Zero Energy Buoyant Lift
Executive Summary
Introducing ZEBL (Zero Energy Buoyant Lift) for moving battery pallets between floor and conveyor level. The ZEBL uses buoyancy for the empty up-stroke and gravity for the loadeddown-stroke, so nomotiveelectrical energy is consumed. The double- Decker layout keeps one deckattheconveyor whilethe other cycles— ensuring continuous flow.
Executive Summary
Introducing ZEBL (Zero Energy Buoyant Lift) for moving battery pallets between floor and conveyor level. The ZEBL uses buoyancy for the empty up-stroke and gravity for the loadeddown-stroke, so nomotiveelectrical energy is consumed. The double- Decker layout keeps one deckattheconveyor whilethe other cycles— ensuring continuous flow.
Why lift batteries one by one during loading and unloading?
Use ZEBL-1 and Save Manpower!
Save Power! Nopower, No air!
Double-Decker Operation Sequence
Conveyor connect directly to lift, batteries slided into double decker pallet
First load lower level and then lift comes downthen load upper level
Takeoutthedoubledecker pallet out with20-batteries andinsert another empty double decker Pallet
Emptydeckerwillmoveup without any power
Repeatthecycle withoutany power
Why ZEBL Over Alternatives?
Zero energy for motion (buoyancyup, gravity down)
The ZEBL operates entirely on natural forces — buoyancy lifts the empty car, while gravity lowers the loaded car. This eliminates the need for motors, saving recurring electricity costs.
Lowest OPEX (no hydraulic oil, minimal wear parts)
The system has no pumps, cylinders, or hydraulic oil. Only simple checks on pulleys, ropes, and seals are required. This keeps annual maintenance at ₹5–10k, compared to ₹40–60k for hydraulics.
Continuous throughput (double-decker always serving conveyor)
With two decks alternating positions, one deck is always available at the conveyor level while the other cycles. This ensures uninterrupted pallet transfer and avoids production delays
Customized fit (platform to pallet size; travel to conveyor height)
Each ZEBL lift is designed to match the customer’s pallet size and conveyor level exactly. This makes integration seamless without changes to the existing assembly line layout
Clean & safe(no oil leaks, quiet operation)
The ZEBLavoids hazards like oil leakage and noisy operation common with hydraulics. It uses water as a medium, runs quietly, and includes interlocks for controlled, safe operation
Significant CO₂ footprint reduction
By requiring no motive power and eliminating oil usage, the ZEBL reduces annual CO₂ emissions by tens to hundreds of kilograms compared to hydraulic and pneumatic alternatives. It supports green, sustainable manufacturing practices
Scope & Customization
- Emptyup mass:~280 kg(car+pallet)
- Travel: set to customer’s conveyor height (ex.750mm)
- Pallet platform: customized to exact dimensions
- Rated load: 1ton, 10batteries approx 350 to 650kg (down stroke) customized to your requirement
If your assembly line is in the first floor, we can make small lift to get batteries one by one to
groundfloor without any power
Cost Comparison per unit (5 Years) verified for you reference with options