An articulated jib manipulator is a type of industrial manipulator with two or more articulated arm segments connected by pivot joints. The central knuckle joint allows the articulated jib manipulator to fold inward, extending its reach far beyond the working envelope of a rigid arm and giving access to every point in the workspace. The articulated jib manipulator belongs to the family of articulated arm manipulators and is used wherever loads must be positioned pendulum-free in confined stations, behind obstacles or across wide swing ranges. Load capacities range from 50 to 800 kg depending on design. Learn more in our What Is a Manipulator guide. Design and function of an articulated jib manipulator An articulated jib manipulator consists of three main assemblies: the support structure (column, wall or ceiling mount), the two-part arm system with knuckle joint, and the load handling device at the arm tip. The joints are rotatably mounted and transfer the load via mechanical levers to the support structure. Pneumatic or electric drives perform the lifting motion, while the operator guides the load handling device manually or with servo assistance. The defining feature is pendulum-free load guidance. Unlike a crane or chain hoist, the load handling device always moves along a mechanically defined path, without lateral swing. This enables centimeter-accurate positioning and safe work directly on the workpiece. Articulated jib manipulator vs. articulated arm manipulator Both terms are often used interchangeably but describe slightly different designs. A classic articulated arm manipulator has a single knuckle joint between column and arm tip. An articulated jib manipulator features additional intermediate joints and therefore offers greater reach and flexibility, ideal for complex workspaces with obstacles. See also our Articulated vs. Rope Manipulator comparison. In practice, many manufacturers use the terms interchangeably. What matters is not the name, but load capacity, working radius and freedom of movement of the specific design. Application areas The articulated jib manipulator is used wherever a rigid arm is not sufficient: body-in-white, final assembly, battery module handling, machine loading, glass pane handling, tire and wheel mounting. It is particularly suited for takt-bound assembly workstations and confined stations. Typical industries: automotive, e-mobility, special machinery, foundries, glass and window manufacturing, logistics. Load capacities and reach Load capacity: typically 50 to 800 kg; heavier loads up to 1,200 kg are handled by the ZH90 lifting axis Working radius: 1.5 to 4.5 meters depending on configuration Lift height: up to 2.5 meters depending on drive and application Drive: pneumatic, electro-pneumatic or fully electric For higher capacities up to 1,200 kg we recommend the ZH90 lifting axis, the most powerful lifting aid in the ZHHT program with pendulum-free linear guidance. Frequently asked questions What is the difference between an articulated jib manipulator and a crane? An articulated jib manipulator guides the load rigidly and pendulum-free, while a crane transports loads freely swinging on a rope. Articulated jib manipulators are ideal for precision positioning in assembly, cranes for pure transport. What loads can it move? Typical capacities range from 50 to 800 kg. For loads up to 1,200 kg, the ZH90 lifting axis is the right choice. The exact configuration depends on the load handling device, reach and dynamic requirements. Which drives are available? Pneumatics is the most common drive: low maintenance and reliable. Electro-pneumatic and fully electric variants offer higher precision and programmable motion for automation and cleanroom applications. Synonyms and related terms The articulated jib manipulator is also known as articulated arm manipulator, knuckle arm manipulator, articulated boom, parallelogram manipulator (with special lever mechanics) or simply industrial manipulator. In German known as Knickgelenkausleger, Knickarmmanipulator or Gelenkarm-Manipulator. Zeilhofer HHT engineers articulated jib manipulators as customer-specific solutions from a modular system: load capacities from 50 to 800 kg, custom load handling devices, all drive types, Made in Germany. Request a free consultation. This article is part of our guide on how to choose the right lifting aid.

A rope balancer is a pneumatic lifting aid with cable drive that balances loads in suspended state through continuous compressed-air counterforce. Unlike a rigid manipulator, the load is not guided by a mechanical lever system but by a steel cable wound on and off by a pneumatically controlled drum. Rope balancers are the fastest and most economical lifting aids for light to medium loads in high-frequency lifting tasks. They are used wherever speed, ease of use and flexibility matter more than pendulum-free precision positioning. See our Lifting Aids Guide for an overview. How a rope balancer works The rope balancer operates on the principle of pneumatic force balance. A compressed-air cylinder pulls the cable upward with adjustable counterforce, matching exactly the weight of the attached load. Result: the load appears weightless in space and can be moved up and down with minimal force. The operator only feels the inertia of the load, not its weight. A 100 kg load can be lifted with the same ease as a single carton, making rope balancers ideal for series production and high-frequency tasks. Design of a rope balancer A typical rope balancer consists of four main components: the support system (rail, crane or column swing), the pneumatic device body with cable drum and control valve, the steel cable with load handling device, and the pendant control. Compressed-air supply runs through a flexible coiled hose. Modern rope balancers have electronic controls with quick-change mounts for different grippers. Different loads can be handled per shift without retooling, an advantage over rigid manipulators with fixed load handling devices. Application areas Rope balancers suit all lifting tasks with high frequency and medium precision requirements: order picking, packaging, small-parts assembly, tool loading, tire and wheel changing, food handling. Also widespread in test and inspection setups because they can be reconfigured quickly. Common industries: automotive (especially final assembly and logistics), food industry, packaging, pharma, electrical engineering and mechanical engineering. Rope balancer vs. articulated arm manipulator Rope balancers and the articulated arm manipulator are the two classic manipulator designs, with clearly different strengths. The rope balancer is faster, lighter and cheaper, but the load hangs on the cable and can swing. The articulated arm manipulator guides the load rigidly and pendulum-free, but is more expensive and slower. Rule of thumb: for loads under 150 kg, high frequency and tolerance for slight pendulum motion, the rope balancer is the most economical solution. For loads above 150 kg, confined stations or centimeter-accurate positioning, the articulated arm manipulator pays off. Detailed comparison: Articulated vs. Rope Manipulator. Load capacities and technical data Load capacity: 5 to 150 kg Lift height: up to 3 meters Working radius: depending on support/rail system, typically 3 to 8 meters Drive: pneumatic (standard), electro-pneumatic (with quick-change) Response: operator force typically under 5 newtons for full capacity Frequently asked questions What is the difference between a rope balancer and a cable hoist? A cable hoist lifts at constant speed by push-button, so the load cannot be finely guided. A rope balancer balances the load weightlessly; the operator guides it by hand. This is many times faster and more intuitive. Do I need compressed air? Yes, classic rope balancers are pneumatic. Electrically balanced variants (intelligent lifting devices) work without compressed air, but they are more expensive and require more maintenance. How fast is a rope balancer? Operating cycles under 5 seconds are typical. A rope balancer is usually two to three times faster than a comparable articulated arm manipulator. This is the main reason for its prevalence in series production. Synonyms and related terms The rope balancer is also called pneumatic rope manipulator, rope manipulator, pneumatic balancer, compressed-air balancer, intelligent balancer (with electronic control) or lifting balancer. In German: Seilbalancer, Seil-Manipulator, pneumatischer Balancer. Zeilhofer HHT offers rope balancers as Acer (floor station) and ZH70 (ceiling-mounted) with capacities up to 150 kg: pneumatic, with quick-change mounts, custom load handling devices and worldwide delivery. Made in Germany. Request a free consultation.

A parallelogram manipulator is a type of industrial manipulator in which the load is guided by a parallelogram lever mechanism. Four articulated levers form a closed parallelogram that keeps the load parallel to the ground during lifting and lowering, without requiring any adjustments from the operator. Parallelogram manipulators are used wherever components need to be lifted, transported, and positioned in a fixed position. They are the most mechanically elegant solution when loads must not tip or change orientation during lifting. An overview of all lifting aid types can be found in the guide "Lifting Aids for Production, Industry, Warehousing, and Logistics". How parallelogram mechanics works The parallelogram manipulator consists of two long, parallel levers connected by two short transverse levers to form a closed quadrilateral. This quadrilateral deforms into a tilted parallelogram during lifting, but retains the parallelism of its sides and thus the orientation of the load-bearing device. In mathematical terms: Even if the lifting angle changes, the angle between the load-bearing device and the ground remains constant. Therefore, a load is always lifted and lowered horizontally, without the operator having to readjust its orientation. Construction of a parallelogram manipulator A parallelogram manipulator consists of three main components: the column or support structure, the parallelogram arm system with pneumatic or electric lifting drive, and the load-bearing device at the end of the arm. The drive generates the lifting motion, which the parallelogram mechanism translates into a horizontal load movement. The load is weight-balanced via pneumatic pressure. The operator does not have to hold the full load, but only overcome the inertia: a typical parallelogram manipulator lifts 200 kg with an operating force of just a few Newtons. Areas of application Parallelogram manipulators are used wherever components need to be lifted in a stable position: for handling glass panes, solar panels, liquid containers, batteries, filled boxes, or workpieces during assembly. They are also common in the food and pharmaceutical industries when containers need to be transported without tipping. Industries with high prevalence: Automotive (especially e-mobility and battery assembly), glass and window industry, semiconductor industry, mechanical engineering and logistics. Parallelogram manipulator vs. articulated boom Both are pendulum-free manipulator designs. The crucial difference lies in the load orientation. An articulated boom or articulated arm manipulator guides the load without pendulum movement, but the load-bearing element can slightly change its orientation during swiveling. A parallelogram manipulator keeps the load permanently in the same orientation via its mechanical parallel guide, without servo motors or sensors. Advantages of a parallelogram boom: purely mechanical position retention, high reliability, low maintenance. Disadvantages: shorter reach and less flexibility than an articulated boom with intermediate joints. Load capacities and technical data Load capacity: typically 50 to 800 kg; heavier loads up to 1,200 kg are handled by the ZH90 lifting axis Working radius: 1.5 to 3 meters Lifting height: up to 2 meters Drive: pneumatic, electropneumatic or fully electric Position retention: purely mechanical via parallelogram lever For loads over 800 kg and up to 1,200 kg, we recommend the ZH90 lifting axis with linear load guidance, the most powerful lifting aid in the ZHHT program. Frequently Asked Questions about the Parallelogram Manipulator What is a parallelogram manipulator used for? For all lifting tasks where the load must remain horizontal or in a fixed orientation, for example, when lifting glass panes, battery modules, liquid containers, or workpieces with an asymmetrical center of gravity. Can a parallelogram manipulator also be operated electrically? Yes. Modern parallelogram manipulators are available in pneumatic, electropneumatic, and fully electric versions. Electric versions are ideal for cleanrooms, food processing, and pharmaceuticals, where compressed air should be avoided. What is the difference between this and an articulated arm manipulator? The articulated arm manipulator has a single articulated joint and can swivel the load-bearing device. The parallelogram manipulator, on the other hand, holds the load in the same orientation using its parallelogram mechanism. The load remains horizontal. Synonyms and related terms The parallelogram manipulator is also known as: parallel-arm manipulator, parallelogram lifting aid, parallel-guided manipulator, or parallelogram lifting arm. In English-speaking countries, it is commonly called a parallelogram manipulator or parallel-arm lifter. Zeilhofer HHT designs and manufactures parallelogram manipulators and lifting aids with parallel guidance as customized solutions from a modular system: load capacities up to 800 kg (up to 1,200 kg with the ZH90 lifting axis), individual load handling devices, Made in Germany. Get a free consultation now. This article is part of our guide on how to choose the right lifting aid.

Choosing the right lifting technology means understanding the task first, then the system. Knowing the load, direction of movement, and cycle time allows you to make a decision that will last 15 to 20 years. That's precisely what the guide from Zeilhofer Handhabungstechnik in Holzkirchen is for: over a dozen articles on selection, drive systems, safety, and application. Manufacturer-neutral, objective, and without sales pressure. Step 1: Determine the appropriate system Manipulator, lifting axis, or hoist? The fundamental question determines everything else. A manipulator moves loads up to 800 kg smoothly and in a stationary position. A ZH90 lifting axis performs linear movements along the Z-axis up to 1,200 kg. The Hebelift ZH is mobile, battery-powered, and moves loads up to 100 kg without compressed air. For a clear distinction between manipulators, cranes, and chain hoists, see the basics: What is a manipulator? and What is a lifting axis? Step 2: Select the drive Pneumatic or electric? Compressed air is robust and inexpensive to purchase, while electric systems score points for energy costs, precision, and documentation. There is no universally better concept, only a suitable one. This drive guide compares the concepts based on energy consumption, maintenance, and application. Step 3: Clarify ergonomics and safety Lifting technology is essential for workplace safety. Manually lifting heavy or awkwardly shaped components creates strains that accumulate over years. The guide to ergonomics at the assembly workstation shows where these strains originate and how they can be reduced. Those already using lifting equipment should also be aware of the annual safety inspection (UVV): the requirements, procedures, and deadlines are all compiled in the guide hub. Step 4: Classify application and industry Logistics, automotive final assembly, commercial kitchen equipment, or special-purpose machine construction: every industry has its own requirements for grippers, reach, and cycle times. The guide "Lifting Aids" provides an overview of industrial lifting aids according to load and application. Zeilhofer Handhabungstechnik is active in 18 industries, with customers in over 50 countries. Ergonomics and cost-effectiveness A lifting aid pays off on two levels. Ergonomically, it reduces sick days and strain-related injuries because one person guides loads instead of lifting them. Economically, it shortens cycle times, reduces damage to components, and ensures stable operation for 15 to 20 years. The investment is not measured solely by the purchase price, but by the avoided follow-up costs of incorrect posture, scrap, and downtime. Individual interpretation Standard solutions rarely fit perfectly. Zeilhofer Handhabungstechnik designs manipulators, grippers, and fixtures to specific components using a modular system. Engineering, design, manufacturing, commissioning, and service are all provided from a single source. Certified according to ISO 9001 and TISAX Level 2 with prototype protection, a crucial factor for sensitive components and pre-production runs. Frequently asked questions: Choosing the right lifting equipment Which lifting system is suitable for my load? This depends on weight, direction of movement, and workplace. A manipulator guides loads up to 800 kg smoothly and stationary, a ZH90 lifting axis moves up to 1,200 kg linearly along the Z-axis, and the Hebelift ZH operates mobile and battery-powered up to 100 kg. The system selection guides compare the different types step by step. Pneumatic or electric: which is better? Pneumatic systems are robust and inexpensive to purchase, while electric drives score points for energy costs, precision, and documentation. The application determines which concept is suitable. This drive guide objectively compares both concepts. How often does a lifting aid need to be inspected? Lifting aids are subject to annual safety inspections. Functionality, safety devices, and wear parts are inspected by a qualified person. Details regarding the requirements, procedures, and deadlines can be found in the safety inspection guide. Is handling technology also available as a custom solution? Yes. Zeilhofer Handhabungstechnik designs and manufactures manipulators, grippers, and fixtures from a modular system, tailored to specific components. Engineering, design, manufacturing, commissioning, and service are all provided in-house in Holzkirchen, Germany. Next step regarding lifting technology All guides can be found in one place in the guide hub. Do you have a specific handling question? Speak directly to the design team or take a look at the product overview. #HandlingTechnology #LiftingTechnology #Manipulator #LiftingAid #Ergonomics #Intralogistics #OccupationalSafety #MechanicalEngineering #MaterialFlow #Industry #Holzkirchen

What happens when you rethink two proven systems and combine their strengths in a single unit? This very question was the starting point for our latest development. The result is the ZH90 Flex-Arm lifting axis, a handling solution that combines the flexibility of a manipulator with the precise, pendulum-free load guidance of a lifting axis. In this article, we show what distinguishes the ZH90 Flex-Arm, for which applications it was developed, and why pendulum-free load guidance makes a real difference in modern production environments. Two systems, one unit Manipulators are known for their flexibility. They reach wide working areas and can be used in a variety of ways. Lifting axes, on the other hand, stand for precise, controlled lifting in the Z-direction. Both systems have their strengths, but in many applications, users desire precisely the combination of both. With the ZH90 Flex-Arm lifting axis, we have achieved this combination. The system guides loads as flexibly as a manipulator and simultaneously as precisely and stably as a lifting axis. The result is maximum control, ergonomic operation, and a movement experience that has to be felt to be believed. The highlights of the ZH90 Flex-Arm lifting axis at a glance The ZH90 Flex-Arm lifting axis was consistently designed for precision, ergonomics, and efficiency. These are the characteristics that distinguish the system: ✓ Load capacity up to 200 kg ✓ Completely pendulum-free load guidance for precise positioning ✓ 4-meter operating radius for maximum freedom of movement ✓ Optional 48-volt battery power for completely wireless operation ✓ Four mounting options: floor or ceiling, stationary or mobile ✓ Ergonomic and intuitive handling even with complex movement sequences Each of these points is the result of over 25 years of experience in the construction of lifting aids and manipulators. Why pendulum-free load guidance is crucial Traditional rope or chain systems have an inherent weakness: the load hangs freely and begins to swing with every movement. This wastes time because the operator has to compensate for every oscillation, and it poses a safety risk if heavy components swing uncontrollably. The ZH90 Flex-Arm lifting axis fundamentally solves this problem. The load remains stably guided and precisely controllable at all times. No oscillation. No unnecessary corrective movements. No compromises in precision and ergonomics. For the operator, this means noticeably more relaxed working conditions. For the process, it means shorter cycle times and reproducible results. This rigid guidance pays off immediately, especially when positioning delicate or heavy components with millimeter precision. Four mounting options for every hall No two production environments are the same. That's why the ZH90 Flex-Arm is available in four mounting options: • Stationary on the floor, for fixed workplaces with a clearly defined area of operation • Mobile on the floor, if the system is needed in changing positions • Stationary on the ceiling to keep valuable floor space free • Movable on the ceiling, for maximum flexibility along a track This allows the system to be integrated into existing hall structures, rather than requiring the hall to be adapted to the system. The right option depends on your layout, traffic flow, and component flow. We would be happy to advise you on this. Work wirelessly with 48-volt battery power The ZH90 Flex-Arm lifting axis can be equipped with a 48-volt battery upon request. This allows the system to operate completely wirelessly and independently of a fixed compressed air or power supply at the installation site. This opens up new possibilities: flexible workspaces, easy layout adjustments, and a tidy work environment without disruptive utility lines. The battery technology is derived from our experience with the battery-powered Hebelift ZH and is designed for continuous industrial use. For which industries was the ZH90 Flex-Arm developed? The ZH90 Flex-Arm lifting axis is suitable wherever components need to be moved precisely, safely, and ergonomically. Typical applications include the automotive and e-mobility industries, mechanical and special-purpose machine construction, logistics, and general assembly. The ZH90 Flex-Arm's pendulum-free load guidance system demonstrates its advantages particularly in areas where rope or chain systems were previously used. It is also worth considering as a supplement to or alternative to a conventional articulated arm manipulator. Designed and manufactured in Germany The ZH90 Flex-Arm lifting axis was developed and manufactured by Zeilhofer Handhabungstechnik in Holzkirchen. From design and fixture construction to commissioning, everything is done in-house. This ensures short communication channels, high quality, and a single point of contact who knows the system inside and out. For modern production processes where precision, ergonomics and efficiency are crucial, the ZH90 Flex-Arm is an investment that makes a difference in everyday work. Get to know the ZH90 Flex-Arm Every application is different. That's why we configure the ZH90 Flex-Arm lifting axis specifically for your project, according to your requirements, from the load capacity and mounting option to the appropriate fixture. Let's work together to develop the right solution for your application. Contact us and experience the ZH90 Flex-Arm lifting axis live. #ZeilhoferHHT #LiftingAxisZH90FlexArm #HandlingTechnology #Manipulator #LiftingAxis #Industry #MechanicalEngineering #Ergonomics #Production #SpecialMachineEngineering #Innovation #MadeInGermany

In many production and assembly areas, the variety of components is constantly increasing. Different shapes, weights, and requirements mean that classic handling solutions quickly reach their limits. This is precisely where our new articulated arm manipulator with interchangeable gripper system comes in. The solution was specifically developed to handle a wide variety of components simply, quickly, and safely, without lengthy changeover times or complicated processes. The intelligent interchangeable gripper system allows for flexible switching between different picking and gripping solutions. This saves time, reduces strain on employees, and ensures maximum efficiency in daily work. Frequently asked questions about the manipulator with interchangeable gripper system What is a changeover gripper system? A quick-change gripper system allows for the rapid exchange of different grippers on a single manipulator. This enables the safe and efficient handling of various components using only one handling system. For which components is the system suitable? The system is suitable for a wide variety of components, from sensitive components to heavy or complexly shaped workpieces. What are the advantages of a manipulator with an interchangeable gripper system? The main advantages are greater flexibility, reduced changeover times, ergonomic working, more process reliability and more efficient production. Can the system be customized? The interchangeable gripper system is individually developed and precisely adapted to the requirements of the respective company and the components. Do you want to make your handling processes more flexible? Then talk to us. Together we develop a customized handling solution that perfectly suits your components, processes and requirements: efficient, ergonomic and future-proof. #zhht #HandlingTechnology #Automation #Industry40 #ProductionTechnology #MechanicalEngineering #IndustrialAutomation

In the dairy industry, every detail counts, not only in terms of product quality, but also with regard to occupational safety, ergonomics, and hygiene. Repetitive lifting and stacking of heavy block molds is part of everyday life in many production facilities and represents a considerable physical strain for employees. At the same time, the handling solutions used must meet the strictest hygiene requirements. We have developed an articulated arm manipulator for dairy plants precisely for this challenge, combining ergonomic operation with consistent hygienic design. The starting point in dairy production In modern production lines, molds containing cheese, quark, or other delicate products must be handled, rotated, and stacked with precision. The requirements are demanding: Weight of the block molds: approx. 85 to 90 kg Dimensions: 1,100 × 570 × 100 mm Stacking height: up to 1.80 m Side pickup of the mold without damage Fully food-safe, washable surfaces Manual lifting in this weight and frequency class is neither ergonomically sound nor economically viable in the long run. Illness-related absences, risk of injury, and long-term musculoskeletal problems are the inevitable consequences. The solution: Articulated arm manipulator for dairy plants Our articulated arm manipulator for dairy plants relieves the operator of the entire load and enables virtually weightless handling of the block molds. A pneumatic load compensation system allows the workpiece to "float" in any desired position. Lifting, rotating, swiveling, and stacking are performed with minimal effort and intuitive hand guidance. The specially developed gripper securely picks up the block molds from the side, ensuring reliable processing even of delicate geometries. Its reach and lifting stroke are designed to effortlessly achieve stacking heights of up to 1.80 m, deliberately without electric travel, relying solely on ergonomic lifting assistance technology. Hygienic Design: Conformity considered from the outset Food-related applications require uncompromising design in accordance with applicable standards. Our articulated arm manipulator for dairy plants meets these requirements: DIN EN 1672-2: Food processing machinery, hygiene requirements DIN EN ISO 14159: Hygiene requirements for machine design Regulation (EC) No 852/2004 including the HACCP concept Hygienic design principles: closed profiles, smooth surfaces, washable, without dirt traps or dead spaces. Material selection, weld design, gap dimensions and surface roughness are designed to ensure that cleaning and CIP processes can be carried out reliably and efficiently. This is a key factor for the auditability of the entire production line. Advantages at a glance ✅ Noticeable ergonomic relief for employees ✅ Reduction of illness-related absences and injury risks ✅ Safe stacking of block molds up to 1.80 m high ✅ Full hygienic design and HACCP compliance ✅ Pneumatic lifting aid principle without electrical travel paths ✅ Seamless integration into existing production processes For which industries is the articulated arm manipulator of interest? What was developed for dairy plants is also suitable for many other hygienically sensitive areas of the food and process industries: Cheese dairies and creameries Meat and sausage production Bakery and convenience food production Pharmaceutical and cosmetics production Packaging and stacking processes with hygienic requirements Your next step Are you looking for a customized lifting aid for your production facility with hygienically sensitive requirements? We will work with you to develop the right solution, from the concept phase through standards-compliant design to commissioning. Contact us. We'll take the weight off your shoulders. #zhht #articulatedarmmanipulator #dairies #hygienicdesign #foodindustry #liftingaid #ergonomics #HACCP

How a custom-made assembly fixture from Zeilhofer HHT makes the production of sliding steps and boarding aids for rail vehicles faster, safer and more reproducible. Zeilhofer HHT assembly fixture with two synchronized ZH90 lifting axes for mounting sliding steps. Sliding steps, the underestimated key component in passenger flow A sliding step extends and retracts well over a million times during its lifespan, in all kinds of weather, in ice and snow, at every single stop. It is the transition between the platform and the vehicle, closes the gap to the platform edge, and is therefore one of the most safety-relevant components on the rail vehicle. Behind this seemingly simple feature lies a technically sophisticated product with an electric toothed belt drive, safety interlock, switching strips, light barriers, and sensors for motor current and distance-time measurement. Leading manufacturers of rail vehicle door systems supply these systems in several product families for light rail, metros, regional trains, intercity, and high-speed trains worldwide. The designs are becoming ever wider, more complex, and more varied. Before they can be put into service, however, they undergo a complex assembly process. This is precisely where our new assembly fixture comes in. The challenge in assembly Complete sliding steps are large, heavy, and geometrically unwieldy. The drive mechanism, locking system, sensors, safety edges, light barriers, tread plate, control unit, and wiring are all integrated into a single module, sometimes weighing several hundred kilograms and with component widths of up to 1,500 mm. For the operator, this means the following in a classic setup: Gripping, holding and aligning, component by component, screw by screw Working overhead or on the ground because the step doesn't rotate Lifting with two people or positioning with improvised crane solutions Constantly turning the top and bottom sides, depending on the installation type (insert, built-in or under-floor step) This costs strength, time, and concentration. It leads to inconsistent tightening torques, a higher reject rate, and, above all, physical wear and tear on employees. Often, the assembly of a single sliding step is the bottleneck for an entire production line. The solution: An assembly fixture with two synchronously moving ZH90 lifting axes Instead of pushing the process to its limits, we reimagined it. Our solution combines two linear aluminum lifting axes (ZH90) that support the sliding step on the left and right, with a continuously swiveling mounting frame in between. The entire system rests on a floor-guided rail system, movable and precisely reproducible. Specifically, this means for the worker: The entire sliding step is clamped in place once, and stays there. The two ZH90s lift the component weightlessly and in parallel to any desired height. The operator can rotate the sliding step continuously into any working position using the swivel mechanism. All activities, above, below, on the drive, sensors and switching strips, are carried out at an ergonomic height. Operation is via a central terminal that triggers both axes synchronously. The system does not work against the worker, it works with him. The unique selling point: synchronized parallel stroke What makes this fixture unique on the market is the precisely synchronized movement of both ZH90 lifting axes. Both columns move parallel, at identical speed and in identical position, throughout the entire stroke. There is no overshoot, no tilting, and no need for subsequent alignment. This is precisely the technical requirement for being able to guide a rigid, wide sliding step smoothly. With classic single-lift columns or conventional crane solutions, this plane-parallel load guidance cannot be reliably achieved. Even the slightest deviations cause stress on the component and damage attachments such as switching strips, light barriers, or locking elements. The ZH90 already offers the necessary prerequisites as standard: rigid load guidance, high torsional stiffness (3,000 Nm), a load capacity of up to 1,200 kg per axis, and a repeatable linear stroke of up to 1,600 mm. We have mounted two of them on a common rail system, synchronized them mechanically and in terms of control, thus creating a lifting unit that can move an entire sliding step as a single component. Continuous swiveling: the component follows the worker The second key component of the fixture is the continuously rotatable mount. The sliding step is not rigidly held between the two ZH90s, but rather mounted on a continuous pivot axis. This allows it to be positioned at any desired angle, horizontally, vertically, and in any intermediate position. In practice, this means that the worker adapts the component to their body position, not the other way around. Screw points that previously had to be reached while lying down or overhead are now more easily accessible. The result: Ergonomic working height in every assembly phase Reproducible movement sequences and more consistent tightening torques Significantly less strain on shoulders, back and knees Shorter cycle time because no changeover of the workpiece carrier is necessary Higher quality due to a constant field of view of the respective mounting point Which sliding steps can be mounted with this fixture The fixture is designed for the entire range of modern sliding step platforms. Stroke, pivot axis and mounting geometry are dimensioned for each individual component, while the underlying double ZH90 platform remains identical. Technical specifications of the fixture Performance feature Value Lifting axes used 2 × ZH90, parallel synchronized Load capacity per axis up to 1,200 kg Suitable component width (clear entry) approx. 800 to 1,500 mm (suitable for common sliding step systems) Stroke max. 1,600 mm per axis Component swivel range stepless, > 180° Travel path on rails customized Drive electric, synchronized Control Operating terminal with central release Safety compliant with Machinery Directive 2006/42/EC, CE compliant Certifications ISO 9001, TISAX Level 2 with prototype protection The stroke, swivel range, mounting geometry and travel length of the floor rail are individually designed for each customer's specific sliding step. Who might find this fixture interesting? Manufacturers of sliding steps and entry aids The solution is specifically designed for the final assembly of sliding steps for rail vehicles. It is suitable for OEMs and their Tier 1 suppliers in the rail sector, as well as other European and international providers of sliding steps and boarding aids for high-speed trains, regional trains, metros, and trams. Manufacturers of other large-area, heavy panel assemblies The combination of parallel synchronized lifting and stepless swiveling is valuable wherever a large, bulky component needs to be mounted in different positions across several stations. Typical applications outside of sliding step installation include: Ramps, platform lifts and extendable boarding aids for vehicles and buildings Large-area high-voltage storage systems and battery housings in electromobility Body modules, floor and side wall assemblies in commercial vehicle and special vehicle construction Control cabinet and enclosure construction in energy technology Large equipment and machine modules in plant engineering Plate-shaped heavy-duty components in cleanroom and semiconductor manufacturing Engineering from Germany: complete solutions from a single source We develop, design, manufacture, and maintain every system ourselves, from the initial requirements specification through design and steel construction to commissioning at the customer's site. Using the standard ZH90 modular system, we create a fixture that is precisely tailored to your component, cycle time, and warehouse logistics. What you as a customer receive from us: Complete mechanics including floor rail system and mounting frame Synchronized control of both lifting axes with a customer-specific operating concept CE conformity assessment and full documentation On-site commissioning, training and service, worldwide Certified quality according to ISO 9001 and TISAX Level 2 with prototype protection Talk to us Do you manufacture sliding steps for rail vehicles or a similar heavy, wide-area component and are looking for a solution that allows your employees to work more ergonomically, faster, and more reproducibly? Then please get in touch with us. #zhht #railwaytechnology #railvehicletechnology #slidingstep #assemblydevice #ergonomics #liftingaxisZH90

14 kg may sound manageable at first, but if battery casings have to be moved frequently, it quickly becomes a real burden for employees. Unwieldy geometries, repetitive movements and high cycle times lead to physical strain in everyday life and, in the long term, to limitations. Our solution for battery housing handling: a specially developed gripper for battery housings. It makes this possible: ✅ Safe pickup ✅ Precise movement ✅ Flexible rotation and swiveling of components This allows the worker to optimally reach every side of the housing and perform his tasks without restrictions. Even seemingly "light" components require thoughtful handling, especially when they are moved in production cycles. #zhht #handlingtechnology #automotiveindustry

TISAX® (Trusted Information Security Assessment Exchange) is the recognized automotive industry standard for assessing information security. It ensures that sensitive information, prototypes, and business-critical systems are reliably protected. ✅ Confidentiality: Confidential customer and development data is protected from unauthorized access. ✅ Protection of Prototype Parts and Components: Prototypes and pre-production parts are physically and organizationally secured. ✅ High Availability: Important systems and processes remain stable and available. 👉 For our customers, this has meant reliable protection of sensitive information, consistent safeguarding of prototypes and pre-series parts, and the stable availability of central systems and processes for years. Zeilhofer HHT holds TISAX Level 2 with prototype protection. #zhht #TISAX #InformationSecurity #CyberSecurity #PrototypeProtection

✅ Specially developed for passenger car tires Optimized for safe picking up, moving and putting down in everyday work. ✅ Battery-powered and flexible in its use The power supply is provided via a rechargeable battery, completely without cables or hoses. ✅ Product recognition The system detects the tire and automatically stops in the correct position. ✅ Extendable gripping device For maximum flexibility in handling in different situations. ✅ In-house developed omni-wheels They enable virtually floating movement in all directions. #zhht #mechanicalengineering #automotiveindustry

With our new ZH90 lifting axis with suction device, the handling of glass elements becomes a clean & controlled process. The key functions: ✅ A strong suction device for the secure holding of various glass elements ✅ Swivel function for flexible alignment of the elements ✅ Rigid load guidance for precise, smooth handling without pendulum movements ✅ Mobility within the rail system for an extended working area The result is a consistently controlled process, from pickup to positioning, while noticeably relieving the burden on employees. #zhht #glassindustry #handlingtechnology