Zeilhofer Handhabungstechnik develops customized handling equipment for the assembly of electromobility components. Electromobility is introducing new components into vehicle assembly for which there is no equivalent in traditional combustion engine production. One of these is the on-board charger, or OBC for short. For production, this means a new assembly, a new assembly step, and new handling requirements directly on the assembly line. This article shows the special features of OBC assembly, how a handling device secures the process, what role the gripper plays, and which systems are suitable for which load ranges. Explainer video: Manipulator for OBC mounting What is an on-board charger? The on-board charger, also known as OBC or vehicle charger, is the permanently installed charging device in an electric or hybrid vehicle. It converts the alternating current (AC) from a household socket, wallbox, or public AC charging station into direct current (DC), which the traction battery can then absorb. It is bypassed during DC fast charging; during any AC charging cycle, it determines the maximum possible charging power. Technically, the core of an OBC consists of an AC/DC converter stage with power factor correction and a subsequent DC/DC stage. This power electronics is housed in a robust, usually water-cooled aluminum enclosure with sealed high-voltage and low-voltage connectors. While the component appears insensitive externally, it is highly sensitive internally. This very contradiction shapes the requirements for its assembly. Why OBC assembly places special demands The OBC is typically bolted to the bodywork in a continuous process. Unlike simple add-on parts, this involves several requirements simultaneously: The OBC must be safely removed from the delivery container without damaging any connector surfaces, sealing surfaces, or cooling connections. It must be moved towards the body in a controlled manner, including a swiveling movement into the correct installation position. Until it is fully screwed in, it must be held exactly in position without the worker having to bear the load permanently. Depending on the vehicle variant or charging capacity, different OBC variants are used, which should be able to accommodate the same device. The installation space in the lower body area is limited; interfering contours are not permitted. Everything must work in cycle, without any loss of time compared to the line speed. Furthermore, there is the economic aspect: A damaged OBC is not a cheap item. Scrap due to uncontrolled movement or impact during handling costs more than the handling solution that prevents it. The assembly process step by step In practice, the process is divided into five sections, which a handling device should cover completely: Removal: The gripper picks up the OBC directly from the logistics container, without intermediate storage and without manual repositioning. Transport: The component is moved to the bodywork suspended and guided; the worker only indicates the direction. Alignment: The OBC is brought into the intended installation position via swivel and rotary axes. Holding: The device securely fixes the component in position while the screwing process takes place. Return movement: After release, the device returns to the starting position for the next cycle. Manipulator, manual labor or robotic cell? There are basically three approaches to OBC mounting, and each has a clear profile. Purely manual assembly without tools is the quickest setup and requires no investment. However, it puts strain on the worker with every cycle, and the risk of damage to the sensitive electronics is high. With increasing production volumes, it quickly becomes a bottleneck and a health hazard. A fully automated robot cell handles all the movement, but requires high investment, complex programming for each vehicle variant, protective enclosure, and a corresponding amount of space. It is also inflexible when there are frequent changes to variants or layouts. The articulated arm manipulator with its adapted gripper falls in between and best meets the requirements of OBC assembly: It relieves the worker of the weight and guides the component precisely, while leaving the sensitive fine positioning and screwing in human hands, where they belong for a safety-relevant component. It requires no protective enclosure, operates directly alongside the worker, and can be adapted with comparatively little effort when changes are made to the component or line. Zeilhofer's handling solution for OBC assembly Zeilhofer Handhabungstechnik has developed a rail-guided handling device for OBC assembly, which is mounted above the assembly line. It follows the vehicle during continuous operation, allowing the worker to perform the entire assembly process while in motion. A pneumatically operated gripper picks up the OBC from the logistics container, guides it in a controlled manner with a pivoting motion to the vehicle body, and holds it there in position until the bolting is complete. The gripper is designed to be able to remove different OBC variants directly from the delivery container without creating any interfering contours or requiring a change of gripper. For plants that frequently adjust their production lines or relocate equipment between sites, the system is also designed for rapid relocation, including power supply and peripherals. Engineering, design, manufacturing, commissioning, and service are all provided by a single source in Holzkirchen. The gripper determines process reliability. Every lifting aid is only as good as its fixture. In OBC assembly, the end-of-arm tooling (gripper) must engage surfaces that are mechanically robust and consistently leave sensitive areas such as connector contacts, sealing surfaces, and coolant connections clear. At the same time, it should be able to handle multiple component variants so that a second fixture doesn't need to be kept on hand in the factory. The overview of fixtures, grippers, suction cups, and magnets shows how such end-of-arm tooling is created, from the gripper to the suction cup and on to the special fixture. Safety, standards and plant security A handling device for OBC assembly is a load-handling device and is therefore subject to the Machinery Directive. Additional requirements apply for continuous line operation: CE conformity for the entire system including device and control Testing and documentation as a load-bearing device, for example as part of a TÜV check Recurring UVV inspection according to DGUV regulations during ongoing operations Safety-related integration into the conveyor control system to prevent collisions between the device and the conveyor technology. Acoustic or visual warning before the device enters a safety area Designed for different load ranges Unlike heavy assemblies such as high-voltage batteries or cockpits, the focus in OBC assembly is not on maximum load capacity, but rather on precision, repeatability, and careful handling of a sensitive component. Depending on the requirements, different systems from the product overview are used: Articulated arm manipulator: pendulum-free up to 800 kg, working radius up to 4.5 m, ideal for swiveling and positioning at a fixed station Acer and ZH70 rope manipulators: lightweight, fast and integrable into any rail system, for loads up to 150 kg ZH90 Flex-Arm lifting axis: combines rigid Z-guide with articulated arm, up to 200 kg, for applications requiring vertical precision and horizontal reach ZH90 lifting axis: linear Z-axis up to 1,200 kg for heavy assemblies in the same production environment This means that one supplier covers the entire spectrum of e-mobility assembly, from delicate power electronics to complete batteries. The article "Battery Module Handling: Safe in E-Mobility" shows how this works with heavy components. The guide "What is a Lifting Axis?" explains which system is generally suitable for which direction of movement. Economic benefits The benefits of a handling solution in OBC assembly can be summarized in four points: Less waste because the component is guided and precisely picked up and placed. Reduced physical strain and therefore fewer days off work due to overhead and awkward postures. More stable cycle times, because the process remains reproducible regardless of daily form and physical strength. Increased acceptance in the workplace because one operator can handle the component alone and safely. Areas of application Handling equipment for on-board charger (OBC) assembly is used wherever electric vehicles are mass-produced, regardless of the automotive manufacturer. With increasing model diversity and growing production volumes in electromobility, the ergonomic and reliable handling of these new components is becoming increasingly important for more and more plants. Zeilhofer Handhabungstechnik is ISO 9001 certified and operates according to TISAX Level 2 with prototype protection, which is particularly crucial for confidential automotive projects. Its systems are in use in 18 industries and over 50 countries. Frequently asked questions about OBC mounting with manipulator What is an on-board charger? The on-board charger is the charging device permanently installed in an electric vehicle. It converts alternating current from a wallbox or socket into direct current for the traction battery and thus determines the vehicle's maximum AC charging power. Why isn't a simple mounting system like other attachments sufficient for the OBC? The OBC connects sensitive power electronics with tightly sealed connectors. An imprecise grip or an impact during insertion can damage the component or sealing surfaces. Therefore, the gripper must be precisely matched to the geometry and sensitive areas of the OBC. Can one manipulator handle multiple OBC variants? Yes. With a suitable gripper design, different OBC variants, depending on factors such as charging power or vehicle model, can be removed directly from the delivery container using the same device. Changing the gripper is unnecessary. How is the OBC held securely in place until it is screwed in? The handling device secures the component in its intended installation position and holds it firmly in place until the operator has completed the bolting to the body. The operator does not bear the weight of the component at any time. Does this also work in continuous operation? Yes. The handling device is guided in a rail system above the line and follows the vehicle, allowing assembly to take place while the vehicle is in motion. For system safety, it is integrated into the conveyor control system. Does a handling device for OBC assembly need to be tested? Yes. As a load-bearing device, it is subject to the Machinery Directive and is inspected and documented accordingly, for example as part of a TÜV inspection. During operation, recurring UVV (accident prevention regulations) inspections according to DGUV (German Social Accident Insurance) regulations are also required. Can the system be moved to a different location? Yes, provided this is taken into account during the design phase. Zeilhofer designs handling equipment for automotive production upon request so that the device and peripherals, including power supply, can be implemented quickly. Pneumatic or electric? For OBC assembly, the gripper is typically pneumatically operated because compressed air is readily available in assembly lines and pneumatic grippers are fast, robust, and easy to maintain. Where compressed air is unavailable, electric versions are possible. Are you planning how to handle your OBC installation? Zeilhofer Handhabungstechnik develops customized handling solutions for the assembly of on-board chargers and other electromobility components, from concept review and design to manufacturing and commissioning on the production line. We analyze your process and develop a suitable manipulator or gripper. Request a free consultation now. #OBC #OnBoardCharger #EMobility #AutomotiveIndustry #Manipulator #HandlingTechnology

Zeilhofer Handhabungstechnik develops customized manipulators for rolls, tubes, sheets, and other components. Paper rolls, film rolls, plastic rolls: In many production processes, rolls are an integral part of the daily material flow. What may appear similar at first glance often differs considerably in practice, especially in core diameter. If each roll size requires its own fixture, this results in unnecessary setup times, additional investments, and more storage space for interchangeable fixtures. We developed a manipulator with an interchangeable expanding mandrel specifically for this task. The article "Individual Grippers and Fixtures: Custom Construction for Every Geometry" also demonstrates how different component geometries can be represented in a single device. Explainer video: Manipulator with interchangeable spreading mandrel A challenge that many companies are familiar with. Rolls differ in weight, width, and material, but most importantly in core diameter. Anyone who regularly processes different types of rolls knows the problem: a separate fixture is needed for each size, or the equipment has to be laboriously reconfigured every time the rolls change. This costs time, ties up storage space, and increases investment costs. Furthermore, manual tool changes on the fixture are often associated with tool use, waiting times, and an increased risk of injury. Our goal was therefore clear: a holder that reliably accommodates multiple core diameters without requiring a complete fixture replacement. The article "Efficient Handling of Rolls" also describes how strenuous manual handling of rolls without aids can be. Switch flexibly instead of undertaking costly conversions. The core of the solution is the interchangeable spreading mandrel. It can be replaced in just a few steps, thus enabling the use of rolls with different core diameters, without having to change the entire fixture. Instead of maintaining multiple manipulators or undertaking complex conversions, a quick change of the expanding mandrel is sufficient. This saves setup time and simultaneously increases flexibility in everyday production, especially with frequently changing roll formats. The expanding mandrel is one of the holding devices that we individually design as part of the overall system; you can find more information on the page Devices, Grippers, Suction Cups & Magnets. This is how the spreading mandrel is changed. The replacement process itself takes place in a few clearly defined steps and usually requires no special tools: Detach the roll and move the manipulator into the changeover position. Release the locking mechanism of the current expanding mandrel. Remove the expanding mandrel and attach the appropriate mandrel for the new core diameter. Close the lock and perform a function test. Pick up the next roll and continue working This transforms a setup process that previously required tools and several minutes of downtime into a single step during operation. Safe roll handling for a wide variety of applications Safely handling and precisely moving heavy rolls requires reliable handling technology. The manipulator takes on almost all of the roll's weight, enabling controlled movement with minimal effort. This reduces strain on employees and improves workplace safety. At the same time, rolls can be positioned precisely, for example, on production machines, winding systems, or packaging lines. Depending on the system, our articulated manipulators move loads up to 800 kg, and the ZH90 lifting axis even up to 1,200 kg, all with zero oscillation and precision. The article "Manipulators for Heavy Rolls of Different Sizes" describes the general advantages of a manipulator over a crane or chain hoist for handling rolls. Interchangeable spreading mandrel compared to other solutions There are three common approaches to roll insertion. A comparison shows where the interchangeable spreading mandrel demonstrates its strengths: One fixed device per roll size: very quick changeover, but high investment and storage costs, as a separate system must be available for each core diameter. Modification of the existing equipment: lower investment, but long setup times, tool usage and system downtime with each change Interchangeable spreading mandrel: one basic device with multiple mandrels, changeover in minutes without special tools, low investment with high flexibility Custom-designed for your rolls Not every roll is the same. That's why each handling solution is individually tailored to the specific application. During the planning phase, we clarify, among other things: roll weight roll diameter Core diameter Roll width Material properties Work processes ergonomic requirements Based on this, a tailor-made solution is created that can be optimally integrated into the existing production process. Improved ergonomics and higher productivity A manipulator with an interchangeable expanding mandrel not only improves workplace ergonomics but also ensures more efficient processes. The quick mandrel change allows for handling different roll formats without lengthy interruptions. This reduces setup times, increases system availability, and improves material flow, especially with frequently changing production orders. A similar principle also proves beneficial for other cylindrical components such as tube bundles; see Tube Bundle Handling with Manipulators. Areas of application A manipulator with an interchangeable spreading mandrel is suitable for numerous industries, including: Paper industry Film production Plastics processing Packaging industry printing industry textile industry Logistics and material flow Wherever rolls with different core diameters need to be moved safely, the interchangeable spreading mandrel ensures maximum flexibility. For flexible locations without permanent installation, mobile solutions are also available, as described in the article "Mobile Lifting Aid for Handling Rolls". Process: From consultation to commissioning Consulting: Initial technical consultation, analysis of roll range, core diameters and work processes Concept: Individual concept including device, control system and quotation with price indication Manufacturing: Design and manufacturing in Holzkirchen, Germany, in-house technicians, certified to ISO 9001 and TISAX Level 2 with prototype protection. Commissioning: On-site assembly, training and commissioning, worldwide, optionally with a maintenance contract Individual handling technology is our strength. Every production process places different demands on roll handling. That's why Zeilhofer Handhabungstechnik develops customized manipulators and holding devices precisely tailored to the specific workflows. The interchangeable spreading mandrel demonstrates how intelligent design and practical solutions can be combined, similar to the manipulator with interchangeable gripper system for flexible production processes. The result is ergonomic workstations, safe processes, and cost-effective handling of a wide variety of roll formats. Frequently asked questions about the manipulator with interchangeable spreading mandrel What is a replaceable spreading mandrel? An interchangeable spreading mandrel is a replaceable mount on the manipulator that allows for the use of rolls with different core diameters. The mandrel can be changed in just a few steps, eliminating the need for a complete fixture change. How long does it take to replace the spreading mandrel? The replacement process typically takes only a few minutes and requires no special tools. The exact duration depends on the specific design and locking mechanism, which we tailor to each individual case. What core diameters can be covered with an interchangeable expanding mandrel? That depends on the individual design. Since each solution is designed specifically for the project, we determine the covered core diameters together with the customer during the initial consultation. What advantages does an interchangeable spreading mandrel offer compared to several individual devices? Instead of maintaining multiple manipulators or fixtures, simply changing the spreading mandrel is sufficient. This reduces investment costs, saves storage space, and shortens setup times in daily production. Can an existing manipulator be retrofitted with an interchangeable spreading mandrel? In many cases, yes. Whether a retrofit is possible depends on the existing model and the mounting interface. We would be happy to check this using your existing system. Up to what weight can rolls be handled? The articulated manipulator handles rolls up to 800 kg, and the ZH90 lifting axis up to 1,200 kg, each with zero oscillation and precision. The exact load capacity depends on the roll weight, diameter, and application. For which industries is this solution suitable? Especially for the paper industry, film manufacturing, plastics processing, packaging industry, printing industry, textile industry and logistics, anywhere where rolls with different core diameters need to be moved. Further topics from the blog and guide You can find more in-depth information about roll handling and manipulators in these articles: Guide: Roll lifters and roll handling Guide: What is a manipulator? Guide: Comparison of articulated and rope manipulators Guide: Lifting aids for production & industry Efficient handling of rolls Manipulators for heavy rolls of different sizes Mobile lifting aid for handling rolls Pipe bundle handling with manipulators Custom grippers and fixtures: Special construction for every geometry Manipulator with interchangeable gripper system for flexible production processes How to handle your rolls flexibly and ergonomically? Do you process different types of rolls and are looking for a holder that covers multiple core diameters? Our engineers will be happy to advise you and design a customized solution for you, Made in Germany, from a single source. Our guide to roll lifters and roll handling offers more in-depth information on roll lifters, variants and selection criteria.

Sacks are a daily part of handling in many production processes, yet they remain an underestimated problem. A 25-kilogram paper sack filled with granules, powder, or bulk material is grabbed, lifted, moved, and emptied over a machine, hundreds of times per shift. This strains backs and shoulders, wastes time, and carries the risk of a sack tearing or falling with every handling. This is precisely where one of our solutions comes in: a rope manipulator that picks up sacks with a suction device and guides them almost weightlessly. In this project, the Acer model rope manipulator was used, designed for loads up to 150 kg and equipped with a suction cup that securely picks up the bag from the surface. The example of a rope manipulator for rollers also demonstrates what a customized lifting concept looks like in practice. Explainer video: Rope manipulator for bags The problem with handling bags Sacks are bulky, flexible, and slippery. They are difficult to grip, shift their weight when lifted, and lack a defined edge for easy handling. Moving them by hand all day risks musculoskeletal strain, which is one of the most common causes of lost workdays in production. The usual requirements are almost always the same: the bag should be picked up quickly, safely moved over a certain distance, and precisely placed down or emptied. Without aids, this means heavy lifting in an awkward posture. With the right system, it becomes an effortless, repeatable process. Why a rope manipulator with a suction cup is better than a hose lifter A vacuum tube lifter is often suggested for lifting bags. While it works, it has inherent weaknesses. With a tube lifter, the negative pressure itself bears the load, and a continuously running vacuum blower must operate even when stationary. This consumes energy and generates a constant noise level. If the seal weakens, for example with dusty paper bags, or if there is a power outage, the holding force is immediately compromised. The Acer rope manipulator cleanly separates carrying and gripping. The load is carried mechanically via two independent wire ropes and a pneumatic counterweight system, while the bag is gripped solely via the suction cup. This results in clear advantages in everyday use: Two redundant wire ropes and an integrated pressure accumulator keep the bag secure even in the event of a failure of the compressed air supply, whereas with the tube lifter, the holding force depends on the vacuum. No continuously running vacuum blower: The pneumatic weight compensation is more energy-efficient and quieter than a continuously delivering side channel blower. High load capacity up to 150 kg, where tube lifters for heavy bags often reach their limits. The suction device is designed to match the bag type, instead of using a standard bellows for everything, and can be combined with other devices for mixed tasks. Large working radius of up to 4,000 mm for repositioning over long distances within the station. Our guide to vacuum tube lifter alternatives explains in more detail when a mechanically guided device is generally the better choice compared to a vacuum tube lifter. Special version: Attachment to a precast concrete column A cable manipulator can be anchored to the floor, bolted to the ceiling, attached to a steel structure, or moved along a rail system. This project required a special solution: The Acer was attached directly to a precast concrete column in the production hall. This demonstrates the flexibility of the installation. Instead of installing additional steel structures or occupying valuable floor space, the existing building structure of the hall is utilized. The result is a stable suspension point, a clear floor for the flow of people and materials, and a workstation located precisely where the bag is needed. We design such column-adjacent fixings on a project-specific basis, tailored to the structural requirements and the surrounding environment. Double rope technology: Safety as standard The core of the rope manipulator consists of two independent ropes that guide the load. If one rope fails, the second holds. Additionally, an integrated pressure accumulator secures the load in case of a compressed air supply failure. This redundancy is crucial when handling sacks over machines, hoppers, or containers, as a falling load would endanger both personnel and equipment. Individual suction device for each bag type No two bags are alike. Paper, plastic, or fabric; smooth or rough surfaces; different formats and fill levels: the suction device is therefore designed to fit the component and supplied in compliance with CE standards from a single source. For mixed tasks at the same station, combinations with other end-of-arm tools can also be implemented. Each device is individually created, tailored to the component, process, and working environment. Typical areas of application A cable manipulator with a suction cup for bags is used wherever medium-weight bags need to be moved quickly and precisely: in food and feed production, in chemical and plastics processing, in the building materials and minerals industries, in recycling, and in logistics and packaging. The same system philosophy can be applied wherever barrels and containers need to be lifted, tipped, or emptied in addition to bags. The same principle applies everywhere; only the type of bag and the device change. Everything from a single source From on-site needs analysis and design to manipulator, suction device, control system, and after-sales service, Zeilhofer Handhabungstechnik delivers the complete system. Manipulator, gripper, mechanics, and control system work together seamlessly to form a perfectly coordinated overall solution. This results in a system precisely tailored to the bag type, production hall, and process, ensuring ergonomic workstations and efficient, safe production. Frequently asked questions about the rope manipulator for bags How heavy can bags be when using a rope manipulator? The Acer rope manipulator can handle bags up to 150 kg. Thanks to pneumatic weight compensation, the load is held almost weightlessly, requiring minimal effort from the operator. For lighter, particularly fast applications, the ZH70 offers a more compact version with a capacity of up to 70 kg. Why is a suction cup on a rope manipulator better than a hose lifter? In a cable manipulator, the load is mechanically supported by two independent cables, while the suction cup only handles the gripping. In contrast, a vacuum lifter relies on a vacuum to provide the support, requiring a blower to run continuously. As a result, the cable manipulator is more energy-efficient, quieter, and remains safe even in the event of a leak or loss of compressed air. How safe is the rope manipulator during sack handling? Two redundant wire ropes guide the load. If one rope fails, the second holds. Additionally, an integrated pressure accumulator keeps the load securely in position even if the compressed air supply fails. This double safety feature is crucial, especially when handling loads over machines and containers. Can the rope manipulator be attached to a concrete support? Yes. In addition to floor, ceiling, steel structure, and rail mounting, attachment to a precast concrete column is also possible. This special design utilizes the existing building structure of the hall, keeps the floor clear, and is tailored to the specific project requirements, including structural analysis and surrounding environment. For which types of bags is the suction device suitable? The suction device is designed to suit the specific bag type, whether paper, plastic, or fabric. It is supplied as a complete, CE-compliant unit and can be combined with other devices such as grippers or hooks for mixed applications. How to handle bags ergonomically and safely? Do you move bags by hand every day and are looking for a fast, effortless solution? Our engineers will be happy to advise you and design your rope manipulator with a suitable suction device individually, Made in Germany, from a single source. Our guides on handling technology offer more in-depth information on individual topics. #RopeManipulator #BagHandling #HandlingTechnology #SuctionLifter #HoseLiftAlternative #Ergonomics #Manipulator #zhht

When three different components become a single handling solution, there is more to it than just a new fixture. That was exactly the task in one of our projects: a customer from the commercial vehicle industry needed a way to handle three different truck bumper types safely and ergonomically with just one pick-up fixture. The goal was to make the production process more flexible, reduce setup times and avoid investing in several fixtures. The answer was not an off-the-shelf product, but a specially developed pick-up fixture for truck bumpers that can be adjusted to the respective component type in just a few steps. What such a system looks like when components are switched over rather than swapped is also shown in the example One manipulator, two modes. Explainer video: Pick-up fixture for truck bumpers A challenge many companies know Product variety is increasing in almost every production. New models, different versions and ever smaller batch sizes are part of everyday life today. This often means: a separate fixture for every component. The consequences are well known. More storage space, longer changeover times, higher investment costs and unnecessary interruptions in the production flow. Our goal was therefore clear from the start: one fixture should safely hold all three bumper variants. Switch flexibly instead of retooling laboriously The heart of the solution are integrated adjustment mechanisms and selector switches. With them, the operator sets the pick-up fixture to the desired bumper type in no time. A complete change of the fixture is no longer necessary. The benefits show immediately in daily use. The production flow stays smooth, setup times are significantly reduced and the risk of operating errors drops. Especially with changing production orders, this flexibility makes a noticeable difference. A similar approach for series production with frequent component changes is described in the article Manipulator with interchangeable gripper system for flexible production processes. Developed for real production environments Every pick-up fixture from Zeilhofer is created where it will later be used: in the actual production process. That is why we look not only at the component itself, but at the entire workflow. Before design begins, we clarify the decisive questions: How is the bumper picked up? Where are the gripping points? Which movements must the manipulator perform? How quickly do components need to be changed? Only once all requirements are known does construction start. The result is not a standard fixture, but a solution tailored exactly to the specific application. Less technology. More efficiency. A better solution often means not more technology, but the right technology. Instead of providing three different fixtures, a single pick-up fixture handles all three variants. This saves not only acquisition costs. Maintenance, storage and operation also become much simpler. For our customers this means more cost-efficiency together with higher process reliability. In this project, the articulated-arm manipulator moves the bumpers sway-free and precisely. Depending on the system, our manipulators handle loads up to 800 kg, and the ZH90 lift axis up to 1,200 kg. Developed together. Perfectly matched. The pick-up fixture was developed as part of a complete handling system. Manipulator, pick-up, mechanics and control interlock and form a perfectly coordinated overall solution. This creates ergonomic workstations, safe motion sequences and a reliable production process, even with frequently changing components. Because mechanics and control come from a single source at Zeilhofer, the entire system can be implemented as a CE-compliant complete solution. Custom handling technology is our strength Every production is different. That is why we do not develop off-the-shelf solutions. Whether gripping fixture, suction fixture, magnetic fixture or complex special pick-up: every fixture is custom-designed and adapted exactly to the component, process and working environment. This pick-up fixture for truck bumpers, too, shows how intelligent engineering and practical experience can be combined. Because modern handling technology today does not only mean moving components safely. It creates flexible processes, relieves employees and helps companies produce more economically. Frequently asked questions about the pick-up fixture for truck bumpers Can one pick-up fixture handle several component types? Yes. With integrated adjustment mechanisms and selector switches, a pick-up fixture can be designed to hold several component variants. In this project, a single fixture covers three different truck bumper types. A complete change of the fixture is not required. How does switching between component types work? The operator sets the fixture to the desired bumper type in just a few steps via adjustment mechanisms and selector switches. This significantly reduces setup times and lowers the risk of operating errors with changing production orders. What advantages does one fixture for several variants offer? A variant-flexible fixture saves acquisition costs for several individual fixtures, reduces storage space and maintenance effort and keeps the production flow smooth. The result is more cost-efficiency together with higher process reliability. Up to what weight can bumpers and components be handled? The articulated-arm manipulator handles loads up to 800 kg, the ZH90 lift axis up to 1,200 kg, each sway-free and precise. The pick-up fixture is designed to match the respective load class and component. Handle your components flexibly and ergonomically? You handle different component variants and are looking for a fixture that covers several types? Our engineers will be glad to advise you and design your solution individually, Made in Germany, from a single source. For more depth on individual topics, see our guides on handling technology. #HandlingTechnology #Bumper #PickUpFixture #VariantHandling #Manipulator #ComponentHandling #AutomotiveIndustry #zhht

Aerospace is a megatrend, and southern Germany is one of its centers. Around Munich, a dense cluster of manufacturers, suppliers and research has formed. For a handling technology manufacturer from Holzkirchen, this future industry is therefore right on the doorstep, with short distances and close cooperation. Manufacturing of a SpaceX rocket Megatrend aerospace on the doorstep The region south of Munich is a strong location for aerospace: civil and military aviation, space, propulsion and suppliers. This proximity is a practical advantage. Handling solutions can be developed, adapted and commissioned together on site, without long travel distances. Zeilhofer Handhabungstechnik manufactures in Holzkirchen, in the middle of this cluster. This enables short response times and close coordination throughout the entire course of the project. Requirements of a high-technology industry Aerospace demands the highest precision, complete documentation and the protection of sensitive data. Components are large, heavy and sensitive. Sway-free handling protects functional surfaces, reproducible processes secure constant quality. How large components are moved safely is shown in the article Handling technology for aerospace. What the industry expects from handling technology: Highest precision and repeat accuracy. Sway-free guidance to protect sensitive components. Protection of sensitive design data. Individual fixtures for complex geometries. Suitable systems for large components For vertical lifting, the ZH90 lift axis up to 1,200 kg is suitable, for complex movements the articulated manipulator up to 800 kg. Grippers and fixtures are designed for the respective geometry. A system overview is given in the guide to lifting aids. Zeilhofer Handhabungstechnik is certified to ISO 9001 and works in accordance with TISAX Level 2 with prototype protection, which is especially decisive in this industry. Practical example: structural component in final assembly In the final assembly of aircraft structures, a large-area structural component of around 500 kg has to be attached to the fuselage section with millimeter precision. Tolerances are tight, the surface is sensitive, and any knock would mean expensive rework. An articulated manipulator with sensitive controls guides the component sway-free and lets the worker carry out the final positioning by hand with feeling. This combines the load capacity of the machine with the precision of the human, exactly the combination that high-technology manufacturing in aerospace demands. Frequently asked questions Why is proximity to the aerospace cluster an advantage? Short distances make it possible to develop, adapt and commission handling solutions together on site, with fast response times and close coordination. What requirements does the industry place on handling technology? Highest precision, complete documentation, protection of sensitive data and sway-free guidance of sensitive, often large components. Which systems are suitable for large components? The ZH90 lift axis up to 1,200 kg for vertical lifting and the articulated manipulator up to 800 kg for complex movements, each with an individual fixture. How is the protection of sensitive data ensured? Zeilhofer HHT works in accordance with TISAX Level 2 with prototype protection and is certified to ISO 9001. Part of the cluster? Do you manufacture in aerospace and are looking for a handling partner from the region? Our engineers are happy to advise you and design your solution individually, Made in Germany, from a single source. For more depth on individual topics, see our guides on handling technology. #HandlingTechnology #Aviation #Aerospace #Manipulator #LiftAxis #ComponentHandling #zhht

If you move plates every day, you know the weak points in the process: large formats bend, sensitive surfaces get pressure marks, the weight strains employees, and every new plate size means retooling. Whether sheet metal, glass, plastic panels, wood-based boards or mixed assembly plates: safe and economical handling is not decided by the manipulator alone, but by the right handling attachment. This article is aimed at everyone who handles flat components and shows which attachment is suitable for which plate and what matters when making the choice. Why the attachment decides between success and scrap A plate is not a simple component. It is large, often heavy and rarely dimensionally stable. If it is held in the wrong place or with the wrong attachment, it bends, slips or gets damaged. With sensitive surfaces such as painted sheet metal, glass or visible parts, the wrong attachment alone leads to costly scrap. The handling attachment is therefore the actual interface between the plate and the handling system. It determines whether the load is distributed evenly, whether the surface stays protected and whether the operator can work ergonomically and safely. The right attachment by plate type Which attachment is the right one depends above all on material, surface and format. Suction attachments are the first choice for large, smooth plates. Sheet metal, glass, plastic panels, wood-based boards or assembly plates are picked up flat and gently via suction pads, without pressure marks on edges or surface. Adjustable suction attachments cover several formats with a single system. Monitored vacuum technology ensures the necessary process reliability. Our article What is a suction device? explains the basics. Magnetic attachments are suitable for ferromagnetic plates made of steel or iron, especially when the surface is insensitive or suction is impeded by perforations, oil or rough surfaces. Depending on the application, permanent or electromagnets are used. Gripping attachments come into play where plates have to be gripped at the edges, tilted or positioned precisely, for example with thick, very heavy or irregularly shaped plates that cannot be cleanly suctioned. In practice, the combination of surface, weight, format and process step decides. We analyse exactly these factors before construction so that the attachment fits the plate precisely. What to consider when choosing Before deciding on an attachment, it is worth looking at a few key points: weight of the plate and matching load capacity class surface condition and sensitivity largest and smallest format to be handled centre of gravity and risk of bending required movements such as lifting, tilting or turning cycle time in the process The more precisely these requirements are known, the more precisely the attachment can be designed and the safer and more economical the handling will later run. In terms of load capacity, the range extends depending on the system from the Hebelift ZH up to 100 kg, the ZH90 Flex-Arm up to 200 kg and the manipulator up to 800 kg, through to the ZH90 lifting axis up to 1,200 kg. The attachment is designed to match the respective load capacity class. One system for many formats Companies with high variant diversity in particular face the question of whether a separate attachment is needed for each plate size. It is not. An adjustable suction attachment picks up different formats with just one handling system, shortens setup times and saves investment costs. Our practical example Manipulator with suction attachment: flexible handling of assembly plates up to 100 kg shows what this looks like in concrete terms. Everything from a single source A major advantage is that manipulator, control and handling attachment are developed together. This creates fewer interfaces, simplifies commissioning and allows the entire system to be implemented as a CE-compliant complete solution. Customers receive not a single part, but a coordinated overall system, from component analysis to commissioning. Developed for a wide range of industries Plates are handled in almost every industry. Zeilhofer supplies 18 industries, including mechanical engineering, metalworking, control cabinet and plant construction, automotive and supplier industry, glass and window industry as well as the wood industry. In each of these applications, the attachment is precisely tailored to the respective plate and process. Frequently asked questions about plate handling Which attachment is suitable for handling plates? For large, smooth plates such as sheet metal, glass or plastic, suction attachments are the first choice. Ferromagnetic plates can be handled with magnetic attachments, thick or irregular plates with gripping attachments. The choice depends on material, surface and format. How are sensitive plates handled without damage? Via suction attachments with flatly distributed suction pads, the load is picked up evenly, without pressure marks on edges or surface. Monitored vacuum technology additionally ensures safety with sensitive surfaces such as painted sheet metal or glass. Does every plate size need its own attachment? No. An adjustable suction attachment can pick up different formats with just one handling system. This shortens setup times and lowers investment costs compared to several individual attachments. Up to what weight can plates be handled with a manipulator? Depending on the system, from the Hebelift ZH up to 100 kg to the ZH90 lifting axis up to 1,200 kg. The attachment is designed to match the respective load capacity class. Handle your plates safely and ergonomically? You move sheet metal, glass, plastic or assembly plates and are looking for the right attachment? Our design engineers are happy to advise you and design your solution individually, Made in Germany, from a single source. For more depth on individual topics, see our guides on handling technology. #HandlingTechnology #PlateHandling #SuctionAttachment #Manipulator #ComponentHandling #zhht

Civil aviation faces a long production ramp-up: the order books of the aircraft manufacturers are filled for years, and manufacturing has to increase its rates significantly. Handling technology for aviation manufacturing helps to move large and sensitive components safely, ergonomically and in cycle. Turbine manufacturing Production ramp-up in aviation: the challenge Higher production rates meet demanding components: structural components, engine parts and landing gear are large, heavy and often sensitive on functional surfaces. At the same time, quality requirements are extremely high. Manual handling quickly reaches its limits here, both in ergonomics and in the required precision. Handling technology takes the weight off and guides the component sway-free. This protects worker and component and makes the higher rates manageable in the first place. The industry context is provided by the article Handling technology for aerospace. Moving large, sensitive components sway-free For vertical lifting of heavy structural components, the ZH90 lift axis up to 1,200 kg is suitable. For turning, tilting and precise joining, an articulated manipulator up to 800 kg is used. Decisive is the sway-free load guidance, which protects sensitive surfaces and functional surfaces. Typical tasks during the production ramp-up: Reposition structural components and fuselage segments safely. Position and join engine components precisely. Handle landing-gear components sway-free. Design workstations ergonomically to staff them more broadly. Precision and reproducibility In aviation, tolerances and documentation are particularly critical. Sway-free, reproducible handling ensures that every component is fed in the same position and without damage. How individual grippers for complex geometries are created is shown in the article Custom grippers and fixtures. Confidentiality and quality Aviation projects are often subject to strict confidentiality and quality requirements. Zeilhofer Handhabungstechnik is certified to ISO 9001 and works in accordance with TISAX Level 2 with prototype protection. Every solution is engineered individually, from the needs analysis to commissioning. Frequently asked questions How does handling technology support the production ramp-up in aviation? It takes the weight off large components and guides them sway-free. This makes higher production rates manageable and protects worker and component alike. Which components can be handled? Structural, engine and landing-gear components up to 800 kg with an articulated manipulator and up to 1,200 kg with a lift axis, moved sway-free. How is the required precision ensured? Through sway-free, reproducible load guidance that feeds every component in the same position and without damage. Are confidentiality requirements met? Yes. Zeilhofer HHT works in accordance with TISAX Level 2 with prototype protection and is certified to ISO 9001. Ramping up your aviation manufacturing? Are you increasing your production rates in aviation? Our engineers are happy to advise you and design your solution individually, Made in Germany, from a single source. For more depth on individual topics, see our guides on handling technology. #HandlingTechnology #Aviation #Aerospace #Manipulator #LiftAxis #ProductionRampUp #zhht

In many companies, assembly plates in various dimensions have to be moved every day. Often this means using several handling attachments or time-consuming retooling. Both cost time and reduce productivity. With our manipulator with suction attachment, this problem is a thing of the past. The individually adjustable suction attachment can be quickly set to different formats. This allows various assembly plates to be safely picked up, transported and positioned with just one handling system. Companies benefit from significantly shorter setup times and much higher flexibility. Production processes stay dynamic and can easily adapt to changing products or customer requirements. Manipulator with suction attachment Manipulator with suction attachment: individually adjustable for maximum flexibility The heart of this solution is the specially developed suction attachment for assembly plates. Unlike rigid standard solutions, the position of the suction elements can be individually adjusted. This allows the pickup to be optimally matched to different plate sizes. Whether smaller assembly plates or large-format components, the suction pads are positioned exactly where safe load pickup is required. This flexibility offers numerous advantages: safe handling of a wide variety of plate sizes quick adaptation to changing components lower setup times higher process reliability economical use of a single manipulator for multiple applications Companies with a high variant diversity in particular benefit from this solution, as no separate attachment is needed for each plate size. Tailor-made handling technology for individual requirements No production is the same as another. That is why we develop each handling attachment individually according to our customers' requirements. Already during project planning, we analyse the entire production process together. Among other things, we take into account: weight of the assembly plates dimensions and formats surface condition centre of gravity of the component desired movements working environment and cycle times On this basis, a precisely matched handling attachment is created that guarantees maximum safety and maximum efficiency. A solution from a single source At Zeilhofer Handhabungstechnik, customers receive not just a manipulator or a suction attachment, but a fully coordinated overall system. Manipulator, control and handling attachment are developed together and optimally matched. This results in fewer interfaces, easier commissioning and high operational reliability. The result is a durable and economical solution that integrates easily into existing production processes. Ideal for a wide range of industries The manipulator with suction attachment is suitable wherever assembly plates or comparable flat parts have to be moved safely. Typical areas of application are: mechanical engineering control cabinet construction metalworking plant construction automotive industry manufacturing of technical assemblies special machine construction Wherever different plate sizes are handled, the adjustable suction attachment ensures significantly more flexibility and more efficient workflows. Which attachment is suitable for which plate type, whether suction, magnetic or gripping attachment, is explained in our guide Handling plates safely: which attachment fits your plate? More flexibility. More ergonomics. More economy. A modern manipulator with suction attachment is far more than a lifting aid. It is an intelligent handling system that supports companies in making production processes more efficient, safer and more ergonomic. Thanks to the individually adjustable suction attachment for assembly plates, a wide variety of plate sizes can be handled with just one system. This reduces setup times, lowers investment costs and at the same time increases the flexibility of the entire production. With a load capacity of up to 100 kg, a precisely adjustable pickup and ergonomic operation, our manipulator with suction attachment offers the ideal solution for companies that want to make their handling processes future-proof. Because modern handling technology today does not just mean moving loads. It means relieving employees, optimising processes and giving companies the flexibility to respond quickly and safely to new requirements. Frequently asked questions about the manipulator with suction attachment How heavy may the assembly plates be? The manipulator with suction attachment handles assembly plates with a load capacity of up to 100 kg. For higher loads, other systems such as the ZH90 lifting axis up to 1,200 kg are available. Can one system pick up different plate sizes? Yes. The position of the suction elements can be individually adjusted so that different formats are safely picked up with just one handling system. This eliminates separate attachments per plate size. Which materials is the suction attachment suitable for? For large, smooth and airtight plates such as sheet metal, plastic panels, assembly plates or glass. For porous or heavily structured surfaces, alternative attachments such as magnetic or gripping attachments are an option. Does the manipulator reduce the physical strain on employees? Yes. The load is carried by the manipulator, the operator guides the plate almost effortlessly. This relieves the back, lowers the risk of injury and makes the workplace ergonomic. For more depth on individual topics, see our guides on handling technology. #HandlingTechnology #SuctionAttachment #AssemblyPlates #Manipulator #PlateHandling #zhht

The offshore build-out is one of the largest industrial tasks of the coming years. By 2030, considerable capacity is to come online, and the components for it are getting bigger and heavier. For wind component production this means: the handling must grow with it. Handling solutions for offshore components are a central building block here. Offshore wind turbines Offshore build-out by 2030 and its consequences for manufacturing Offshore turbines are significantly larger than onshore turbines, and their components are correspondingly heavier. Hubs, generators and structural components reach weights that can no longer be managed manually. At the same time, the pressure on unit numbers and on-time delivery rises. Sway-free handling technology is the prerequisite for manufacturing these heavy components safely and in cycle. Anyone who invests early in scalable handling solutions gains a head start in ramping up offshore production. Handling heavy offshore wind components safely For sway-free vertical lifting, the ZH90 lift axis up to 1,200 kg is suitable. For complex movements when turning and joining, an articulated manipulator is used. Heavy flange connections, typical in tower and foundation construction, are covered in the article Flanges, indispensable and often extremely heavy. What matters especially with offshore components: High load capacities for large, heavy components. Sway-free guidance to protect functional surfaces. Reproducible processes for constant quality. Robust design for continuous operation in series. Invest early and scalably The ramp-up by 2030 rewards forward-looking investments. Handling technology can be expanded in stages, from the single workstation to the line. Which form of procurement fits, from purchase to leasing and hire purchase, is covered in our article on procurement options. The system overview is given in the guide to lifting aids. Zeilhofer Handhabungstechnik engineers every solution individually, is certified to ISO 9001 and works in accordance with TISAX Level 2 with prototype protection. Practical example: generator housing for offshore turbines A typical scenario from offshore manufacturing: a generator housing of around 900 kg has to be removed from processing, turned 180 degrees and guided to the assembly station. With crane and slings this takes several minutes, ties up two employees and is a safety risk with every turn. With a ZH90 lift axis and a suitable turning device, a single worker performs the same task sway-free, faster and reproducibly. The housing is guided impact-free, and functional surfaces stay protected. As unit numbers rise in the offshore ramp-up, this time gain per component adds up to a noticeable capacity effect. Frequently asked questions Why does the offshore build-out require special handling solutions? Because offshore components are significantly larger and heavier than onshore components and can no longer be managed manually. Sway-free handling technology makes them safe and able to be put into cycle. Which loads occur with offshore components? Depending on the component, several hundred to over a thousand kilograms. The ZH90 lift axis lifts up to 1,200 kg sway-free. Is an early investment worthwhile? Yes. Anyone who invests early in scalable handling solutions gains a head start in ramping up offshore production by 2030. Is the technology designed for continuous operation? Yes. The systems are engineered robustly for industrial continuous operation in series production. Planning for the offshore ramp-up? Are you preparing your production for the offshore build-out? Our engineers are happy to advise you and design your solution individually, Made in Germany, from a single source. For more depth on individual topics, see our guides on handling technology. #HandlingTechnology #Offshore #WindPower #Manipulator #LiftAxis #HeavyLoad #zhht

The addition of wind turbines is picking up noticeably, and with it the demand for components. Hubs, generators, flanges and tower segments have to be manufactured in higher numbers. For component manufacturing, the wind power boom means above all one thing: produce faster, without compromising on ergonomics and quality. Manufacturing of wind turbines What the wind power boom means for component manufacturing More turbines mean more components, and heavy ones at that. Manufacturing has to increase its cycle rate while shop-floor space and personnel remain limited. Handling technology decouples output from pure muscle power: heavy components are moved sway-free, workstations become more broadly staffable, processes reproducible. This way rising demand can be met without increasing the workforce to the same extent, which would often not even be possible given the shortage of skilled labor. Hubs, generators and flanges in focus The central components are heavy and partly sensitive. For vertical lifting, the ZH90 lift axis up to 1,200 kg is suitable, for turning and joining an articulated manipulator up to 800 kg. Heavy flanges are a topic of their own, covered in the article Flanges, indispensable and often extremely heavy. Where handling technology starts in component manufacturing: Turn hubs and align them for assembly. Reposition generator components sway-free. Position and join flange connections precisely. Handle tower segments and housings safely. Quality and ergonomics despite the pace Higher pace must not come at the expense of quality and health. Sway-free load guidance protects component and worker at the same time. What role ergonomics plays at the assembly workstation is explored in the guide to ergonomics at the assembly workstation. Whether the investment pays off is shown in What does a manipulator cost. Zeilhofer Handhabungstechnik engineers every solution individually, is certified to ISO 9001 and works in accordance with TISAX Level 2 with prototype protection. Practical example: hub assembly in series In hub manufacturing, one task repeats a hundred times: the hub, several hundred kilograms depending on the turbine class, has to be turned several times and positioned exactly for bolting the blade bearings. Manually this is barely possible, and with the crane too slow and too imprecise for the series cycle. An articulated manipulator with a turning device guides the hub sway-free into every required position, always the same and without effort by the worker. This keeps the cycle constant, regardless of who staffs the workstation. It is precisely this repeat accuracy that makes the boom in component manufacturing manageable in the first place. Frequently asked questions What does the wind power boom mean for manufacturing? More turbines mean more heavy components. Manufacturing has to increase its cycle rate while personnel and space remain limited. Handling technology closes this gap. Which components are particularly critical? Above all hubs, generators, flanges and tower segments, because they are heavy and partly sensitive and have to be joined precisely. How is quality maintained despite the higher pace? Through sway-free load guidance, which protects component and worker and feeds every part reproducibly in the same position. Which load capacities are possible? Depending on the system up to 1,200 kg with the ZH90 lift axis and up to 800 kg with the articulated manipulator. Equipped for the build-out? Do you manufacture wind components and want to be equipped for the rising build-out? Our engineers are happy to advise you and design your solution individually, Made in Germany, from a single source. For more depth on individual topics, see our guides on handling technology. #HandlingTechnology #WindPower #ComponentManufacturing #Manipulator #LiftAxis #ComponentHandling #zhht

Choosing the right lifting aid determines whether a workstation becomes ergonomic, safe and economical. Anyone moving loads up to 1,200 kg faces the question: manipulator, lift axis, rope manipulator or lifting device? This guide walks you through the selection step by step and shows what matters in terms of load capacity, installation space and application. As a manufacturer from Germany, Zeilhofer Handhabungstechnik has been developing custom lifting aids for 18 industries since 1999. The following criteria help you narrow down the right solution. Custom gripper for 48V generators Step 1: Determine load weight and centre of gravity The most important starting value is the actual weight of the load, including gripper or fixture. The centre of gravity matters too: a load picked up off-centre requires different kinematics than one guided centrally. Up to 100 kg: the Hebelift ZH for light, fast handling. Up to 150 kg: the rope manipulator ZH70 / Acer for suspended loads. Up to 800 kg: the manipulator for sway-free, guided movement. Up to 1,200 kg: the lift axis ZH90 for heavy, precise lifting movements. More on the individual systems: Lift axis ZH90, Articulated manipulator and Rope manipulator. Step 2: Clarify application and type of movement Does the load only need to be raised and lowered, or also turned, tilted and positioned? For purely vertical lifts, a lift axis is often sufficient. For complex movements in space, an articulated manipulator is the right choice because it guides the load sway-free across several axes. Manipulator designs include parallelogram, articulated jib and rope manipulators. The environment also matters: cleanroom, food production or heavy-duty manufacturing place different demands on material, drive and hygiene. Step 3: Check installation space and connection Is a ceiling suspension available, or does the lifting aid need to be floor-standing or mobile? The available installation space, hall height and existing crane runways determine whether a column, wall or ceiling solution makes sense. Step 4: Consider ergonomics and standards A good lifting aid relieves the back and reduces days lost to illness. From 20 January 2027, the new EU Machinery Regulation 2023/1230 also applies, setting higher requirements for the safety of machines and handling systems. Anyone investing today should factor these requirements in already. Select the right lifting aid in just a few steps Not sure which lifting aid suits your application? Our product finder guides you to the right solution in just a few steps and delivers the relevant information for your use case directly. Frequently asked questions Which lifting aid is suitable for heavy loads up to 1,200 kg? For heavy, precise lifting movements up to 1,200 kg, the lift axis ZH90 is suitable. It guides the load stably and positions it precisely. What is the difference between a manipulator and a lift axis? A manipulator moves loads up to 800 kg sway-free across several axes, including turning and tilting. A lift axis is designed for precise vertical lifts up to 1,200 kg. For detailed comparisons, see Manipulator vs. Overhead Crane and Lift Column, Lift Axis or Manipulator. Which lifting aid suits light loads? For loads up to 100 kg the Hebelift ZH is ideal, for suspended loads up to 150 kg the rope manipulator ZH70 / Acer. What changes with the EU Machinery Regulation 2027? From 20 January 2027, Regulation 2023/1230 introduces stricter safety requirements. New lifting aids should already meet these to be future-proof. Find the right lifting aid Use our product finder to select the right lifting aid, or contact us directly. We are happy to advise you on the right solution for your application.

The wind industry is growing, yet manufacturing can barely keep up with the pace. Hubs, generators, flanges and tower segments are heavy and bulky, and the handling slows the lines. Handling technology for the wind industry starts exactly here and speeds up production without requiring more personnel. Manual manufacturing in the wind industry Capacity bottlenecks in the wind industry and their cause The bottleneck rarely lies with the processing machines, but with the heavy manual handling in between. Components often weigh hundreds of kilograms and have to be turned, aligned and joined. If this is done with crane and muscle power, it costs time, is ergonomically critical and hard to put into cycle. Sway-free handling technology takes the weight off and opens up the bottleneck. This makes manufacturing more independent of individual strong workers and easier to plan. That is the prerequisite for managing rising unit numbers at all. Moving heavy components sway-free For vertical lifting of heavy components, the ZH90 lift axis with up to 1,200 kg load capacity is suitable. For turning, flipping and joining hubs or generator components, an articulated manipulator up to 800 kg is used. How heavy, often sensitive flanges are handled is shown in the article Flanges, indispensable and often extremely heavy. More cycle without more personnel Ergonomic lifting aids increase output with the existing team. They lower physical strain, reduce lost workdays and make workstations more broadly staffable. What manual lifting really costs is shown in the article Musculoskeletal disorders in production. Typical bottleneck levers in wind manufacturing: Turn and align hubs and generators sway-free. Join heavy flange connections precisely. Move tower and housing components safely. Design workstations ergonomically to staff them more broadly. Scale step by step Handling technology can be introduced in stages, from the single workstation to the semi-automated line. This lowers the investment risk and allows you to grow with the market. Zeilhofer Handhabungstechnik engineers every solution individually, is certified to ISO 9001 and works in accordance with TISAX Level 2 with prototype protection. An overview of all systems is given in the guide to lifting aids. Frequently asked questions Why do capacity bottlenecks slow wind manufacturing? Because the heavy manual handling between the machines costs time and is hard to put into cycle. Sway-free handling technology takes the weight off and speeds up the process. Which wind components can be handled? Hubs, generators, flanges and tower segments up to 800 kg with an articulated manipulator and up to 1,200 kg with a lift axis, moved sway-free. Does handling technology increase output without more personnel? Yes. Ergonomic lifting aids increase output with the existing team, reduce lost workdays and make workstations more broadly staffable. Can the solution be expanded with growth? Yes. From a single workstation to a semi-automated line, a stepwise expansion is possible, matching market growth. Speed up your wind manufacturing? Do you manufacture wind components and are hitting capacity limits? Our engineers are happy to advise you and design your solution individually, Made in Germany, from a single source. For more depth on individual topics, see our guides on handling technology. #HandlingTechnology #WindIndustry #WindPower #Manipulator #LiftAxis #Ergonomics #zhht