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FullSharp · since 1991

FullSharp built a steel frame carrying a 5T 200 kg rail with a Knight Global air balancer and a battery clamp for a line moving cells between stations a few meters apart. Each cell is clamped once, pushed along the rail and lowered directly at the next station, with no double handling on a cart and less risk of denting the casing.

Battery production lines must move cells back and forth between several workstations spaced a few meters apart. Using a cart means lifting each cell up and down twice, which is slow and risks denting the casing.

FullSharp built a steel frame carrying a 5T 200 kg rail running the length of that area, fitted with a Knight Global air balancer and a battery clamp tool. Each cell is clamped once, pushed along the rail to the next station, then lowered directly, with no intermediate placement.

5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool

Steel frame carrying a 5T rail with a Knight Global air balancer and battery clamp tool in the production area.

Equipment Installed

  • Load-bearing steel frame: columns and beams bolted to the floor, carrying the suspended load plus horizontal push forces during operation.
  • 5T 200 kg rail: mounted on the frame beams, with a trolley running smoothly the length of the line between workstations.
  • Knight Global air balancer: keeps the cell suspended, raising and lowering with the operator's hand force so there is no need for constant button presses.
  • Battery clamp tool: grips both sides of the cell, with a safety latch holding the clamp throughout the move.

Key Specifications

  • Rail load capacity200 kg
  • Rail type5T rail
  • StructureSteel frame
  • Installation photos16 photos

Benefits for the Plant

One continuous move

Each cell is clamped once and runs the length of the rail, cutting out the intermediate placement step.

Casing protected

The load stays suspended and lowers slowly, so the battery casing never hits the table edge or cart sides.

Single-operator use

One worker can handle the entire lift, push, and place sequence.

Actual Installation Photos

5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 1 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 2 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 3 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 4 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 5 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 6 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 7 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 8 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 9 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 10 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 11 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 12 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 13 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 14 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 15 5T 200 kg Rail Frame with Air Balancer and Battery Clamp Tool - photo 16

Click a photo to enlarge. This album has 16 photos taken on site.

Suitable Applications

  • Battery assembly and inspection lines
  • Transfer areas between workstations
  • Finished cell packing stations
  • Plants needing a fixed frame-type lifting zone

Related Products and Projects

Frequently asked questions

How do you move battery cells between workstations safely?

A clamp tool on an air balancer holds the cell once, and the trolley carries it along the rail to the next station, so it is not set down and picked up again on a cart.

What does the air balancer do?

It keeps the cell suspended and raises or lowers with the operator's hand force. FullSharp checks cell weight and casing before building the clamp.

Why use a freestanding steel frame?

Columns and beams bolted to the floor carry the hanging load and push forces, so the rail does not depend on the roof structure.

Similar projects

Installation Consulting for Your Plant

FullSharp measures the distance between workstations, checks the floor and ceiling height before finalizing the frame dimensions. We calculate the rail length, balancer cable travel, and clamp type to match the exact cell type you produce.

Contact us for a site survey and quoteView completed projects