CONTROLS
Controls for Manipulators and Lifting Aids: Pneumatic, Electro-pneumatic, Electric
Zeilhofer Handhabungstechnik equips lifting aids and manipulators with three control concepts: pneumatic, electropneumatic, and electric. In addition, four control options are available, ranging from balancing control and automatic weight detection to up/down control and safety control. The control concept is tailored to the specific load, process, and environment of each project.
PROCESS
FROM INQUIRY TO FINISHED CONTROL SYSTEM
Step 1
REQUIREMENT
We analyze your load, your process, and your environment.
Step 2
CONCEPT SELECTION
Joint selection of drive and control options
Step 3
CONSTRUCTION
In-house development and manufacturing of the control unit
Step 4
COMMISSIONING
On-site assembly, parameterization and acceptance testing at the customer's premises
CONTROL SYSTEMS
CONTROL: THREE CONCEPTS. ONE DECISION.
Every Zeilhofer system is as intelligent as needed, from simple manual or pneumatic balancing solutions to fully automated, PLC-integrated systems. You choose the right concept, we configure the drive and control precisely according to your requirements and seamlessly integrate the solution into your process.
01 PNEUMATIC
COMPRESSED AIR and INTUITIVE
Pneumatics enable intuitive and safe operation. Vertical movements are balanced, meaning no buttons are needed. Ideal for manual, synchronized handling.
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Robust technology, low maintenance
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Ideal for manual workplaces
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Operating pressure 6–7 bar
02 ELECTRO-PNEUMATIC
HYBRID and SEMI-AUTOMATIC
All the advantages of pneumatics are retained. In addition, semi- and fully automated processes can be implemented. The right choice when manual and automated processes are combined.
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Balancing control + automation
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Semi-automatic and fully automatic operation possible
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PLC integration possible
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Optimized for serial production processes
03 ELECTRIC
AIR-FREE and AUTOMATIC
The purely electric control system operates entirely without compressed air. Even the heaviest loads, as well as semi- and fully automated processes, are handled reliably.
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No compressed air connection required
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Full automation possible
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Robot & Line Integration
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Suitable for the heaviest loads
DECISION GUIDE
WHICH CONTROL SYSTEM SUITS YOUR APPLICATION?
PNEUMATIC
Compressed air: yes, 6 to 7 bar
Vertical movement: balancing, no push-button
Automation: manual
PLC integration: no
Typical use: manual workstations in cycle operation
ELECTRO-PNEUMATIC
Compressed air: yes
Vertical movement: balancing and automatic
Automation: semi- and fully automatic
PLC integration: yes
Typical use: series processes combining manual and automated steps
ELECTRIC
Compressed air: no
Vertical movement: semi- and fully automatic
Automation: semi- and fully automatic
PLC integration: yes, including robot and line integration
Typical use: heaviest loads, plants without compressed air supply
Detailed comparison of drive types: Pneumatic or electric lifting?
CONTROL OPTIONS
FOUR options: tailored to your process
Beyond the control concept, the operation can be adapted to the application using four control options. These determine how the load is picked up, weighed, moved, and secured.
A balancing control
For virtually weightless movement of loads. The system switches to load mode as soon as the load has been securely picked up: vertical movement is effortless, without pressing any buttons.
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Ideal for frequently changing loads
B Automatic weight detection
Components of varying weights are moved vertically at the touch of a button. If the component is in the air, the system can be switched to balancing control at the touch of a button: ideal for changing components.
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For parts of varying weight
C Up and down control
Vertical movement is controlled via push-buttons. An additional push-button allows for acceleration of the travel movement. Small movements can be performed without pressing any buttons.
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For defined lifting positions
D Safety control
The load can only be released if the gripper is in a defined end position or receives authorization via an index signal. Maximum protection against unintentional release: ideal for safety-critical processes such as the assembly of high-voltage batteries or heavy components.
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For safety-critical applications
PRODUCT COMPATIBILITY
CONTROL CONCEPTS BY PRODUCT
Every product can also be extended with the Multi-Axis Module ZH3 for precise rotation and positioning movements.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS ABOUT CONTROL
01 Which controller is right for my application?
Pneumatic control is suitable for intuitive, balancing handling in manual operation. Electropneumatic control complements this with semi- and fully automated processes. Electrical control requires no compressed air and is suitable for the heaviest loads as well as fully automated processes. Zeilhofer tailors the control concept to the specific application within each project.
02 What is a balancing control system?
With a balancing control system, the machine switches to load mode after the load has been safely picked up. The load can then be moved vertically almost weightlessly without having to press a button. This enables ergonomic, fatigue-free work.
03 Can Zeilhofer technology also work without compressed air?
Yes. With purely electric controls, lifting aids and manipulators can be operated entirely without compressed air. Heavy loads and semi- or fully automated processes are also possible.
04 What is a safety controller?
With the safety control system, the load can only be released when the gripper is in a defined end position or a release signal has been given. This prevents unintentional lowering. This option is suitable for safety-critical processes such as the assembly of high-voltage batteries or heavy components.
05 What is the difference between balancing control and up/down control?
With balancing control, the system switches to load mode once the load has been picked up, and the load is moved vertically without pressing a push-button. With up/down control, vertical movement is controlled via push-buttons, and an additional push-button accelerates the travel movement. Balancing control suits frequently changing loads, up/down control suits defined lifting positions.
06 What is automatic weight detection?
Components of different weights are moved vertically at the push of a button. As soon as the component is in the air, the operator can switch to balancing control at the push of a button. This is ideal when parts of different weights are handled at the same workstation.
07 Can Zeilhofer control systems be integrated into a PLC or robot cell?
Yes, for electro-pneumatic and electric systems. Electro-pneumatic control enables PLC integration for semi- and fully automated processes, and electric control additionally allows integration into robot cells and production lines. Purely pneumatic systems operate without a PLC connection.
08 Which control systems are available for which products?
All three control concepts, pneumatic, electro-pneumatic and electric, are available for the ZH90 lifting axis, the ZH90 Flex-Arm lifting axis and the Hebelift ZH. The articulated arm manipulator is available pneumatically or electro-pneumatically, each up to 800 kg. The cable manipulator Acer is purely pneumatic, the ZH70 is pneumatic or electro-pneumatic. The Multi-Axis Module ZH3 extends every product with rotation and positioning movements.