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FullSharp · since 1991

FullSharp installed a 500 kg overhead rail system on the plant ceiling with an ENDO air balancer running on a trolley, so loads can travel between several positions across a wide machine shop. The two-way rail grid covers the whole work area from above, the operator moves the load with a light push, and the floor and walkways stay completely clear.

When a load has to travel through several positions across a wide area, a hand cart or manual carrying both cost labor and slow things down. Plant floors are often packed with machinery, leaving no room for a standing lifting device, and any floor-based solution ends up blocking a walkway.

FullSharp installs a 500 kg overhead rail system on the ceiling, suspending an ENDO air balancer that runs on a trolley. The entire work area is covered by an overhead rail network, and the operator gives it a light push to send the load in the right direction, keeping the floor clear.

500 kg Overhead Rail System with an ENDO Air Balancer

A 500 kg overhead rail system mounted on the plant ceiling, with an ENDO air balancer lifting a load.

Equipment Installed

  • 500 kg overhead rail system: main and cross rails hung from the ceiling by rods, covering the work area in a two-way grid.
  • ENDO air balancer: balances the load on compressed air, holding it suspended at any height when the operator lets go.
  • Rail-running trolley: wheels roll smoothly inside the rail, so a light push moves the whole assembly.
  • Control handle: a lifting lever built into the balancer head, operated with one hand.
  • Air filter and regulator: stabilizes the incoming air pressure, keeping the equipment running smoothly and lasting longer.

Key Specifications

  • Rail system load500 kg

Benefits for the Plant

Clear floor space

The whole system hangs from the ceiling, leaving walkways and machine placement untouched.

Reaches many directions

The main and cross rail grid lets loads travel to almost any point in the area.

Lifts almost effortlessly

The air balancer carries the weight, so the operator only needs to guide the load.

Actual Installation Photos

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Click a photo to enlarge. A 17-photo gallery from the actual site.

Suitable Applications

  • Machine shops moving blanks between machines
  • Sub-assembly areas for heavy components
  • Tool and die shops moving molds in and out of machines
  • Indoor semi-finished goods warehouses

Related Products and Projects

Frequently asked questions

Why hang a lifting system from the ceiling instead of using a floor crane?

When the floor is full of machines, a floor-standing crane or cart blocks walkways. A ceiling-mounted rail system hangs from rods above the work area, so the floor stays free and the load can still reach every station under the rail grid.

How does an air balancer work on a rail system?

The air balancer uses compressed air to carry the load weight and holds it at the chosen height. It hangs from a trolley on the rail, so the operator lifts, positions and pushes the load along the main and cross rails with very little effort.

Can the rail grid be extended later?

Overhead rail systems are built from main and cross rails hung by rods, so the layout can be planned to cover the current work area and extended when the line changes. FullSharp surveys the site and sizes the rails to the real load and route.

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Consulting for Your Plant

FullSharp inspects the ceiling structure and its load-bearing capacity before planning the rail route. Our engineers draw a rail layout that covers your actual work area, select an air balancer to match the load and travel distance, then install, test, and warranty the equipment on site.

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