Column manipulator and lifting aid with tool gripper during tool changes at CNC machines
Column manipulator and lifting aid with tool gripper during tool changes at CNC machines
MECHANICAL ENGINEERING / TOOL CHANGE
LIFTING AID FOR TOOL CHANGES
A lifting aid for tool changes picks up milling and turning tools, clamping devices as well as injection moulds and stamping dies, lifts them sway-free in front of the machine and lets the operator place them into the holder with millimetre precision. Zeilhofer Handhabungstechnik from Holzkirchen, Germany, builds such lifting aids for tools up to 1,200 kg: as the mobile Hebelift ZH with 48 V battery for several machines, as an articulated arm manipulator or as the lifting axis ZH90 directly at the machine. For turning heavy tools there is the lift-and-turn device ZH up to 4,000 kg.
Tools are compact, heavy and expensive. Changing them with an overhead crane or chain hoist means fighting a swinging load, risking damage to cutting edges and mould surfaces and often needing a second person. Lifting them by hand into the machine with outstretched arms quickly exceeds what is acceptable under the German Load Handling Ordinance.
CHAPTER 01
WHAT IS A LIFTING AID FOR TOOL CHANGES?
A lifting aid for tool changes is a hand-guided handling device: it carries the weight of the tool while the operator guides the movement. Unlike a crane, the tool does not hang on a rope but sits firmly in a gripping device on a rigid axis or an articulated arm. It does not swing and can therefore be brought precisely to the tool holder, spindle or mould clamping plate.
Three designs have proven themselves: the mobile Hebelift ZH, which moves between several machines without compressed air and without rails; the articulated arm manipulator, mounted at one machine with a working radius of up to 4.5 m; and the patented lifting axis ZH90 on the ceiling, floor or rail for tools up to 1,200 kg. The multi-axis module ZH3 additionally rotates the tool with 250 Nm, for example from the storage position into the installation position.
CHAPTER 02
WHEN DOES A LIFTING AID FOR TOOL CHANGES PAY OFF?
Not every tool needs a lifting aid. Four indicators show when it makes economic and ergonomic sense.
01 Tools inserted with outstretched arms
What matters is not only the weight but the posture. Lifting a tool into a machine in front of the body strains the back and shoulders far more than carrying the same weight close to the body. The Key Indicator Method (KIM) assesses exactly this combination.
02 Frequent tool changes per shift
Small batch sizes mean many set-ups. Every change that involves a crane, a second person or waiting time extends machine downtime. A lifting aid directly at the machine makes the change plannable and repeatable.
03 Expensive and sensitive tools
Cutting edges, mould surfaces and fits cannot tolerate knocks. Sway-free lifting and sensitive lowering prevent damage that quickly costs more than the lifting aid itself.
04 The crane is busy, too imprecise or not available
An overhead crane is built for transporting large loads, not for millimetre-precise insertion. Where it is busy or missing, a dedicated lifting aid works independently of it.
CHAPTER 03
WHICH SYSTEM FOR WHICH TOOL WEIGHT?
The load capacity is the first filter. After that, the number of machines, the available space and the required precision decide. Zeilhofer builds a suitable system for every weight class, including gripping device and control.
01 Hebelift ZH: up to 100 kg, mobile
Mobile, moved by hand, with Zeilhofer's 48 V battery technology. One device serves several machines, without compressed air and without rails. Ideal for milling and turning tools, clamping devices and small moulds.
02 ZH90 Flex-Arm: up to 200 kg, long reach
Lifting axis with articulated arm: the precision of the ZH90 with long reach. For injection moulds and stamping dies at machines with changing transfer points.
03 Articulated arm manipulator: up to 800 kg
Stationary on the floor or ceiling, working radius up to 4.5 m, pneumatic or electro-pneumatic. For heavy tools at one fixed machine.
04 Lifting axis ZH90: up to 1,200 kg
Patented linear lifting axis for sway-free lifting on the ceiling, floor or rails. Pneumatic up to 800 kg, electro-pneumatic or electric up to 1,200 kg.
05 Lift-and-turn device ZH: up to 4,000 kg
Lifts, rotates and tilts heavy tools, for example to turn them for maintenance and assembly. Replaces a separate tool turner.
06 Multi-axis module ZH3: 250 Nm for rotation
Adds a rotary axis with 250 Nm rated torque to each of these systems, for example to rotate the tool from the storage position into the installation position.
CHAPTER 04
MANIPULATOR, TOOL CHANGE CART, CRANE OR TOOL TURNER?
There are four types of equipment for tool changes. Which one fits depends on whether the tool is lifted and inserted or pushed in at table height.
Lifting aid / manipulator: up to 1,200 kg
For tools that are lifted and inserted into a holder. The operator guides, the load does not swing, one person is enough. Up to 1,200 kg this is the most precise solution.
Tool change cart: tonne range
For heavy press tools and injection moulds that are pushed into the machine at table height. No lifting into the holder, but a fixed transfer height instead.
Overhead crane and chain hoist: transport
For transporting large loads through the shop. During insertion the load swings, fine positioning is difficult and a second person is often needed.
Tool turner: rotating and turning
Turns heavy tools by 90 or 180 degrees, for example for maintenance and assembly. At Zeilhofer, the lift-and-turn device ZH up to 4,000 kg does this.
CHAPTER 05
IN PRACTICE: TOOL CHANGES AT MACHINING CENTRES
The following three practical examples show the most common applications: machining centres, injection moulding and stamping machines, and mobile tool changes at several machines.
Requirements:
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Milling and turning tools up to 50 kg
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Precise insertion into the tool holder
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No knocks against spindle or cutting edges
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Recurring changes in shift operation
Zeilhofer solution
A manipulator with a pneumatic gripping device picks the tool up from the rack and inserts it precisely into the holder of the machining centre. The operator guides the tool without effort, and the device holds it securely until it is seated in the holder. Following the same principle, a leading engine manufacturer converted the tool change at its large machining centres to Zeilhofer handling technology.
Benefits in this application
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Tool floats sway-free in front of the spindle
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No knocks against cutting edges or holder
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One operator instead of two
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Independent of the overhead crane
CHAPTER 06
IN PRACTICE: TOOL CHANGES AT INJECTION MOULDING AND STAMPING MACHINES
Injection moulds and stamping dies are compact and heavy, and their mould surfaces cannot tolerate knocks.
Requirements:
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Injection moulds and stamping dies up to 200 kg
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Positioning in front of the clamping plate or tool holder
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Frequent mould changes with small batch sizes
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Tight space at the machine
Zeilhofer solution
A lifting axis or a manipulator with a part-specific gripping device takes the tool from storage or from the transport cart and guides it sway-free to the machine. The operator positions it precisely at the holder. Zeilhofer has implemented such solutions for injection moulds and stamping dies up to 200 kg.
Benefits in this application
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Millimetre-precise positioning without swinging
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Protection of mould surfaces against impact damage
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Repeatable, plannable changes
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Gripping device matched to the tool
CHAPTER 07
IN PRACTICE: MOBILE TOOL CHANGES WITH THE HEBELIFT ZH
One device for several machines: the Hebelift ZH goes wherever a tool is being changed.
Requirements:
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Tools up to 100 kg at several machines
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No compressed air and no crane at every machine
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No fixed rails in the shop floor wanted
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Fast changeover between machines
Zeilhofer solution
The Hebelift ZH is pushed to the machine by hand and works with Zeilhofer's 48 V battery technology, without any power socket or compressed air connection. It picks up the tool with a matching gripping device, lifts it to holder height and holds it until the operator has inserted it. For tool changes, the Hebelift is one of the most frequently chosen Zeilhofer solutions.
Benefits in this application
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One device for several machines
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No compressed air or power connection needed at the machine
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No structural changes in the shop
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Available as pneumatic, electro-pneumatic or electric version
CHAPTER 08
GRIPPING, ROTATING AND TURNING TOOLS
The gripping device decides whether the tool gets into the machine safely and without regripping. Zeilhofer designs it specifically for each tool.
Gripping principles
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Mechanical gripping, e.g. with clamping jaws or pins
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Vacuum suction
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Permanent electromagnet with holding function
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Combined gripping and suction for maximum safety
Rotating and turning
If the tool has to be rotated between storage and machine, the multi-axis module ZH3 adds a rotary axis with 250 Nm rated torque to the lifting aid. Heavy tools up to 4,000 kg are lifted, rotated and tilted by the lift-and-turn device ZH, for example to turn them for maintenance and assembly. This eliminates regripping with a crane.
Safety functions
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Vacuum reservoir holds the load if pressure drops
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Non-return valve against unintentional release
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Dual-circuit vacuum system for redundancy
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Permanent electromagnet that holds even during a power failure
CHAPTER 09
COSTS, FINANCING AND DELIVERY TIME
The price depends mainly on tool weight, gripping device and control. The following guide values are net, excluding installation and commissioning. Base unit and gripping device are rarely priced separately.
Through its financing partner Würth Leasing, Zeilhofer offers leasing over 24, 36 or 48 months as well as hire purchase. Delivery time is usually 15 to 25 weeks, depending on complexity.
Guide prices per system
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Hebelift ZH: from approx. €10,000, with gripping device usually €15,000 to €30,000
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Articulated arm manipulator: from approx. €12,000, usually €20,000 to €25,000
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Lifting axis ZH90 and ZH90 Flex-Arm: from approx. €15,000, usually €20,000 to €25,000
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Custom designs from approx. €30,000
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Complex lifting axis solutions up to approx. €150,000
What sets Zeilhofer solutions apart?
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Design and manufacturing in Holzkirchen, Germany
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ISO 9001 certified since 2008
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TISAX Level 2 with prototype protection
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Demo units on site, response within 24 hours on working days
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Inspections, maintenance and spare parts worldwide
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 Which lifting aid is suitable for tool changes?
It depends on the tool weight and the number of machines. For tools up to 100 kg at several machines, Zeilhofer's mobile Hebelift ZH is the most common choice. Up to 200 kg with long reach, the ZH90 Flex-Arm fits; up to 800 kg the articulated arm manipulator; and up to 1,200 kg the lifting axis ZH90.
02 How heavy can tools be during a change?
Zeilhofer lifting aids lift tools up to 1,200 kg without swinging. Zeilhofer has already implemented solutions for injection moulds and stamping dies up to 200 kg. For turning heavy tools there is the lift-and-turn device ZH up to 4,000 kg.
03 Manipulator or tool change cart: which is better?
If the tool is lifted and inserted into a holder, a manipulator is the more precise solution up to 1,200 kg because it guides the load without swinging. Tools in the tonne range that are pushed in at table height are better changed with a tool change cart.
04 Can injection moulds be changed with a manipulator?
Yes. A lifting axis or a manipulator with a matching gripping device guides the tool sway-free to the machine. Zeilhofer has built such solutions for injection moulds and stamping dies up to 200 kg.
05 Can tools be changed without compressed air and without a crane?
Yes. Zeilhofer's Hebelift ZH works with a 48 V battery, is moved by hand and needs neither compressed air nor a crane or rails.
06 Can the tool be rotated during the change?
Yes. The multi-axis module ZH3 adds a rotary axis with 250 Nm to any Zeilhofer lifting aid. Heavy tools up to 4,000 kg are turned by the lift-and-turn device ZH.
07 How much does a lifting aid for tool changes cost?
A Hebelift ZH starts at approx. €10,000, a lifting axis ZH90 at approx. €15,000, each net without installation. Including the gripping device, typical solutions cost €15,000 to €30,000. Zeilhofer also offers leasing via Würth Leasing.
08 What is the delivery time?
Zeilhofer usually delivers within 15 to 25 weeks, depending on complexity. A technician answers enquiries within 24 hours on working days.
READ MORE
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In-depth guides on related handling technology topics.
COSTS
How much does a manipulator cost?
MOBILE LIFTING AID
Hebelift ZH without compressed air
