A single wall stone can weigh up to 130 kilograms, with dimensions of up to 80 x 35 x 25 centimeters. At the Weißenburg gravel and stone plant, these blocks are no longer lifted by hand from the conveyor belt onto pallets; since 2021, this task has been handled by a manipulator from Zeilhofer Handhabungstechnik. In Germany, the amount of weight that is generally considered acceptable for manual lifting is regulated by the Manual Handling Ordinance (Lastenhandhabverordnung). More information can be found in the article "How many kg can you lift? Limit values and the key indicator method". Our guide "Industrial Lifting Aids" provides an overview of all types of lifting aids. ZHHT manipulator for handling natural stone at the Weißenburg gravel and stone plant One company in focus: Retaining skilled workers, making work easier A recent BR24 report on the German labor market highlights the challenges facing many medium-sized companies: finding skilled workers, retaining experienced employees, and making jobs future-proof. The report uses the Weißenburg gravel and stone plant as an example. Long-serving employees will be retiring in the coming years, and according to Managing Director Jens Geiger, replacements can't be found overnight. Attractive jobs aren't just created through recruitment strategies, but also directly where employees work every day. This is precisely where our collaboration with the Weißenburg gravel and stone plant begins, a partnership that existed even before the BR24 report. The manipulator in detail: Column device with gripping device For the project “Stacking bricks onto pallets”, Zeilhofer Handhabungstechnik designed a pneumatic handling manipulator as a stationary column device, firmly anchored to the floor, with a working radius of 3,500 millimeters in relation to the product and a working stroke between 100 and 1,000 millimeters. The movement is driven by a robust articulated arm, similar to the one used in our articulated manipulator: The main axis can be manually rotated 330 degrees, the arm rotates continuously 360 degrees, and the gripping device itself rotates another 330 degrees. This allows the manipulator to achieve any orientation required for stacking on the pallet. The gripping device secures the bricks laterally with a pneumatic gripper unit, and specially shaped gripper jaws ensure a secure hold on various brick sizes. A dual-circuit smooth-running balancing control automatically switches from the preset empty weight to the respective load weight, enabling the movement of bricks of different sizes without manual readjustment. The control unit is positioned at two different heights and offset by 90 degrees, allowing operators of varying heights and from different positions to use it. With a weight of 420 kilograms and a noise level of less than 70 decibels per double stroke, the manipulator integrates discreetly into the workplace. From conveyor belt to pallet: the working method The manipulator picks up the bricks from the conveyor belt and places them on pallets, with each loaded pallet reaching a height of up to 1,000 millimeters. The bricks are picked up from above, along their long sides. For upward and downward movements without a brick, the operator doesn't need to operate any buttons or levers; only when gripping does the operator actively move the gripper towards the brick. Guides and a centering mechanism ensure the correct positioning of the brick before gripping. The worker guides the movement, while the manipulator bears the weight of the stones, which can weigh up to 130 kilograms. Repeated lifting and balancing results in a controlled, repeatable sequence of movements. Safe for continuous use The manipulator features a compressed air reservoir with a check valve, which allows for a controlled termination of the work cycle in the event of a power failure. The gripper only releases after it has been safely lowered and completely relieved of pressure. An additional safety device prevents the boom from snapping upwards in the event of a load break, and further check valves protect against hose rupture. The design complies with the EC Machinery Directive 2006/42/EC and the harmonized standards EN ISO 12100-1 and EN ISO 12100-2; the risk assessment is carried out according to EN ISO 14121-1. Like any lifting aid, this manipulator is also subject to annual accident prevention testing according to DGUV Regulation 54; more information can be found in the guide: Accident Prevention Testing for Lifting Aids. Less effort, more safety: the advantages at a glance Form-fitting, secure gripping of masonry blocks between 250 and 800 mm in length Reliable handling for weights up to 130 kg per stone Automatic switching between empty and loaded weight without manual readjustment Swing-free, low-effort movement from the conveyor belt to the pallet quiet operation below 70 dB Safety devices against load loss and hose rupture In daily practical use at the Weißenburg gravel and stone plant since 2021 Handling technology that suits the natural stone industry Natural stones are not standardized building components; they vary in size, shape, weight, and surface. A handling solution must therefore be precisely tailored to the specific task: How heavy is the load, what shapes and sizes are present, how frequently does the handling process occur, and what does the workplace look like? Zeilhofer Handhabungstechnik from Holzkirchen designs manipulators for 18 industries based on precisely this principle. "What is a manipulator?" explains its functionality in detail. Our guide shows how a specific customer requirement can lead to an individual special solution like this one: Special machine construction and special solutions. When skilled workers are hard to find and the goal is to retain experienced employees long-term, the question of physically less strenuous workplaces becomes increasingly important. While handling technology cannot provide a complete answer, it can make a significant contribution. Our guide "Ergonomics at the Assembly Workplace" shows how to fundamentally reduce strain when lifting. How to handle your natural stones or wall stones more ergonomically? Do you move heavy stone blocks, bricks, or other unwieldy loads by hand in your company? Our engineers will develop a custom-designed manipulator for you, from the initial requirements analysis to the fully operational system. Made in Germany, from a single source. Frequently asked questions about the natural stone manipulator How does the manipulator work when stacking bricks? The manipulator picks up the stones from the conveyor belt, and a pneumatic gripper unit grips them securely from the side. The operator guides the movement, and the manipulator carries the weight until it is placed on the pallet. How heavy and large are the stone blocks that the manipulator handles? The wall stones are between 250 and 800 mm long, 200 to 350 mm wide and 120 to 250 mm high, weighing up to 130 kg per stone. What is the working area of the manipulator? The working radius is 3,500 mm relative to the product, and the working stroke ranges from 100 to 1,000 mm. Since when has the Weißenburg gravel and stone plant been using the manipulator? The solution was designed by Zeilhofer Handhabungstechnik in 2021 and has been in daily use ever since. What safety features does the manipulator have? A compressed air reservoir with a check valve allows for the safe termination of the work cycle in the event of a power failure; an additional safety device prevents the boom arm from springing upwards in the event of load loss. The design complies with EC Machinery Directive 2006/42/EC. How loud is the manipulator during operation? The noise level is below 70 decibels per double stroke, which allows for use close to the workplace without additional noise pollution. Can the manipulator also be adapted for other natural stone products? Yes. The receiving device and gripper unit are individually adapted for each project to the dimensions, weight and surface of the respective stone product. Can the manipulator be operated by different employees? Yes, the control unit is arranged in two heights and additionally offset by 90 degrees, so that it adapts to different body sizes and working positions. Does the manipulator need to be checked regularly? Yes, like any lifting aid, it is subject to the annual accident prevention inspection according to DGUV Regulation 54.

A pneumatic handling manipulator has several specific advantages in the logistics industry compared to an overhead crane or jib crane when handling heavy wooden boxes 🚚📦🚢✈️: 1. Power support and ergonomics 🦾 Our manipulator uses compressed air to assist with lifting and moving heavy loads. This significantly reduces the amount of effort required by staff and protects the health of employees. Especially when repeatedly lifting heavy boxes, as is often the case in logistics, the use of manipulators reduces the strain on the back and joints. 2. Precise and safe positioning 🕹️ The manipulator allows precise lifting, lowering and positioning of heavy wooden boxes, as the speed and position can be controlled with little effort by the operator. The uniform pneumatic support and rigid load guidance help to move even bulky or difficult to handle boxes safely, which reduces the risk of accidents. 3. Reduction of physical fatigue ⤵️ Thanks to compressed air support, employees have to exert less physical effort, which reduces fatigue and thus increases productivity in everyday work. This has the advantage that performance can be maintained over longer periods of time and fewer breaks are necessary due to overload. 4. Increase productivity 📈 Since the pneumatic manipulator makes it easier to lift and place heavy loads, employees can work faster and more efficiently. This speeds up the entire logistics process, as wooden boxes can be moved without much effort and in less time. 5. Mobility and flexibility 🤸 In contrast to an overhead crane or jib crane, which is usually mounted on a rail or a fixed point and can therefore only serve a certain area, our pneumatic manipulator is freely movable & can be used flexibly within a larger radius. It can therefore be used more flexibly in different areas of a warehouse or factory hall without being limited to rails. 6. Space-saving solution 📐 Pneumatic manipulators take up significantly less space and can also be used in lower rooms or at workstations with limited space, where an overhead crane would often be impractical or even impossible to install due to space restrictions. 7. Safety and reducing the risk of accidents 🦺 Since the operator of a manipulator is in direct contact with the load and has sensitive control, sudden movements can be better controlled and the risk of pendulum movements or uncontrolled swinging of the load is minimized. With an overhead crane, on the other hand, swinging movements can occur that could compromise safety. For lifting and moving heavy wooden boxes, the pneumatic handling manipulator offers better ergonomics, greater flexibility, smaller space requirements and more sensitive control of the load. An overhead crane would be useful if very heavy or particularly large loads have to be moved that exceed the capacity of a manipulator, or if large areas with heavy loads have to be served regularly. #zhht #Logistics #SupplyChain #Transport #Shipping #WarehouseLogistics #Freight #LogisticsInnovation #SupplyChainManagement #LogisticsTrends #FlowofGoods #EfficientLogistics

A plastic pipe coil or pipe bundle is an arrangement in which several plastic pipes are grouped together in a spiral or ring-shaped structure. 💍 🏭 This structure allows for compact and orderly storage and transport of the pipes, but also has some disadvantages. The biggest disadvantage is probably the size and weight of the pipe bundles and the associated handling and transport. 🏗️ 🫣 However, with the help of our pneumatic lifting aid for pipe coil handling, these bundles of pipes of different sizes and weights can be lifted and moved efficiently and safely. 🔝 🦺 #zhht #pipebundles #ringbundle #plasticpipes #polyethylene #polyvinylchloride #polypropylene #liftingaid

Door leaves are the moving parts of a door, usually made of #wood, #plastic, #metal or other materials. They are the surfaces that can be opened to allow passage through a door. #Door leaves can have different shapes, sizes, weights and designs. Our ZH90 lifting axis enables the precise picking up, turning and positioning of a wide variety of door leaves. It also brings: Increased #safety 🦺 Reduction of work accidents: Door leaves are heavy and unwieldy, which can lead to injuries during manual handling. Our lifting axes minimize this risk. Less physical #strain: Workers are subjected to less physical strain by using our lifting axis, which offers long-term health benefits. Increased #efficiency and #productivity 📈 Faster processes: With the help of our #lifting aid, door leaves can be moved faster and more precisely than with chain hoists, which increases production speed. Constant #performance: Machines do not tire and can work continuously with consistent performance. #Flexibility and #Versatility ⚒️ Adaptability : The lifting axis can be easily adapted to different door leaves and installation situations. Improved #precision and #quality 👮 Precise positioning: Using the patented lifting axis, door leaves can be positioned with millimetre precision, which improves the quality of assembly. Repeatability: The consistent precision of the lifting axis ensures consistent quality in production. #CostSavings 💶 Lower labor costs: The reduced need for human labor leads to cost savings in the long term. Reduced damage: Precise handling minimizes damage to the door leaves, which reduces material costs. Increased #ergonomics 🦾 Better working conditions: Using our ZH90 lifting axis improves working conditions for employees by taking over heavy and repetitive lifting and moving tasks. Overall, the lifting axis helps to increase safety, efficiency and quality in the production and handling of door leaves. #ZHHT #doors #carpenter #frontdoors #interiordoors #door

We as Zeilhofer HHT have been developing manipulators, #lifting axes, #lifting aids and corresponding #devices for more than 25 years. Our #lifting aids are used in a wide variety of industries, which always brings with it new requirements. 🏭 Recently, we have increased our efforts to meet the changing needs of the industry. A key component of this effort is the integration of self-programmed displays and electro-pneumatic controls into our manipulator systems. 🎯 ➡️Self-programmed #Displays: Our self-programmed displays offer operators the ability to monitor and analyze important operational data in real time. This feature allows staff to make accurate decisions and identify potential problems early. In addition, the programmability of the displays allows us to develop customized user interfaces that meet the specific needs of our customers. 💻 👨‍💻 ➡️Electro-pneumatic #controls: The integration of electro-pneumatic controls into our manipulator systems represents a significant advance. This advanced control system combines pneumatic and electronic components to ensure precise and reliable control. By using this technology, our manipulators can carry out complex movements while offering high performance and efficiency. 🕹️🔋 📢The integration of self-programmed displays and electro-pneumatic controls into our manipulator systems has a profound impact on the Industry 4.0 era. These technologies enable our customers to optimize their production processes and ensure precise control over their facilities. The improved usability also helps to improve working conditions for our customers and increase the overall efficiency of their manufacturing. #zhht #display #industry #advantage #customerbenefit #industrie40 #Predictivemaintenance

The power electronics form the central element of the electric drive system of an #electric vehicle. It acts as an interface between the #high-voltage battery and the #electric motor and is largely responsible for controlling the interaction between these two components. 🤓 The inverter, a key component of the power electronics, monitors and controls the electric motor by providing torque and speed control. It also converts the direct current provided by the battery into the alternating current required to operate the electric motor. This conversion is also reversible in the recuperation process. 🔋 The inverter itself consists mainly of a fully assembled circuit board, the handling of which poses special requirements. Our Hebelift ZH supports this process by handling the components efficiently, gently, precisely and in an ESD-conductive manner. ⚡ The components must be securely gripped, rotated and positioned in the #manufacturing process. For these tasks, we offer a selection of electrical, mechanical and cleanroom-compatible #gripper variants as well as various sensor technologies that can be used in combination with our battery-operated lifting aid ZH individually according to your #requirements. 🏭 These solutions relieve the burden on specialists and help to reduce defects by enabling optimal interaction between man and machine. 🛠️ #zhht #inverter #directcurrent #alternatingcurrent #electrification #lift #powerelectronics

Mold boxes are structures that contain sand molds used for casting metal parts. Handling these heavy and often hot mold boxes is a major challenge. 💡 Our molding box manipulator is a special lifting aid used in the foundry industry to handle molding boxes safely and efficiently. It makes work easier, increases safety and brings other advantages: 🔊 ➡️ Ergonomics & Safety: The manipulator is designed to reduce the physical strain on workers and minimize the risk of injury. 🦺 ➡️ Efficiency: Our articulated arm manipulator allows mold boxes to be moved faster and more precisely, improving the efficiency of foundry processes. This leads to higher productivity and less downtime. ⏱️ ➡️ Flexibility: The manipulator is flexible and can be adapted to different sizes and shapes of mold boxes. This makes it versatile in different areas of the foundry. ✔️ ➡️ Precision: Our manipulator and fixture offer high precision in placing and moving mold boxes, which is important to ensure the accuracy and quality of the molded parts. 🦾 Overall, manipulators play an important role in the foundry industry by making the handling of molding boxes safer and more efficient. #zhht #foundry #ironcasting #mouldbox #casting #castings #GIFA

Fuel cells work in a similar way to #batteries through chemical reactions between anode and cathode, in which #hydrogen and oxygen serve as reactants. Hydrogen is split into electrons and protons, with protons migrating through a membrane to the cathode side, while electrons pass through an external circuit to get to the cathode. 🔋💧 There they react with oxygen and protons to form water, releasing energy. This process produces about 1.2 volts per cell, similar to a small flashlight battery. Multiple cells can be stacked to produce higher voltages. Such an assembly is called a "#stack" and can weigh up to 250 kg. ⚡🔌 The #Manipulator shown here is used in the production of exactly these “stacks” and supports the worker in various activities: Assembling the stacks: The two end plates, each weighing up to 15 kg, are picked up, safely positioned and precisely placed using the integrated suction device. 🛠️ Moving the stacks: The 250 kg stack can be lifted, swiveled 90 degrees and put down using the manipulator. 🏗️ #zhht #electromobility #eMobility #hydrogen #fuelcell #fuelcells

Wind turbines are an important source of renewable energy and help reduce greenhouse gas emissions and combat climate change. 💨🌡️ They consist of large, rotating rotor blades mounted on a tall tower. The tower is the supporting pillar of every wind turbine. It forms the connecting link between the multi-ton turbine and the force of nature. 🏞️ Inside these towers, which are up to 190 meters high, there is a climbing ladder. This ladder consists of individual elements that are installed inside the towers and are later used by maintenance personnel to climb up. 🪜 These wall and stair elements, which weigh up to 120 kg, have to be placed in special transport racks during the manufacturing process in order to later be delivered to the construction site. It is precisely in this demanding work step that our manipulator relieves the employee. 🧰👩‍🔧 #zhht #hybridtower #sustainableenergy #windturbines #renewableenergy #windmills #offshore #windturbine #windpower #windfarm #renewableenergy

Mounting plates on #control cabinets are special plates that are used inside a control cabinet to attach electrical #components, such as #switches, #fuses, #relays, and other devices. These plates serve as a basis for mounting the various electrical and electronic components safely and neatly. 🤓 When using mounting plates in control cabinets, there are several challenges that must be considered to ensure an efficient and safe installation. Here are some of the most common challenges: Accuracy of dimensions and positioning 💯 Problem: The mounting plate must be precisely inserted into the #control cabinet and correctly positioned to ensure proper installation of the components. Weight and stability 🏋️‍♀️ Problem: #Mounting plates must be able to support the weight of the components mounted on them without bending or breaking. For this reason, the mounting plates are often very heavy in order to provide sufficient stability. Lack of space 🛠️ Problem: In many #control cabinets the space is limited, which makes the installation of mounting plates and components difficult. Electrical safety 🦺 Problem: Improper installation may result in short circuits, electrical malfunctions, or safety hazards. Time and costs 📉 Problem: Installing #mounting plates and assembling the components is time-consuming and therefore costly. The most efficient and safest solution to the problems and challenges mentioned is our ZH90 lifting axis. It is therefore a worthwhile investment for companies that want to improve their production capacity and quality. #zhht #switchcabinethousing #mountingplate #automation #switchcabinet #circuitdiagram #liftingaxis #switchcabinetconstruction #electricalinstallation #partialmountingplates

#Screw assembly refers to the industrial assembly of screw connections. Screw assembly in industry can be highly specialized and often requires precise tools, machinery and expertise. It plays a crucial role in many manufacturing processes and production lines, especially in industries such as automotive, aerospace, electronics manufacturing and others where precision and reliability are critical. Aspects of industrial bolting assembly include, among others, selecting the right bolts and tools, setting torques, checking bolt connections for correctness and quality assurance measures to ensure that bolted connections meet the required standards. The use of our products in screw technology offers the following advantages: #Precision and #Accuracy: The precise control of lifting axes and manipulators allows screws to be positioned and tightened with high accuracy. This ensures consistent quality of the screw connections and minimizes scrap or rework. 🎯 #Flexibility: Lifting axes and manipulators make it possible to tighten screws at different angles and positions, even in hard-to-reach places or in complex assemblies. This increases the flexibility of screw technology assembly and enables a wide range of assembly situations to be handled. 🔩 #Efficiency: The automated movement of lifting axes and manipulators reduces assembly times and increases productivity. Automation also allows repetitive tasks to be carried out efficiently, reducing working time and costs. ⏳ #Ergonomics and #Workplace Safety: The use of manipulators can help reduce the strain on employees by lifting and positioning heavy workpieces or tools. This helps improve workplace ergonomics and reduces the risk of overload injuries. 🦺 #Quality assurance: By integrating sensors and monitoring systems, lifting axes and manipulators can help monitor and ensure the quality of screw connections. Faulty screw connections can be detected and corrected at an early stage, which improves quality assurance. ✅ Overall, lifting axes and manipulators in screw technology assembly enable efficient, precise and safe assembly of screw connections, which leads to an increase in productivity, quality and workplace ergonomics. #zhht #EMobility #ElectricVehicle #smartfactory #workerassistance #futureworkplace #assemblyassistance #cordlessscrewingtechnology #screwingtools #torques #microscrewings #screws #impulsescrewdriver #positioning #fasteners #screwlocking #automotiveindustry #screwconnections #connectiontechnology #smartmanufacturing #processoptimization #joiningtechnology #schraubtec

Using our reel manipulator over a crane, chain hoist or other lifting aids offers several advantages that increase both efficiency and safety in the workplace. Here are some of the key benefits: 🔊 ➡️ Better precision & control The manipulator and fixture enable more precise control of the movement due to the rigid load guidance, which is particularly important when rolls have to be positioned precisely or maneuvered in tight work spaces. 🕹️ ➡️ Improved ergonomics & safety The manipulator is ergonomically designed to help minimize the physical strain on operators, reducing the risk of injury and fatigue. 🦺 ➡️ Increased efficiency & speed Operating our manipulator is faster and more efficient than using a crane, as less time is needed for setup and positioning. 📈 ➡️ Compact & space-saving Our articulated arm manipulator is compact and therefore requires less space than a crane, which is particularly advantageous in confined working environments. 🤏 ➡️ Flexibility & versatility The manipulator can be adapted to different roll sizes and weights, increasing its versatility. 🗞️ Overall, our reel manipulator offers a number of advantages over traditional crane systems and lifting aids that can lead to improved efficiency, safety and cost-effectiveness in various industrial applications. #Zhht #LiftingSolutions #Innovation #RollHandling #SmartLifting #SimpleAndSafe #IntelligentLifting #LiftingEquipment