Routing automated guided vehicles (AGVs) between ground floors and elevated mezzanines causes line stoppages when cargo lifts lack responsive handshake protocols. This pitless 3-ton hydraulic mezzanine lift combines a 2-cylinder 4-rail structural mast with rapid PVC roll-up doors, executing 90-degree material transfers across a 4700 mm elevation stroke.
AGV Handshake Automation: PLC interface coordinates auto-call, platform alignment, and door cycles.
90-Degree Flow Geometry: 2300×2300 mm deck accommodates right-angle AGV entry and departure.
Pitless Floor-Mount Build: Surface installation with integrated approach ramp eliminates concrete pit excavation.
| Technical Parameter | Standard Specification | Engineering Customization Range |
| Rated Load Capacity | 3,000 kg (3.0 Metric Tons) | Fully Customizable to Client Specifications (1,000 kg – 10,000 kg) |
| Lifting Height / Stops | 4,700 mm (2 Stops / 2 Levels) | Fully Customizable to Client Specifications (2.0m – 18.0m) |
| Platform Usable Dimensions | 2,300 mm (W) × 2,300 mm (D) | Fully Customizable to Client Specifications |
| Clear Shaft Footprint | 3,200 mm (W) × 3,200 mm (D) | Engineered to plant structural column spacing |
| Entry / Exit Flow Pattern | 90° Right-Angle In / Out Flow | Straight-Through (180°) or Same-Side (90°/180°) |
| Drive Mechanism Type | 2 Hydraulic Cylinders (Φ80/60 mm) + 4 Guide Rails | Dual direct-acting cylinder / Telescopic hydraulic mast |
| Mast Structural Profile | H150 Heavy Structural Steel Section Columns | Structural H-beam / Custom rectangular steel masts |
| Platform Subframe Steel | 160 × 80 × 5 mm Structural Rectangular Tubing | Heavy-gauge channel with structural reinforcement |
| Platform Deck Plate | 4 mm Solid Anti-Skid Diamond Steel Plate | 6 mm – 10 mm smooth plate / Stainless steel top |
| Lifting Linear Velocity | 4.0 – 6.0 m/min (Cushioned acceleration) | Fully Customizable to Client Specifications |
| Hydraulic Power Unit | 5.5 kW Low-Noise Electro-Hydraulic Power Pack | Sized per continuous duty cycle and lift rate |
| Lifting Chains & Safety Ropes | LH1244 High-Strength Leaf Chains + 14# Steel Ropes | Multi-strand heavy leaf chain with slack sensors |
| Civil Pit Requirement | None (Zero-Pit Surface Installation with W2300×L600 mm Ramp) | In-pit flush mounting option (200 mm – 400 mm pit) |
| Landing Doors | 2 Sets Yellow PVC Rapid Roll-Up Doors (W2300×H2200 mm) | Steel mesh gates / Vertical bi-parting doors |
| Control System & Interface | Central PLC Controller + AGV Wireless / Relay Handshake | Ethernet/IP, Profinet, or Modbus TCP modules |
| Power Supply Rating | 380V / 50Hz / 3-Phase | Fully Customizable to Client Specifications (208V–480V, 60Hz) |
The lifting tower utilizes four H150 structural steel guide masts anchored to building steel framing. The platform frame uses 160×80×5 mm rectangular steel tubing topped with 4 mm anti-skid steel diamond tread plate, resisting localized wheel depression from counterbalanced AGVs. Dual Φ80/60 mm precision hydraulic cylinders operate in tandem with LH1244 heavy leaf chains and 14# secondary steel safety ropes, maintaining a static load safety factor above 6:1 under 3000 kg payloads.
The 5.5 kW external hydraulic power unit features high-pressure manifold blocks, diagnostic pressure ports, and flow-regulating check valves for quick maintenance checks. Pivot points and mast slider assemblies incorporate high-wear composite slide blocks that reduce steel rail abrasion. GRADIN provides a 12-month complete hydraulic and electrical warranty, field wiring diagrams, PLC interface logic maps, and rapid spare seal kit dispatch.
Ground level access uses a dedicated W2300×L600 mm approach ramp, allowing AGVs and manual pallet trucks to drive onto the platform without civil pit work. Siemens PLC architecture syncs with AGV fleet management software over industrial Ethernet or dry-contact I/O relays to control door opening and carriage dispatch. Facilities combining palletized AGV delivery with overhead vertical sorting can implement complementary heavy-duty freight lifts to connect warehouse tiers.
Landing portals feature two W2300×H2200 mm yellow PVC rapid roll-up doors with transparent center vision strips, interlocked with lift carriage travel. The carriage platform includes 1.2-meter high fixed steel side handrails to contain loads during elevation. Dual mechanical anti-fall safety catches and hydraulic velocity fuses prevent downward carriage drift if hydraulic line pressure drops. The equipment satisfies international machine design and material transfer directives:
ASME B20.1 Safety Standard for Conveyors and Related Equipment
OSHA 1910 Walking-Working Surfaces and Guarding Regulations
ISO 13849-1 Safety of Machinery – Control System Safety Architectures
CE Machinery Directive 2006/42/EC compliance for hydraulic vertical material lifters
Automated Factory AGV Routing: Right-angle transfer of 3-ton palletized production sub-assemblies between ground staging aisles and mezzanine lines.
Automotive Battery Pack Assembly: Elevating heavy traction battery modules from ground delivery AGVs to second-story pack integration decks.
Electronics SMT Buffer Transfer: Moving AGV-delivered component racks to elevated surface-mount technology cleanroom suites.
Consumer Goods Packaging Mezzanines: Transferring palletized raw packaging cartons from warehouse AGVs to upper case-packer platforms.
Machining Center Tooling Distribution: Elevating AGV tooling carts to second-floor CNC machining cells without manual forklift interference.
Clean Manufacturing Retrofit Bays: Surface-mounted vertical lifter installation in leased plants where floor trenching and pit excavation are prohibited.
For this heavy-duty series, we can engineer load capacities up to [300] tons, with platform dimensions and lifting heights customized to your operational envelope. Requirements exceeding our standard engineering matrix will undergo a Finite Element Analysis (FEA) by our engineering team to ensure structural viability before proposing a solution.
To initiate the engineering proposal, please provide the following baseline data:
Rated Load Capacity
Maximum Lifting Height & Closed Height
Platform Dimensions (L x W)
Duty Cycle (e.g., operational cycles per hour/day)
Environmental Conditions (e.g., indoor/outdoor, washdown, explosion-proof)
Pit depth or overhead clearance constraints
Yes. The control systems can be equipped with standard communication protocols (e.g., Profinet, Modbus, Ethernet/IP) utilizing [Siemens / Allen-Bradley / Omron] PLCs. This ensures seamless I/O signal synchronization with upstream/downstream conveyors, AGV/AMR units, and your central control room.
Every custom unit undergoes a mandatory Factory Acceptance Test (FAT) prior to dispatch. This includes continuous operational testing at 100% rated load, static overload testing at [120% / 125%] capacity, and the physical triggering of all mechanical anti-fall and hydraulic safety interlocks. FAT documentation and video proof are included in your engineering package.
Upon final approval of the General Arrangement (GA) drawings, the manufacturing lead time is typically 4 to 8 weeks. Oversized structural components are engineered with a modular design to fit into standard shipping containers (20FT/40HQ). On-site assembly utilizes pre-engineered bolted flange connections and heavy-duty aviation plugs, strictly eliminating the need for field welding.
We provide a standard [12/24]-month warranty covering the structural frame and primary hydraulic/electrical components. To minimize operational downtime, a comprehensive set of standard consumables (e.g., cylinder seal kits, travel switches, relays) is shipped alongside your equipment. During the warranty period, replacement parts for non-human-induced failures are dispatched via priority air freight (DHL/FedEx) within 48 hours.
Beyond the warranty, we guarantee lifetime engineering support. Your custom equipment's CAD drawings, electrical schematics, and BOM (Bill of Materials) are permanently archived in our system. This ensures you receive uninterrupted remote troubleshooting, maintenance guidance, and exact spare parts matching for the entire lifecycle of the equipment.
Gradin Machinery is a leading manufacturer specializing in aerial work platforms and hydraulic lifting solutions. With ISO & CE certifications, we provide safe, reliable, and customized equipment for global industrial needs
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