- Pneumatic Industrial Manipulator heightNon-standard, cross-domain functions, safety requirements span hoisting, pneumatic, mechanical and control safety and custom gripping,Difficult to generalize with a single standard or single certificate。
- A reasonable approach is to focus onLayered judgment on equipment attributes, load risks, pneumatic systems, fixture forms, control logic and site conditions, refer to the corresponding standard direction at each level.
- Factory inspection should go beyond "appearance and operation" and focus onRated load, limit, braking, pneumatic line leakage, air-supply shutoff protection, accidental release prevention and data delivery; On-site acceptance and then verification of foundation anchorage, installation accuracy, compressed-air supply and load trial move.
- Statement of applicability of standards is not equivalent to compliance commitment: Whether special equipment supervision, compulsory certification or third-party testing is involved must be judged based on the attributes of the equipment and the supervision requirements of the project location, and responsibilities must be clearly defined in the contract or technical agreement.
Produced by: AUREK (Engineering Technology Resource Center) Document Category: Standard Applicability Instructions/Factory Inspection Instructions/Customer Acceptance Document Instructions Version: Version A (for engineering reference). This article is an engineering standard applicability description and factory inspection description. The standard directions, inspection items and judgment principles listed are allReference properties; The classification, inspection depth and certification requirements of specific equipment should be judged based on the equipment attributes, load risks and regulatory requirements of the project location, and shall be subject to the official text of the standard and the contract technical agreement. The full text of the PDF can be downloaded in the upper right corner or at the end of the text.
00Abstract
Pneumatic Industrial Manipulators are a type of non-standard power-assisted equipment that uses compressed air as the main energy source and is used to assist operators in transporting and positioning workpieces. It often integrates a power-assisted balancing mechanism, slewing and swing joints, end custom tooling or vacuum gripping systems, and is installed on load-bearing structures such as columns, cantilevers, tracks or frames. Since its functions span multiple engineering fields such as "hoisting", "pneumatic transmission", "machinery and control safety" and "custom gripping", a single standard or certificate is often not enough to summarize all its safety requirements.
Starting from the equipment's functional classification, this white paper outlines standard frameworks that may be relevant to lifting safety, pneumatic-system safety, and machinery and control safety for Pneumatic Industrial Manipulators. It then proposes systematic factory-inspection items, on-site installation and acceptance items, and a document-delivery list, followed by boundaries for certification and third-party testing and a typical Failure Mode and Effects Analysis (FMEA). Its purpose is to help engineering, quality, procurement, and user stakeholders establish a clear framework for safety and compliance decisions and define responsibilities early in a project.
01Introduction
As manufacturing places greater emphasis on ergonomics, productivity, and occupational health, Pneumatic Industrial Manipulators are increasingly used in automotive, appliance, machining, logistics-sorting, glass-handling, and panel-handling applications. Their common feature is the use of compressed air as the primary assist force, enabling operators to lift, rotate, position, and release medium-weight workpieces with less physical effort, reducing musculoskeletal-injury risk and improving cycle-time stability.
However, the Pneumatic Industrial Manipulator is highly customized in terms of structural form. The load range, arm span, number of joints, fixture form, control logic and installation conditions of different projects vary significantly, which makes it difficult to generalize the safety requirements with a single standard or a single certificate. The equipment also involves lifting loads, pressure energy, motion mechanisms and human-computer interaction. Weakness in any link may become a source of risk. Therefore, hierarchical judgment around equipment attributes, load risks, pneumatic systems, fixture forms, control logic and on-site installation conditions is the prerequisite for establishing a reasonable safety compliance framework.
This white paper was prepared by the AUREK Engineering Resource Center as supporting technical documentation for factory inspection and customer acceptance. AUREK is identified only as the publisher and source of engineering context. This document makes no commitment regarding the qualifications, certification status, or compliance of any specific product. The standards, inspection items, and risk-analysis methods described are intended to provide consistent engineering terminology and decision criteria so that responsibilities, inspection depth, and deliverables can be defined in contracts and technical agreements.
02Equipment attributes and standard application boundaries
To determine which standards should be referenced and what kind of inspection should be carried out for a Pneumatic Industrial Manipulator, one must first clarify its equipment attributes. The following is a brief description of common related equipment forms and their engineering characteristics, and on this basis, the boundary relationship between them and concepts such as "hoisting machinery" and "special equipment" is discussed.
2.1 Pneumatic Industrial Manipulator
A Pneumatic Industrial Manipulator typically comprises a fixed base or column, a primary arm, an auxiliary arm (or multistage arm), rotary joints, pneumatic cylinders and a balance-assist mechanism, braking or locking devices, and end-effector tooling. Compressed air generates cylinder force that offsets the weight of the workpiece and mechanism, allowing the operator to guide the workpiece in a near-weightless condition. Unlike electrically driven lifting equipment, this equipment generally uses compressed air as its primary energy source rather than a main drive motor, although solenoid valves, sensors, pushbuttons, and other electrical components may be integrated for control and protection.
2.2 Pneumatic Balancers and Pneumatic Industrial Manipulators
Pneumatic balancers and Pneumatic Industrial Manipulators are normally used for lighter loads or assisted handling of hand tools, emphasizing near-floating suspension within a defined stroke. Their structures are relatively simple, but still require stable air-supply pressure, loss-of-air protection, and inadvertent-release prevention. For standards-applicability decisions, distinguish them from full-arm Pneumatic Industrial Manipulators with more complete structures.
2.3 Vacuum Lifter
A Vacuum Lifter uses a vacuum generator or pump, an air/vacuum reservoir, and one or more suction cups to handle flat-surfaced workpieces such as sheets, panels, and enclosures. Principal safety concerns include generating and retaining the required vacuum, maintaining vacuum after loss of air or power, and suction-cup compatibility with different workpiece surfaces. Requirements for non-fixed lifting attachments, such as the direction of ISO 13155, may be relevant, but actual applicability depends on attachment type and project requirements.
2.4 Jib Crane
Cantilever crane generally refers to a rotating arm lifting device fixed on the ground, column or wall. It is functionally similar to a Pneumatic Industrial Manipulator (both are arm-type, rotatable, and used for lifting), but they are often different in driving methods, load magnitudes, and control logic. Cantilever cranes may fall into the category of "boom cranes" in some cases. For its design and inspection, please refer to the relevant safety regulations for hoisting machinery. Whether the Pneumatic Industrial Manipulator should be treated like a cantilever crane needs to be judged based on its load, lifting function and structural attributes.
2.5 Custom End-of-Arm Tooling and Vacuum-Cup Systems
End-of-arm tooling and vacuum-cup systems are normally customized for a specific workpiece and include mechanical grippers, clamps, dedicated supports, and single or multiple vacuum-cup groups. Safety concerns include retaining gripping or vacuum force, inadvertent-release prevention, behavior after loss of air or power, and compatibility with workpiece geometry. Because the equipment is highly customized, requirements are normally based on technical documentation, internal specifications, and general lifting-attachment/tooling principles; specific acceptance criteria must be stated in the technical agreement.
2.6 Rail / Frame System
Pneumatic Industrial Manipulators are often mounted on rails, beams, or gantry frames to extend their coverage. In addition to the arms, the rail travel mechanism must be assessed for derailment prevention, positioning brakes, structural stiffness, and connection reliability. Frame and rail capacity, deformation control, and installation accuracy directly affect overall stability and safety and must be included in design and acceptance.
2.7 Comparison with Industrial Robots
Industrial robots are usually electrically driven, programmable, and capable of autonomous movement. Their safety requirements revolve around automatic movement and human-machine collaboration. You can refer to the special safety standards for robots. Pneumatic Industrial Manipulators emphasize the power-assisted and balanced characteristics of "people in the loop" - the movement is usually guided by the operator, and the equipment does not decide the movement trajectory autonomously. There are differences between the two in risk sources and control ideas, so the applicable standards and inspection focus are also different.It is not appropriate to simply apply robot standards to summarize all the requirements for Pneumatic Industrial Manipulator.。
2.8 Definition of lifting machinery and special equipment
"Hoisting machinery" and "special equipment" are important concepts at the regulatory level, involving regulatory requirements such as whether type testing, use registration, and periodic inspection are required. Whether a Pneumatic Industrial Manipulator falls into the relevant category cannot be judged by its name alone, but must be comprehensively defined in combination with its lifting function, rated load, structural form, functional purpose and other equipment attributes, and in accordance with the special equipment catalog and management regulations of the project location. The conclusions may differ due to different load magnitudes, installation methods, and regional regulatory standards.
2.9 Boundaries of CCC / CE / Third-Party Testing (Overview)
In terms of certification and compliance systems, different regions and different product forms have different requirements. Compulsory product certification (such as CCC) usually targets products or electrical components within a specific catalog scope; exporting to relevant markets may involve corresponding compliance frameworks (such as relevant directives and harmonized standards corresponding to CE). The applicability judgments of purely pneumatic bodies and subsystems containing electrical components may be different. Whether relevant certification or third-party testing is required must be determined based on the attributes of the equipment and the regulatory requirements of the project location. This boundary will be further explained in Section 09 of this article.
2.10 Standards-Applicability Reference Matrix
The following table summarizes the standard directions that can be referenced in different dimensions related to Pneumatic Industrial Manipulators. The content in the table is an overview of applicable directions.It does not replace specific terms, nor does it constitute a judgment that any standard is "fully met" or "passed". The actual scope of application and requirements of each standard should be determined based on its official text and combined with the attributes of the equipment.
| Standard / Category (Reference Framework) | Description of Potential Scope |
|---|---|
| Machinery Safety Basics ISO 12100 and other directions | Provides a general machinery-safety and risk-assessment framework and may support inherently safe machine design and hazard identification. Applicability and the specific method are governed by the official text. |
| Pneumatic system safety ISO 4414 and other directions | Provides general safety rules for pneumatic fluid-power systems, including principles for circuit design, pressure control, loss of air, and exhaust. |
| Lifting machinery safety GB 6067 series and other directions | Provides safety rules for various types of lifting machinery. Relevant provisions may apply if the equipment is classified by its attributes as jib-type or light lifting equipment; applicability must be determined from those attributes. |
| Crane design GB/T 3811 and other directions | Addresses complete-crane structures and load calculations and may provide a reference for evaluating structural strength, stability, and load capacity. |
| Mechanical and electrical safety IEC 60204-1 / GB 5226 series and other directions | Provides safety requirements for machine electrical equipment. Relevant general and product-specific provisions may apply where the machine includes solenoid valves, sensors, controllers, or other electrical components. |
| Safety control functions ISO 13849-1 / IEC 62061 etc. | Addresses performance requirements for safety-related control parts and methods for determining the required performance level where functions such as emergency stop, safety limiting, or two-hand control are provided. |
| Ergonomics ISO 11228 series and other directions | Addresses evaluation of manual handling and operating forces and may support assessment of human workload and the force required to guide an Pneumatic Industrial Manipulator. |
| Welding and fasteners Welding, GB/T 3098 and other directions | Addresses weld quality and fastener property classes and may support inspection of structural welds, bolt selection, and loosening-prevention design. |
| Spreader/Clamp ISO 13155 etc. | Addresses functional and protective requirements for non-fixed lifting attachments, including vacuum lifting devices, and may support acceptance of custom tooling and vacuum systems. |
| Export market compliance CE corresponding framework and other directions | Supply to export markets may involve applicable compliance frameworks and harmonized standards. Scope and assessment method must be determined from the target market and equipment attributes. |
| Compulsory certification directory CCC and other directions | Applicability is governed by the latest official catalog. A purely pneumatic machine and a subsystem containing electrical components may be treated differently; determine requirements from the equipment attributes and applicable regulations. |
| Company and Customer Acceptance Specifications | Includes acceptance items in the internal quality system, factory-inspection plan, and customer technical agreement. These are as important to equipment delivery as the standards frameworks above and must be defined in the contract. |
Table 2-1. Standards-Applicability Reference Matrix. The table is for reference only. Official standard texts, equipment attributes, customer requirements, and regulations at the project location take precedence; the table is not a certification or compliance statement.
03Interpretation of safety requirements related to lifting
Although the Pneumatic Industrial Manipulator is positioned with "power assistance" as its core positioning, as long as it carries and lifts workpieces, it will inevitably involve lifting-related safety risks. This section provides an engineering interpretation of the reference safety requirements related to lifting from the perspectives of load, structure, stability, limit and braking. These interpretations are directional instructions, and the specific requirements should be based on the official text of the relevant standards and judged based on the equipment attributes.
3.1 Rated Load and Safety Margin
Rated load is a fundamental parameter for safe use. Design must define the rated lifting capacity, allowable load at maximum reach, and their relationship, with an appropriate structural safety margin. The load range that the assist mechanism can balance must correspond to the rated load so that assist force or stability is not lost near the operating limit. The rated load and limiting conditions must be clearly marked on the nameplate and in the manual and verified by the applicable factory and on-site load tests.
3.2 Structural Strength and Stability
The arms, column, base, and connections form the principal load path; their strength and stiffness directly determine load safety. Structural design must address static, dynamic, eccentric, and potential impact loads and the effect of accumulated fatigue on long-term reliability. For fixed equipment, verify overturning stability and anchor requirements. For rail- or frame-mounted equipment, address stability in motion and derailment prevention. Welds and high-strength bolted joints are critical structural nodes and should be inspected against applicable welding and fastener standards.
3.3 Travel Limits and Overtravel Protection
Provide travel limits to prevent collision, instability, or structural damage when the mechanism exceeds its intended range. Limits may use mechanical stops, limit switches, or both and must reliably stop the drive, generate an alarm, or initiate protective action at the endpoint. Verify trigger reliability and reset behavior for every limit so the system produces a dependable safe response outside the design range.
3.4 Braking, Locking, and Fall Prevention
Braking and locking are core safety functions for preventing an unintended load descent or mechanism motion. For a Pneumatic Industrial Manipulator, assess behavior after loss of air, loss of electrical power, or interruption of operation: the mechanism should hold the load at its current position or descend slowly under control, never fall suddenly. Provide reliable braking or mechanical locking at critical degrees of freedom and validate it by loss-of-air testing. Select redundancy for fall-prevention functions according to the load-risk level.
3.5 Warning Labels and Visual Information
Clear warnings and visual information help reduce incorrect operation. The nameplate must state key parameters, including model, rated load, and rated supply pressure. Motion zones, gripping zones, and hazard points require appropriate warning labels. Apply relevant safety-color and sign standards as appropriate and verify completeness and correctness during factory inspection.
04Interpretation of safety requirements for pneumatic systems
The pneumatic system is the energy core of a Pneumatic Industrial Manipulator. Compressed air provides assistance but also stores energy; abnormal discharge, leakage, or pressure fluctuation can directly affect load retention and machine stability. This section provides an engineering interpretation of potentially relevant pneumatic-system safety requirements. Applicable pneumatic-safety standards and their official texts take precedence.
4.1 Air-Supply Quality and Pressure Stability
Supply-pressure stability and cleanliness directly affect assist performance and component life. The system must operate stably throughout its specified inlet-pressure range, avoiding reduced assistance from low pressure and impact motion from pressure fluctuation. Control moisture, oil mist, and particles by filtration, water separation, and drying where required. Verify adjustment, drainage, and exhaust functions of filter-regulator components during inspection.
4.2 Pneumatic-Circuit Sealing and Leakage Control
Pneumatic leakage wastes energy and can also cause gradual loss of assistance, unintended load descent, or abnormal motion. Lines, fittings, valves, and cylinder connections must seal reliably and be leak-tested at operating pressure using leak-detection fluid or an electronic detector. Use reliable sealing and loosening-prevention measures on critical connections and, where necessary, a check device at the supply connection to slow abnormal depressurization.
4.3 Loss-of-Air Protection and Depressurization Behavior
Loss-of-air protection is a defining safety requirement for pneumatically assisted equipment. If the air supply is unexpectedly interrupted or the system loses pressure, the equipment should prevent a sudden load drop. Cylinder locks, check valves, counterbalance valves, or mechanical brakes can hold the mechanism in position or permit a controlled slow descent. Simulated loss-of-air testing should verify that the load is held reliably or released in a controlled manner under depressurized conditions.
4.4 Pressure Control and Overpressure Protection
The system must provide appropriate pressure control and overpressure protection to prevent component damage or hazardous motion caused by abnormal pressure rise. Pressure-safety, relief, and pressure-limiting devices must match the system design pressure and be functionally verified during inspection. Systems with air receivers or multi-stage vacuum also require assessment of vessel and line pressure capacity and associated safety accessories.
4.5 Exhaust and Residual Energy
Residual compressed air is a potential energy source during maintenance, repair, or an emergency. Provide safe exhaust and depressurization so maintenance personnel can release residual pressure under controlled conditions. State the procedure clearly in the manual and incorporate it into inspection and maintenance practices.
05Machinery safety and control safety requirements
In addition to lifting and pneumatic hazards, a Pneumatic Industrial Manipulator presents crushing, shearing, collision, and other mechanical hazards from moving components, as well as safety functions implemented by control logic. This section gives an engineering interpretation of machinery guarding and control safety. Relevant machinery-safety and functional-safety standards may provide methodological guidance; official texts take precedence.
5.1 Mechanical Guarding of Moving Parts
Rotary joints, hinges, moving cylinder components, and tooling opening/closing zones can create crushing or shearing hazards. Design should reduce hazardous gaps through inherently safe measures wherever practicable and provide guards or barriers where hazards cannot be eliminated. In areas of close operator interaction, assess the need for additional presence-sensing protection or safety-distance requirements based on the task.
5.2 Operating Method and Protection Against Incorrect Operation
Operating methods must balance efficiency and safety. Critical load-release operations should require a clear indication of intent, such as two-hand control, coordinated foot-pedal action, or a confirmation step, to reduce the risk of unintended release. A single incorrect operation must not cause hazardous motion; validate the logic through inadvertent-release-prevention testing.
5.3 Emergency Stop and Safety Functions
Where electrical controls are provided, emergency stop, safety limits, interlocks, and other safety functions must match the risk level. Functional-safety standards may guide the required reliability and architecture of safety-related control parts. Emergency stops must be readily accessible, easy to actuate, and place the equipment in a safe state; inspection must verify prompt and reliable response.
5.4 Electrical Safety (Where Electrical Components Are Included)
For equipment incorporating solenoid valves, sensors, controllers, or displays, apply relevant electrical-safety standards for machinery. Address component selection, wiring reliability, protective bonding and insulation, overload and short-circuit protection, and cable retention and protection. Interfaces between electrical and pneumatic subsystems, such as a solenoid valve controlling an air circuit, must not produce hazardous coupled motion under abnormal conditions.
5.5 Ergonomics and Operating Load
A fundamental purpose of a Pneumatic Industrial Manipulator is to improve ergonomics. Required guidance force, handle placement, sight lines, and working posture should follow ergonomic principles; applicable ergonomics standards may support evaluation of operator workload. Good ergonomics improves comfort and also reduces incorrect operation and safety risk associated with fatigue or poor posture.
06Factory inspection project design
Factory inspection should not just stop at the level of "whether the appearance is intact and whether it can operate". For Pneumatic Industrial Manipulator, more attention should be paid to items closely related to safety, including structure and welds, fastening and anti-loosening, pneumatic line leakage and pressure, load and limit, braking and air-supply shutoff protection, fixture retention and prevention of accidental release, and complete delivery of data. The following table provides a systematic design of factory inspection items for reference when formulating specific inspection programs. The inspection depth and judgment criteria should be determined based on the equipment attributes and specified in the contract or technical agreement.
| No. | Inspection Item | Description and Method (Reference) |
|---|---|---|
| 1 | Appearance inspection | Check the appearance of the coating, markings and welds to confirm that there are no obvious deformations, cracks, rust and burrs; check whether the nameplate information and safety warning signs are complete and clear. |
| 2 | Dimensional and assembly inspection | Check whether the key structural dimensions and installation positions comply with the drawings; check whether the joint clearance, bearing assembly and fit are normal; confirm that the movable parts move flexibly and there is no abnormal jamming. |
| 3 | Weld and structural parts inspection | Conduct visual inspection of welds to confirm that there are no obvious defects; non-destructive testing methods can be used to check important welds and structural parts; confirm that the connection parts meet the design requirements. |
| 4 | Bolt tightening inspection | Check the tightening of fasteners according to design requirements, and recheck the connecting bolts between the main structure and joints; confirm that anti-loosening measures (self-locking nuts, spring washers, etc.) are installed in place. |
| 5 | Pneumatic Leak Test | Pressurize the system to operating pressure. Use leak-detection fluid or an electronic detector to inspect lines, fittings, valves, and cylinder connections. Confirm reliable sealing and any required check-valve provisions. |
| 6 | Air-Supply Pressure Check | Verify that rated supply pressure stably reaches the design value and calibrate the pressure indication. Check air quality (water, oil, and particles) and the adjustment and drainage functions of filter-regulator components. |
| 7 | Filtration, Regulation, and Safety Components | Confirm correct installation and responsive operation of filtration, regulation, and oil-mist treatment components; functionally verify pressure-safety, pressure-limiting, and related protective devices. |
| 8 | No-load running test | Make each degree of freedom move through the entire stroke without load, check the smoothness of the movement and the brake action; confirm that there is no abnormal vibration, jitter or abnormal sound. |
| 9 | Rated-Load Test | Carry out lifting, turning and other actions under the rated load to verify the load-balancing ability and smooth operation of the assist mechanism; confirm that there is no impact in the lifting and does not exceed the safety limit. |
| 10 | Static-/Dynamic-Load Verification Approach | Static load: Keep stationary under the rated load and observe the load-bearing stability of the structure and braking; Dynamic load: Make continuous movements under the load and check whether there is any displacement or looseness (the specific load and duration are subject to the agreement). |
| 11 | Rotary joint and brake testing | Check the smoothness and free range of the rotary joint motion; verify the reliability of the rotary lock or brake in the air-depleted state, and confirm that the joint will not rotate freely accidentally. |
| 12 | End-Stop and Anti-Collision Test | Verify timely and reliable end-stop actuation when the manipulator reaches a travel limit. Confirm that the system enters a reliably safe condition if the design range is exceeded. |
| 13 | Loss-of-Air Protection Test | Simulate interruption of the air supply and verify that the mechanism locks or descends slowly under control while retaining the load at its current position. Confirm protection against a sudden gravity-driven drop. |
| 14 | Tooling Grip / Vacuum-Holding Test | Functionally test the tooling or suction cups. Verify stable gripping of representative workpieces or vacuum holding at rated load, and check correct operation of directional and control components. |
| 15 | Inadvertent-Release Prevention Test | Verify the misoperation protection logic and confirm that the load can be released only under safe conditions; test whether the release locking behavior is effective in the event of air loss or power loss. |
| 16 | Vacuum-Retention Test | For equipment with a vacuum system, test vacuum retention after loss of air/power. Confirm that the vacuum level remains within the allowable range for the specified time and inspect vacuum-generation and control components for leakage. |
| 17 | Noise, Smoothness, and Operating Force | Confirm that operating noise is acceptable and motion is smooth and free of binding. For hand-guided equipment, verify that operating force is within a reasonable ergonomic range. |
| 18 | Nameplate, Labels, and Manual Check | Verify that the nameplate information is complete and correct, and that warning signs are complete; confirm that the instructions include safety warnings, operating procedures and maintenance requirements, and are accompanied by pneumatic circuit diagrams, electrical diagrams and inspection records. |
Table 6-1. Factory Inspection Plan (Reference). Record every inspection result and obtain the responsible person's signature. Specific items, methods, and acceptance criteria must be selected for the equipment and are subject to the contract or technical agreement.
07On-site installation and acceptance projects
Passing factory inspection does not by itself establish that the equipment can be used safely on site. Safety performance also depends heavily on the foundation, installation accuracy, air-supply conditions, and operating environment. After installation, each item in a systematic acceptance plan must be verified and documented. The following table provides a reference plan for preparing an on-site acceptance form.
| No. | Acceptance Item | Description and Method (Reference) |
|---|---|---|
| 1 | Foundation and Anchoring | Compare the foundation drawing with the installed foundation and confirm that site conditions meet the design requirements. Check anchor-bolt specifications, embedded locations, tightening, and loosening prevention, and verify the reliability of base-to-foundation connections. |
| 2 | Installation Verticality and Levelness | Measure the verticality and levelness of columns, jibs, and other components using a level or plumb reference. Confirm that there is no material inclination and correct with shims where necessary. |
| 3 | Working-Radius Verification | Confirm that the installed working radius meets design and use requirements and that the motion zone is unobstructed. At maximum reach, verify that joints do not interfere and that required safety clearance remains. |
| 4 | Lift-Stroke Verification | Operate to the travel limit both unloaded and at rated load. Verify the accuracy and stopping reliability of limit switches or mechanical stops, and recalibrate limits if overtravel occurs. |
| 5 | On-Site Air-Supply Pressure | Measure site supply pressure and confirm that it remains within the specified inlet range. Check supply-line diameter and filtration, and verify stable pressure with controlled pulsation. |
| 6 | On-Site Air Quality | Check moisture, oil, and particle levels in the compressed air and verify correct operation of filtration, water separation, and drying equipment. Where necessary, compare pressure indications with sensor readings. |
| 7 | Operating Space and Interference | Have the operator simulate normal work and check the entire motion envelope for interference with the ceiling, adjacent equipment, workpieces, or personnel routes. Confirm that the operating space meets ergonomic requirements. |
| 8 | Rated-Load Trial Handling | Under appropriate safety supervision, handle the rated load or an equivalent test load through lifting, transverse movement, and other required motions. Verify balance and responsiveness under actual operating conditions, with particular attention to brake response under load. |
| 9 | Workpiece-Gripping Verification | Trial-handle an actual workpiece to verify the compatibility and reliability of the tooling or suction cups. For vacuum lifting equipment, check sealing and vacuum level. Confirm correct release and reset behavior. |
| 10 | Operator Training | Train operators in machine functions, safe operation, and emergency response. Confirm familiarity with brakes, limits, emergency stops, and other safety devices, then document training completion. |
| 11 | Inspection-Checklist Delivery and Acknowledgment | Provide the user with daily inspection and maintenance checklists stating frequencies, items, and criteria. Obtain acknowledgment of receipt and understanding of the implementation responsibility. |
Table 7-1. On-Site Installation and Acceptance Plan (Reference). On-site acceptance must produce a written report stating conclusions and corrective-action recommendations. Issues must be corrected and pass reinspection before the equipment is released for use.
The installation environment materially affects safety performance. Insufficient foundation stiffness can cause machine movement and positioning error; inadequate air pressure or quality can destabilize assistance or accelerate component wear; and insufficient operating space can cause collisions in normal use. Verify these factors during acceptance and define responsibility for site conditions in the contract or technical agreement.
08Document delivery list
Acceptance covers more than the machine itself. Complete, clear accompanying documentation is equally important: it records the equipment's technical state and supports operation, maintenance, and allocation of responsibilities. Certificates, manuals, pneumatic and electrical schematics, inspection records, checklists, and the on-site acceptance form are therefore as important as the delivered equipment. The following table provides a recommended document list.
| Document Name | Purpose and Contents (Reference) |
|---|---|
| Certificate of Conformity | States the product name, model, serial number, manufacturer, and manufacture date and serves as evidence that the product passed factory inspection. |
| Operation Manual | Describes machine structure and operating principles, operating steps, safety precautions, maintenance, and common troubleshooting. Pneumatic and electrical schematics and a parts list should be included. |
| Packing List | Lists the components, spare parts, and tools shipped with the equipment for verification at delivery and receipt. |
| Factory Inspection Record / Report | Summarizes the result and disposition of each factory-inspection item, including records for key items such as pressure, load, limits, loss-of-air protection, and tooling. |
| Pneumatic and Electrical Schematics | Provides pneumatic and electrical control schematics for on-site connection, maintenance, and troubleshooting. |
| Risk-Assessment Record | Documents identified equipment hazards and analysis of the corresponding safeguards as supporting evidence for safety design and acceptance. |
| Wear-Parts List | Lists consumable and wear parts, including seals, filter elements, and brake components, together with recommended replacement intervals for maintenance and spare-parts planning. |
| Inspection and Maintenance Plan | Provides a daily inspection checklist and maintenance manual stating inspection items, frequencies, and criteria to support long-term safe operation. |
| Tooling / Vacuum-Holding Test Record | For custom tooling or suction-cup systems, provides performance-test records for gripping force or vacuum holding, vacuum retention, and related functions. |
| On-Site Acceptance Form | Signed by the user or a third party after the on-site inspection passes, confirming that installation and functions meet the agreed requirements. |
| Training Records | Attendance or acknowledgment records for required operator safety and operating training. |
Table 8-1. Document Delivery List (Reference). The contract or technical agreement must define the required document scope and format, and the agreed terms govern.
09Security certification and third-party detection boundary description
The need for certification and third-party testing is often what customers are most concerned about and most likely to misunderstand. What needs to be clear is:A statement of applicability of a standard does not equate to a compliance commitment, "Can refer to a certain standard" does not mean "has passed the certification of the standard", "how a certain type of equipment is usually handled" does not mean "this equipment must belong or not belong to a certain category". The specific requirements for certification and testing should be judged based on the equipment attributes, load risks and regulatory requirements of the project location, and the responsibilities of each party should be clarified in the contract or technical agreement.
9.1 Determination as Special Equipment / Lifting Machinery
Whether the equipment is regulated as lifting machinery or special equipment—and may therefore require type testing, registration for use, or periodic inspection—must be determined from its lifting function, rated load, structure, and installation method against the catalogs and management rules at the project location. The conclusion may vary with load range, local regulatory interpretation, and operating conditions. Official regulations and catalogs take precedence.
9.2 Compulsory Product Certification (e.g., CCC)
Compulsory product certification normally applies to products or electrical components within a specified catalog. Applicability may differ between a purely pneumatic machine and a subsystem containing electrical components. If motors, controllers, or other electrical components are integrated, determine their certification requirements from the latest official catalog and equipment attributes. The contract should state whether an application is required and which party is responsible.
9.3 Export-Market Compliance (e.g., Frameworks Associated with CE)
Supply to export markets may involve applicable compliance frameworks and harmonized standards. Determine scope, assessment method, and technical-documentation requirements from the target-market rules and equipment attributes. Such compliance normally involves risk assessment and preparation of technical documentation and differs from third-party certification; a qualified professional must confirm the project-specific requirements.
9.4 Third-Party Testing and Witnessing
Some industries or customers may require a qualified testing body to perform type testing or witness factory inspection or on-site acceptance. If the contract requires third-party participation, plan the inspection scope, acceptance criteria, and required documents in advance and allocate responsibility for organization, cost, and outcomes.
10FMEA risk analysis
Failure Mode and Effects Analysis (FMEA) is an engineering method for identifying potential equipment risks, assessing consequences, and developing controls. The following table addresses typical Pneumatic Industrial Manipulator risk scenarios and lists representative failure modes, causes, consequences, and mitigation directions for design, inspection, and acceptance. The content is a general example; design and safety engineers must complete equipment-specific analysis and ratings for each project.
| Risk / Hazard | Possible Causes | Potential Consequences | Mitigation Measures (Reference) |
|---|---|---|---|
| Unexpected Load Release | Pneumatic pressure loss; balance-assist failure; overload | Workpiece drop causing personal injury or equipment damage | Provide reliable braking/locking and check valves; limit descent speed; clearly establish the rated load and strictly prohibit overload. |
| Crushing / Shearing Injury | Personnel in the motion path; insufficient joint clearance | Body pinched by moving components or tooling | Reduce hazardous gaps or provide physical guarding; establish safe-work procedures; use two-hand or confirmation-based control for critical release actions. |
| Structural Failure / Fracture | Accumulated fatigue; weld defects; unsuitable material selection or insufficient design margin | Failure of an arm or connection, potentially causing a serious accident | Verify the structure against loads and safety margins; inspect welds to applicable specifications; schedule periodic structural and fatigue inspections; use conforming materials. |
| Air-Supply Leakage / Pressure Loss | Aged lines; loose fittings; valve failure | Assist force gradually fails or motion becomes abnormal, causing the workpiece to descend | Periodically inspect and replace seals and tighten fittings; provide pressure monitoring and alarms; use loss-of-air protection to hold the load or permit controlled slow descent. |
| Loss of Vacuum | Poor suction-cup sealing; vacuum-component failure | Vacuum-held load falls | Select suitable suction cups and seals; provide vacuum retention and indication; regularly clean and replace aged components; provide a low-vacuum alarm and holding logic. |
| Electrical-Control Failure (If Present) | Solenoid-valve failure; loose wiring; missing protection | Loss of function or safety function | Apply relevant electrical-design standards; provide required protection and emergency stop; secure wiring reliably; schedule periodic electrical inspections. |
| Overload / Incorrect Operation | Use above the rated load; operator error | Structural damage or unintended motion | Clearly mark load limits and train operators; provide error-prevention and confirmation logic; add load sensing or limiting measures where necessary. |
| Noise Hazard | High-velocity airflow; mechanical friction | Hearing effects from prolonged exposure | Optimize pneumatic circuits to reduce turbulent-flow noise; apply noise controls at critical locations; provide required hearing protection in the work area. |
Table 10-1. Typical Failure Mode and Effects Analysis (Example). This table identifies principal risks and control directions. For an actual project, design and safety engineers must complete the FMEA and risk rating using equipment-specific details.
11Conclusion
Pneumatic Industrial Manipulator are a type of highly non-standard power-assisted equipment with cross-domain functions. Its safety requirements span many fields such as hoisting, pneumatic transmission, machinery and control safety, and custom gripping. Therefore,One standard or one certificate cannot simply be used to summarize all security requirements. A reasonable approach is to make hierarchical judgments around equipment attributes, load risks, pneumatic systems, fixture forms, control logic and on-site installation conditions, identify key risks at each level and take corresponding design, inspection and protective measures.
During the factory inspection, the scope of inspection should go beyond "appearance and operation ability" and focus on items directly related to safety such as rated load, limit, braking, pneumatic line leakage, air-supply shutoff protection, prevention of accidental release, clamp holding capacity, and data delivery. During the on-site installation and acceptance process, factors affected by on-site conditions such as foundation anchorage, installation accuracy, compressed-air supply conditions, working space and load trial moving should be further verified, and a written acceptance record should be formed.
Certificates, manuals, pneumatic and electrical schematics, inspection records, checklists, and on-site acceptance forms are as important as the equipment itself because they document technical status and responsibility boundaries. Certification and compliance statements must remain cautious: standards applicability defines design and inspection references, not an automatic compliance guarantee. Determine whether special-equipment regulation, compulsory certification, or third-party testing applies from equipment attributes and regulations at the project location, and define responsibility in the contract or technical agreement.
All parties should agree early in the project on equipment classification, inspection depth, certification needs, and document-delivery scope and record those terms in the contract and technical agreement. A layered, traceable engineering method clarifies responsibility across design, manufacture, acceptance, and use while supporting long-term safe operation and continuous improvement.