- Installation planning should consider workpiece arrival, gripping, transfer, placement, operator access and equipment maintenance together.
- Core elements: pick-up/placement points, working radius, lifting stroke, rotation range, fixture size, personnel positions, passages and maintenance space.
- Draw the complete motion path before choosing the fixing point. Include equipment outlines, door-opening envelopes, access routes and service space in the clearance requirements.
- Determine installation dimensions from site measurements and design drawings.
Installation position affects the working envelope and operating posture for pneumatic industrial manipulators, pneumatic balancing hoists, vacuum lifters and their tooling. Use site measurements and design drawings to check equipment placement together with the complete handling sequence.
01How location affects operation and clearance
An excessively distant pickup point may cause overreaching; a placement point too close to the equipment may restrict slewing; proximity to equipment doors or aisles may obstruct maintenance or access. Check reachability, operating posture and clearance at every motion position. Include the overall dimensions, gripping orientation and parking envelope of custom tooling.
02Installation planning inputs
Pickup and placement points
Mark pickup locations such as bins, pallets, conveyors, material carts or equipment outlets, and placement locations such as fixtures, machine tools, assembly benches or the next workstation. Record the height, direction, changes in centre of gravity and orientation requirements at each point, and check that the equipment can perform the actual motions.
Working radius
The working radius must cover the required pickup and placement points and intermediate orientation-adjustment areas. Insufficient radius restricts movement, while excessive radius may increase footprint and interference. Select it against the complete path.
Lifting stroke
Lifting stroke must cover the heights needed to clear bins, pass over fixtures, enter equipment and place the workpiece. Include tooling height, lifting-point position, turning space and operator sightlines as well as workpiece height. For machine loading, also check the opening and internal clearances.
Rotation range
Simulate slewing through pickup, movement, obstacle clearance, placement and return, checking machine enclosures, control cabinets, fences, racks, utility lines and operator positions. Check the actual swept envelope, rather than recording only the maximum slewing angle.
Tooling dimensions and orientation
Include the outlines of suction cups, jaws, wrap-around clamps or turning mechanisms in the layout. Check the space required during approach, gripping, orientation changes and parking separately. Determine the tooling parking position together with the equipment fixing point.
Operator position
The operating position should allow a natural stance, a clear view of the workpiece and convenient handle control. If the main motions require detours, sideways posture, stepping over utility lines or frequent backward steps, adjust the fixing point or pickup/placement layout.
Access routes and maintenance space
Keep pedestrian and material-flow routes clear during movement, equipment parking, tooling storage and temporary load holding. Reserve access to air lines, control valves, travel limits, bearings, column fixings and tooling for maintenance.
03Dynamic interference checks
- Draw the motion path before selecting the fixing point: check the manipulator, tooling and workpiece envelopes segment by segment through lifting, translation, rotation, lowering, positioning and return.
- Equipment clearances: keep the motion path clear of enclosures, open doors, service openings, emergency-stop controls, electrical cabinets and material inlets/outlets.
- Plan tooling parking: mark the parked position and check whether the tooling occupies space above an access route or obstructs bin replacement or equipment inspection.
- Service lines and headroom: avoid tension, entanglement and crushing of air hoses, vacuum lines and cables. For suspended or rail-mounted systems, check overhead beams, lighting, ducts and cable trays.
- Allow room for adjustment: check positional margins against known workstation changes and avoid placing routine operations at the limits of the equipment's reach.
04Installation location checklist
| Inspection Item | Required checks | Common risks | Recommended practices |
|---|---|---|---|
| Pickup point | Bin, pallet, conveyor or equipment-outlet location | Excessive reach and operating effort | Confirm the coverage based on the actual picking action |
| Placement point | Fixture, machine, assembly bench or next station | Inaccurate placement and difficult positioning | Plan the path based on the workpiece posture and placement height |
| Working radius | Coverage of pickup, placement and intermediate movements | Insufficient radius or excessive range causes interference | Determine the reasonable radius based on the actual movement path |
| Lifting stroke | Workpiece, fixture and equipment height relationships | Workpieces cannot pass over tooling or enter equipment | Verify site measurements against design drawings |
| Rotation range | Clearance throughout rotation | Collision with equipment, guards, racks or people | Do dynamic range simulations and set limits if necessary |
| Tooling dimensions | Custom-tooling outline, gripping method and orientation | Fixture collides with workpiece, equipment or table | Incorporate fixture dimensions into overall workstation layout |
| Operator positions | Operator standing, observation and control position | Awkward posture or entry into hazardous areas | Ensure that personnel have a natural and safe operating space |
| Aisle safety | Clearance of pedestrian, material-flow and maintenance routes | Affecting traffic or material turnover | Reserve safe passages and equipment parking areas |
| Equipment interference | Relationship with equipment doors, control cabinets, and inspection openings | Affecting door opening, maintenance or equipment operation | Use equipment envelopes as mandatory layout constraints |
| Maintenance access | Access to tooling, circuits, controls and mounting points | Difficult to maintain and inconvenient to adjust | Reserve space for maintenance and replacement |
