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For a battery production line whose ceiling could not carry a rail, FullSharp built a freestanding two-column frame with a 200 kg rail on top, carrying a Knight Global air balancer and a battery gripper. The frame does not touch the roof, and the trolley runs the full length to pick up and place batteries at both ends.
A battery production line needs a wide lifting zone, but the ceiling often cannot bear the load required to hang a rail. Bolting the rail onto the existing roof structure would need heavy reinforcement, costing time and complicating acceptance inspection.
FullSharp builds a freestanding two-column frame standing on the workshop floor, resting a 200 kg-rated rail on top and carrying a Knight Global air balancer with a battery gripper tool. The self-supporting frame does not touch the roof, and the rail runs the full length of the frame to pick up and place batteries at both ends.
Two-column frame resting a 200 kg rail on top, carrying a Knight Global air balancer and battery gripper tool in the workshop.
Equipment Installed
- Two-column steel frame: both legs anchored to the floor with expansion bolts, fitted with base plates and bracing to resist sway when the trolley reaches the end of the rail.
- 200 kg-rated rail: rests on top of the frame, with the trolley running the full length to cover both work positions.
- Knight Global air balancer: keeps the battery suspended, the worker pushes and the battery follows, letting go stops it.
- Battery gripper tool: clamp jaws hug both faces of the battery, with a mechanical lock preventing release while the load is still suspended.
Key Specifications
- Rail load capacity200 kg
- StructureTwo-column frame
- Installation photos20 photos
Benefits for the Factory
Does not touch the roof
The self-supporting floor frame means no need to reinforce the factory's roof structure.
Wide work zone
The trolley runs the full rail length, covering both the pick-up and drop-off points.
Runs steadily
The two columns and bracing keep the rail from vibrating when lifting a load at the end of the rail.
Actual Installation Photos
Click a photo to enlarge. Album of 20 photos taken on site.
Suitable Applications
- Battery and cell assembly lines
- Inspection and charging areas
- Transfer stations between two conveyors
- Workshops with a metal roof that cannot bear a hanging load
Related Products and Projects
- 5T 200 kg rail
- Knight Global air balancer
- Standard structures: hanging frames, gantry cranes
- 5T 200 kg rail project — completed installation
- Knight Global air balancer project — completed installation
- Support frame project — completed installation
Frequently asked questions
How is the battery held securely?
Clamp jaws hug both faces of the battery, with a mechanical lock that prevents release while the load is still suspended.
Does a two-column frame sway at the end of the rail?
Both legs are anchored with expansion bolts and fitted with base plates and bracing, so the rail stays steady when lifting at the end.
Why use a freestanding frame instead of the roof?
Hanging the rail from the existing roof would need heavy reinforcement and complicate acceptance. A self-supporting frame avoids that.
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Installation Consultation for Your Factory
FullSharp visits the workshop to measure column spacing, check the concrete floor and the aisle around the frame's location. We then recalculate the frame's load rating, the clear height to keep, and the clamp jaw type matching your battery size.