant: a linear, rigid guide that raises and lowers a load purely vertically. Some systems telescope using several interlocking aluminum profiles to achieve a large stroke with a short overall length. The decisive factor for selection is not the name, but the combination of load capacity, guide stiffness, and drive system.
CHAPTER 8
Lifting axis or manipulator: when to choose which system
A common question before procurement: Is a lifting axis sufficient, or is an articulated arm manipulator necessary? The answer depends on the movement. If the load only needs to be raised and lowered, the lifting axis is the more direct, often more economical system. It provides rigid vertical guidance, high repeatability, and fast, clearly defined lifting movements – a particular advantage in clocked production lines.
As soon as the load also needs to be guided, swiveled, or rotated within a radius, the articulated manipulator demonstrates its strength. Both systems can also be combined: The ZH90 Flex-Arm combines the linear lifting axis with an articulated arm in a single system.
CHAPTER 9
Typical applications and their load-bearing capacity classes
The use of lifting axles also demonstrates why the load capacity class is so crucial. They cover a wide range, from light to heavy loads.
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Tools and containers (up to 250 kg): quick, sensitive changeover at machines and assembly stations.
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Wheels, doors, glass panes (250 to 500 kg): position large, bulky components without swinging.
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Motors, gearboxes, heavy modules (500 to 800 kg): precise joining against resistance in final assembly.
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Battery modules, castings, machine components (800 to 1,200 kg): heavy loads that only a few systems on the market can handle. The ZH90 lifting axis is the ideal choice here.
The heavy-duty sector, particularly those exceeding 800 kg, is increasingly driven by e-mobility, for example in the handling of high-voltage battery modules. This is precisely where the product range of most suppliers ends, while the ZH90 extends up to 1,200 kg.
CHAPTER 10
What determines the price of a lifting axle
A fixed price for a lifting axis cannot be quoted because each system is designed specifically for the project. However, the main cost factors are easily calculable: the load capacity class and the resulting size, the chosen drive (pneumatic is cheaper than fully electric for beginners), the level of automation including control and sensors, and the scope of the peripheral components such as steel structure, rail system, customer-specific fixtures, and grippers.
Purchasing the lifting axis as a complete system from a single source saves on interfaces and coordination effort compared to individually procuring the axis, steel structure and gripper from different suppliers.
CHAPTER 11
Three common mistakes when choosing
Mistake 1: Weighing only the component
The load capacity must include the gripper and its holder, not just the workpiece itself. If the load-handling device is omitted, the axis will be overloaded during operation. Always specify the total weight and include a safety margin.
Mistake 2: Ignoring the center of gravity
An off-center load creates a moment that the guide must absorb. Specifying only the weight in kilograms without mentioning the center of gravity risks undersizing the system. The load's center of gravity must be included in every inquiry.
Mistake 3: Planning too narrowly for the future
Those who work manually today may want to partially automate in two years. A system that cannot later be adapted for collaborative or automated operation quickly becomes a dead end. Future scalability should be considered from the outset.
CHAPTER 12
Procurement for the future: the EU Machinery Regulation 2027
From January 20, 2027, EU Machinery Regulation 2023/1230 will apply directly in all EU member states, replacing the previous Machinery Directive. There is no transition period for placing machinery on the market under the old regulations. Among other things, the regulation tightens ergonomic requirements: In the future, not only physical but also psychological strain on operators must be reduced to a minimum.
For procurement, this means that a lifting axis purchased today should already meet these requirements to ensure its future viability beyond 2027. Lifting aids such as lifting axes and manipulators reduce the manual lifting of heavy loads, thus supporting both ergonomics and compliance. More information can be found in the article "EU Machinery Regulation 2027 and Ergonomics" .
CHAPTER 13
Quick check of lifting axles
Three pieces of information are sufficient for an initial assessment. This does not replace technical advice, but it does narrow down the possible solutions.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 What is the maximum load capacity of a lifting axle?
Most industrial lifting axes are designed for loads of approximately 500 to 750 kg. Some systems offer higher capacities: Zeilhofer's ZH90 lifting axis moves loads up to 1,200 kg, thus covering the heavy-duty range relevant for battery modules, castings, or motors.
02 Pneumatic or electric, which is better?
It depends on the process. Pneumatic systems are sensitive and inexpensive to start with, but require compressed air. Electric systems offer consistent cycle times and maximum accuracy, even without a compressed air network. Electropneumatic systems combine both. For many applications, the electropneumatic option is a good compromise.
03 Can a lifting axle handle off-center loads?
Yes. An off-center load creates a moment that the rigid guide of the lifting axis absorbs. It is important to specify the load's center of gravity during the design process to ensure the correct frame size is selected.
04 What distinguishes a lifting axis from a manipulator?
The lifting axis moves loads purely vertically in the Z-direction. A manipulator additionally guides the load in space, pivoting, rotating, and positioning it within a radius. For purely vertical movement, the lifting axis is sufficient; for working on a surface, a manipulator is the right choice. Both can also be combined.
05 Will I receive the lifting axle as a complete unit?
Yes. Zeilhofer supplies individual lifting axes or complete systems from a single source, including steel construction, rail system, customer-specific fixtures, grippers, and control systems. All systems are developed and manufactured in Holzkirchen.
06 What is the difference between a lifting axis and a lifting column?
Keiner im technischen Sinn. Hubachse, Hubsäule, Teleskophubachse und Linearhubgerät bezeichnen dasselbe Prinzip: eine lineare, starre Führung für die vertikale Lastbewegung. Die Begriffe werden je nach Hersteller und Region unterschiedlich verwendet.
07 When is a lifting axis better than an articulated arm manipulator?
A lifting axis is the better choice if the load needs to be moved primarily vertically, top suspension is possible, and short cycle times are required. The linear guide provides direct force transmission and high repeatability. An articulated arm manipulator is worthwhile if the load also needs to be freely swiveled and rotated in space.
08 What stroke does a lifting axis achieve?
Standard strokes range from approximately 1,200 to 1,600 mm, depending on the size of the unit. Telescopic profiles allow for even greater strokes of several meters without a corresponding increase in the overall length when retracted. The required stroke is determined on a project-specific basis, taking into account the hall height and application.
09 How much does a lifting axle cost?
A fixed price cannot be quoted, as each system is designed specifically for the project. Costs depend on the load capacity class, drive system, level of automation, and the scope of the peripheral equipment, including the steel structure, rail system, fixture, and gripper. For a reliable estimate, information on the load, component, and environment is sufficient.
10. Does a lifting axle need to be checked regularly?
Yes. As a lifting aid, a lifting axle is subject to annual safety inspections. Regular maintenance ensures availability and service life. Details can be found in the guide "Safety Inspections for Lifting Aids ".
11 Was ändert sich mit der EU-Maschinenverordnung 2027 für Hubachsen?
From January 20, 2027, EU Machinery Regulation 2023/1230 will apply without a transition period. It tightens ergonomic requirements and addresses both the physical and mental strain on operators. A newly acquired lifting axis should already meet these requirements to ensure future compliance.
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FURTHER GUIDES ON THIS TOPIC
In-depth guides on related topics in handling technology.
BASICS
What is a lifting axle?
Structure, operating principle and typical applications of linear load guidance, explained in an easy-to-understand way.
DRIVE
Pneumatic or electric lifting?
A direct comparison of drive types: When compressed air is worthwhile and when electric drive is superior.
DELIMITATION
Manipulator, crane or chain hoist
Which system solves which task: load range, precision and cost-effectiveness in an objective comparison.