Efficient Gearbox Assembly with Lifting and Rotating Modules
How can heavy gearboxes be assembled safely, ergonomically, and efficiently? A leading gearbox manufacturer faced exactly this challenge. Together with clamping and manufacturer specialist Matzat, a high-performance assembly fixture was developed that combines lifting, lowering, rotating, and press-fitting in one integrated system.
The result: significantly improved working conditions, enhanced safety, and more efficient assembly processes.
Challenge: Assembly of Gearboxes with heavy Weight and poor Ergonomics
In conventional workbench assembly, the processes quickly reached their limits:
- Gearboxes weighing between 150 and 350 kg
- No ergonomic adjustment of working height
- Limited accessibility to components
- Rotation of workpieces only possible by crane
- Increased risk of accidents due to manual handling
Additional requirements further increased complexity:
- High variety of component variants
- Accessibility required from five sides
- Mobile press-fitting device with up to 25 tons pressing force