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FullSharp built a 5T rail frame along a motorcycle assembly line carrying a Knight Global 200 kg air balancer, for heavy motors fed into the frame at line pace by two workers who struggled to align the bolt holes. The balancer floats the motor at the right height, so one worker pushes lightly to line it up, with nothing on the tight floor.
The assembly line must feed motorcycle motors into the frame continuously, in step with the line's pace. The motors are heavy and bulky, so even two workers lifting together struggle to align the bolt holes; repeating the motion all shift strains shoulders and slows the line's rhythm. Floor space on the line is also tight, leaving no room for floor-standing equipment.
FullSharp built a 5T rail frame running along the line and carrying a Knight Global 200 kg air balancer. The air balancer holds the motor floating at the right height, so the worker only needs a light push to align it into position. The load rests on air pressure, so the hands bear almost no force.
A 5T rail frame carrying a Knight Global 200 kg air balancer at the motorcycle motor assembly stage.
Equipment Installed
- 5T rail structural frame: a freestanding steel frame running along the line, carrying the rail without depending on the factory roof structure.
- Knight Global 200 kg air balancer: an air-pressure load balancer that keeps the motor floating and moving up and down with very light hand force.
- Control handle on the arm: the worker guides the motor's direction and adjusts its height without leaving the work position.
- Trolley and rail line: moves the air balancer along the length of the line to serve multiple adjacent assembly stations.
- Air filter and regulator: stabilizes the air supply pressure to the balancer, keeping the lifting stroke steady through the whole shift.
Key Specifications
- Rail frame5T
- Air balancer capacity200 kg
- Balancer brandKnight Global
Benefits for the Plant
Steady line rhythm
The motor is always ready at hand, so each station's assembly time no longer stretches out.
Hands bear no load
Air pressure carries the motor's weight; workers only guide direction and align the bolt holes.
No floor space used
The frame and rail sit overhead, keeping the walkways and work area beneath the line unchanged.
Installation Photos
Click a photo to enlarge. Album of 22 photos taken on site.
Suitable Applications
- Motorcycle and parts assembly lines
- Engine, gearbox, and drivetrain assembly stations
- Inspection and run-in testing for heavy products
- Placing parts into fixed jigs
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Frequently asked questions
How do you lift motors into a frame on an assembly line?
An air balancer holds the motor floating at the right height, so the worker can align the bolt holes with a light push instead of holding the weight.
Why use a rail frame along the line?
The rail lets the balancer travel with the work along the line, and the floor stays free because nothing stands next to the conveyor.
What capacity is the balancer?
The Knight Global air balancer in this project is rated at 200 kg on a 5T rail frame. FullSharp designs the gripper around the real motor.
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Get a Custom Installation Consultation
FullSharp surveys the line's pace, the motor's weight and shape, and the worker's operating height to select the air balancer's stroke and the rail layout. We build a gripping tool matched to the part's exact grip points and run a trial on the line. Contact FullSharp to schedule a site survey.