Machine move-in on the upper floor using a crane, a temporary installation platform, and the Robot-40 dolly

Equipment trio makes light work of heavy lifting: ZEISS is one of the world’s leading technology companies in the optical and optoelectronic industry. For example, the company manufactures optical and mechanical components and systems for medical, measurement, and semiconductor technology at its Jena site. A 5-axis machining center weighing 24.5 metric tons was to be moved in on the upper floor of the production facility. The SCHOLPP team completed the project within three days using three proven tools.

Elevated move-in of a machine tool

ZEISS regularly engages the SCHOLPP installation team to move in machinery and handle internal relocations at its optics and mechanics production facilities in Jena. For this project, a Nakamura JX-250 5-axis machining center with a robotic system was on the to-do list. The machine tool for complex turning and milling operations had a total weight of 24.5 metric tons. Due to the dimensions of 6 x 3 x 3 meters, bringing it in directly on the upper floor was the only option.

The bottom of the facade opening was six meters up. To unload, lift, and transport the machine, the experienced installation team brought all the necessary equipment with them to Jena: a tool container along with the appropriate slings and lifting gear, a temporary installation platform (40 t), two articulated telescopic boom lifts, an electric forklift (5 t), the Robot 40 heavy-duty dolly (40 t), and two truck-mounted cranes (60 t and 130 t).

Preparing the construction site: Temporary installation platform

The day before the move-in, SCHOLPP’s installers set up the construction site in front of the ZEISS building. To do this, a small truck-mounted crane (60 metric tons) placed the tool container and all of the equipment on the factory grounds. Due to the machine’s heavy weight of 24.5 metric tons, a sturdy temporary installation platform had to be erected in front of the building opening. The key here was to create a precise transition between the platform and the access opening, without any gaps or height differences. SCHOLPP can also lift lighter machines weighing up to 16 metric tons up to the building using a suspended crane platform.

To unload and lift the machining center, a more powerful truck-mounted crane (130 metric tons) was set up in front of the factory the following day. The Nakamura machine was unloaded from the delivery truck and hoisted onto the installation platform. Some of the installers worked from articulating boom lifts. When using this technical solution, the specific occupational safety regulations for working at heights must be observed. These were precisely defined in advance by the project and installation manager in close consultation with the SCHOLPP safety engineer based on the expected risk.

Small but powerful: Robot-40 self-propelled heavy-duty dolly

The Robot-40 self-propelled heavy-duty dolly was already on the installation platform before the heavy machine tool was unloaded. The machine was then placed directly on top of it. This allowed it to be transported from the platform to its final location in the production facility without any delay. With the self-propelled and agile Robot-40 system, transporting goods along winding routes in cramped workshops is no problem. Despite its high load-bearing capacity of up to 40 metric tons, the Robot-40 offers excellent maneuverability: it is flexible, saves time, and offers millimeter precision. The project was completed on schedule on the third day with the dismantling of the installation platform and the cleanup of the construction site.

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