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.
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
The implemented solution combines multiple functions within one compact assembly fixture. It is now permanently integrated into the assembly process and enables flexible and safe handling of heavy gearboxes.
Components Used
- 4x lifting modules, 300 mm stroke, synchronized operation
- 1x electric rotating module
- 2x block cylinders for the press-fitting unit
Technical Data
- Maximum load capacity: 500 kg
- Workpiece weight: 150–350 kg
- Press-fitting force: up to 25 tons
Key Functions
- Synchronous lifting and lowering for ergonomic working conditions
- Electric rotation for optimal accessibility to components
- Integration of a mobile press-fitting device
- Safe positioning throughout the entire assembly process
The complete solution was implemented within only 8 weeks.
With the new assembly fixture, all key challenges were successfully solved:
Improvements at a Glance
- Ergonomic working conditions through flexible height adjustment
- Reduced assembly time thanks to optimized processes
- Increased occupational safety during assembly by replacing the handling by crane with a rotating module
- Enhanced efficiency by accessibility from all relevant sides
The added value and listed benefits were clearly evident in practice immediately after testing:
As a result, several additional fixtures were reordered within a short period of time.
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