Pneumatic Industrial Manipulator User Manual

Pneumatic Industrial Manipulator

Operation Manual

Figure 1 Example of a column-type Pneumatic Industrial Manipulator (the actual structure is subject to the project drawings)

Read this manual in full before installation, commissioning, operation, or maintenance, and retain it for future reference.

00File description and device information

This is the general operation manual for AUREK Pneumatic Industrial Manipulators and applies to custom column-mounted, mobile, overhead-mounted, and similar configurations. Because the manipulator, tooling, installation configuration, and control logic are customized for the customer's workpiece and site conditions, refer to the contract, final drawings, equipment nameplate, pneumatic schematic, electrical schematic, and acceptance documents for the actual configuration.

0.1 Version History

0.2 Equipment Nameplate and Project Record

01Safety instructions

Improper operation may cause an accident. This equipment must be operated, maintained, and serviced only by trained and qualified personnel. Operators must understand site hazards, rated equipment parameters, tooling action logic, and emergency shutdown/unloading procedures.

1.1 Warning Levels

1.2 Prohibited Practices

1.3 Personal Protective Equipment and Site Requirements

Personnel performing installation, commissioning, or maintenance MUST wear the required personal protective equipment, including a hard hat, safety footwear, and protective gloves.

Provide clear access routes, safety labels, and necessary guarding or segregation around the work area. The floor must be free of significant oil contamination, standing water, and obstructions.

Do not operate the equipment at night or in poorly lit areas. The operator must continuously monitor the workpiece and tooling.

Compressed air must be clean, dry, and stable. The air supply must not contain oil, water, contaminants, or corrosive gases.

Personnel who are unwell, have consumed alcohol, or have taken medication that impairs judgment must not operate the equipment.

02Product overview

AUREK Pneumatic Industrial Manipulators are used for industrial workpiece handling, machine loading/unloading, assembly assistance, flipping and positioning, and transfer between workstations. Pneumatic balancing, rigid arms, and custom tooling work together to reduce manual-handling effort and improve handling stability and workstation efficiency.

2.1 Intended Applications

It is suitable for customized handling of light loads, heavy loads and special working conditions, as well as production scenarios that require the reduction of manual lifting, lifting, turning and alignment.

Typical industries include auto parts, new energy batteries, general manufacturing, logistics handling, electronics manufacturing, aerospace, etc.

Typical workpieces include automotive seats, sheet-metal parts, headliner trim, motor stators, cartons/enclosures, panels, tires, high-temperature castings, and roller products.

End-of-arm tooling can be customized for workpiece geometry, weight, surface condition, gripping surface, and motion path. Examples include vacuum cups, grippers, hooks, internal-expansion grippers, and inflatable shafts.

2.2 ARK-Series Installation Configurations

2.3 Engineered Delivery Process

03Structure and main components

A Pneumatic Industrial Manipulator normally consists of a base/column, rotary joints, main arm, secondary arm, lift cylinder, air receiver, pneumatic control enclosure, control handle, brakes, tooling interface flange, and custom tooling. Arm length, number of joints, brake type, tooling structure, and pneumatic-control logic are adapted to site conditions for each project.

Figure 2 Schematic diagram of the product structure of the Pneumatic Industrial Manipulator (the number corresponds to the table below, the specific structure is subject to the actual object)

3.1 Operating Principle

The equipment uses pneumatic balancing and a lever mechanism. The cylinder applies a balancing force to the load through the force arm, while a precision regulator sets and stabilizes cylinder pressure so the operator can raise, lower, translate, steer, and position the load with low operating force. Control logic switches between unloaded and loaded states; loss-of-air protection, joint brakes, and tooling interlocks reduce the risk of unintended movement.

3.2 Tooling-to-Machine Interface

Tooling design must match the workpiece center of gravity, gripping surface, surface material, allowable indentation, handling motion, and cycle time.

Vacuum tooling must include a vacuum generator/vacuum pump, vacuum gauge or vacuum switch, filter, and any required loss-of-vacuum protection.

Mechanical gripper tooling requires confirmation of gripping force, contact materials, slip and damage prevention, end stops, gripped-position feedback, and release interlocks.

For high-temperature workpiece tooling, evaluate thermal-insulation materials, air-tubing temperature rating, personnel safety distance, and the effect of nearby heat sources.

Tooling may be replaced, removed, or installed only after the workpiece has been unloaded, the air supply/electrical power shut off, residual pressure released, and the absence of motion hazards confirmed.

04Technical parameters and selection

4.1 Project customization parameters

4.2 Standard and Optional Features

4.3 Information Required Before Selection

05Transportation, storage and unpacking inspection

5.1 Transport and Storage

Do not stack product packages more than three high. Do not climb or stand on packages or place heavy objects on them.

During transport, do not overturn the tooling, subject it to severe impact, leave it tilted for prolonged periods, or apply abnormal external forces to it.

Protect packages from moisture, direct sunlight, rain, and corrosive-gas environments.

For long-term storage, keep the equipment dry and ventilated and protect critical moving parts against corrosion, dust, and impact.

Before returning the equipment to service, complete the Pre-Start Inspection and Maintenance Inspection Checklist.

5.2 Unpacking Inspection

06Installation and debugging

6.1 Pre-Installation Preparation

Confirm that the foundation, steel structure, or mobile base has sufficient capacity for the equipment and dynamic loads.

Confirm that site air-supply pressure, flow, line diameter, filtration, and drying capacity meet the equipment requirements.

Confirm that the installation area is free of obstructions and that the rotation radius has no fixed interference points or personnel-traffic hazards.

Clean and decontaminate bearings, rollers, rotary connections, pins, bolts, and other kinematic pairs; lubricate as required and check fastener tightness.

Install in accordance with the general arrangement drawing, foundation drawing, pneumatic schematic, electrical schematic, and approved project drawing.

6.2 Column-Mounted Foundation Requirements

Column-mounted manipulators are generally secured to the foundation with expansion anchors or chemical anchors. The standard recommendation is a concrete thickness of at least 200 mm and a strength grade of at least C25. If the site foundation is inadequate, embedded-anchor or reinforcement design must be completed by qualified professionals.

Figure 3 Installation diagram of column foundation (for reference only, the project shall be subject to the foundation drawing)

6.3 Overhead-/Rail-Mounted Installation Requirements

The overhead steel structure, gantry, rails, lifting points, and connections must be verified for load capacity. Do not attach the equipment directly to an unverified lightweight roof or non-load-bearing member.

Provide mechanical end stops and anti-drop devices at rail ends, and safety buffers at both ends of the travel range.

After installing overhead-mounted equipment, verify the lowest point, highest point, personnel clearance height, and interference with surrounding equipment.

All work at height MUST comply with site regulations for working at height.

6.4 Commissioning Procedure

07operating procedures

7.1 Pre-Start Inspection

7.2 Typical Operating Sequence

7.3 Control Functions

Control names and quantities vary by tooling type, flipping mechanism, and interlock method. Typical controls are listed below. The labels on the actual equipment and the pneumatic/electrical schematics take precedence.

7.4 Unloaded- and Loaded-Balance Adjustment

Unloaded-pressure adjustment: With no workpiece gripped, adjust unloaded pressure so the manipulator raises easily and remains stably suspended. Turning clockwise normally increases pressure; turning counterclockwise decreases it.

Loaded-pressure adjustment: After gripping a standard workpiece, switch to the loaded state, then adjust loaded pressure so the workpiece remains stably suspended.

When switching frequently among workpieces of different weights, follow the project's multi-pressure/multi-load logic. Never make unauthorized valve-manifold adjustments based solely on experience.

If the manipulator raises, lowers, or drifts rapidly on its own, or if operating force increases significantly, stop production immediately and recheck balance and the air supply.

08Maintenance and inspection

Regular maintenance improves equipment stability and reduces unplanned downtime. Maintenance personnel MUST be trained and familiar with the equipment structure, pneumatic-control logic, tooling functions, and potential hazards. Before any maintenance work, unload the workpiece from the tooling, secure the arms, shut off the air supply/electrical power, and release residual pressure.

8.1 Routine Maintenance

8.2 Detailed Equipment Inspection Checklist

Note: “Daily” means the visual/functional check performed by the first operator on duty. “Weekly,” “1 Month,” and “6 Months” are periodic inspections by maintenance personnel or the designated responsible person. Every abnormal inspection result MUST be recorded and tracked through close-out.

8.3 Lubrication and Air-Supply Requirements

Moving parts are lubricated before shipment or use self-lubricating components. During normal service, follow the project-specific maintenance requirements.

Never add oil to the compressed air; doing so can contaminate the valve manifold, filter, and precision pneumatic components.

The air supply must be stable, clean, and dry. If the site has high moisture or dust levels, add upstream filtration, a dryer, or an air receiver.

If regulator drift, an abnormal pressure-gauge reading, or delayed valve response is found, have qualified personnel inspect or replace the affected component.

09Troubleshooting

9.1 Basic Troubleshooting Requirements

If an abnormal condition threatens personnel, equipment, or product safety, activate the emergency stop or shut down the equipment immediately.

Isolate the main air supply and prevent unintended restoration. Apply lockout/tagout when necessary.

Report the fault to the site supervisor and record the symptom, time, operating conditions, workpiece weight, and operating steps.

Qualified personnel must identify and correct the fault. Do not force a reset or resume production before the fault is corrected.

After correction, you MUST inspect assembly, pneumatic circuits, tooling, safety devices, and the work area. Conduct a test run only after confirming that no personnel remain in the area.

9.2 Common Faults, Causes, and Corrective Actions

10Decommissioning, relocation and retirement

10.1 End-of-Shift Shutdown

Unload the workpiece and place it in a stable position; confirm that the tooling is unloaded.

Move the tooling to its lowest safe position or designated parking position, clear of personnel routes and equipment interference zones.

Engage the required joint brakes, shut off the air supply/electrical power, and release residual pressure.

Clean the control handle, tooling, vacuum cups/gripper pads, and floor; complete the inspection record.

10.2 Long-Term Shutdown

Shut off and isolate the air supply/electrical power. Remove or secure tooling accessories that could be damaged by external forces.

Apply corrosion protection to exposed metal, moving parts, and flange mating surfaces.

Cover the pneumatic control enclosure, pushbutton panel, and precision components with dust covers or packaging material.

Before returning the equipment to service, complete a full-equipment inspection, airtightness check, unloaded/loaded commissioning, and safety-function tests.

10.3 Relocation and Disposal

Before relocation, qualified personnel must assess the foundation, steel structure, lifting plan, disassembly/reassembly sequence, and recommissioning requirements.

Do not place relocated equipment directly into production. Recommission and re-accept it in accordance with the installation and commissioning procedure.

At disposal, segregate and handle metal structures, pneumatic components, electrical components, oil-contaminated parts, and packaging materials in accordance with local regulations.

Figure 4 Example of high-temperature casting handling application (the fixture configuration is subject to the project design)

Appendix A Contact and Service