| Document No. | AUREK-OM-ARK-001 |
|---|---|
| Version/Date | V1.1 / 2026-06 |
| Applicable Products | ARK-Series Pneumatic Industrial Manipulators and Custom Tooling |
| Manufacturer | Jiangsu AUREK Intelligent Technology Co., Ltd. |
| Official Website | www.aurek.cn |
Read this manual in full before installation, commissioning, operation or maintenance, and retain it for site reference.
00Document and equipment information
This manual applies to AUREK column-mounted, mobile, overhead-mounted and other pneumatic industrial manipulators. The arm, tooling, mounting structure and control logic are configured for the workpiece and site conditions. Before use, check the equipment information in the contract, project drawings, nameplate, pneumatic and electrical diagrams and acceptance documents.
| Important Information Any operation not expressly permitted by this manual shall be considered prohibited. Exceeding the rated load, making unauthorized changes to pneumatic/electrical circuits or the structure, or bypassing a safety device may cause equipment damage or personal injury. |
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0.1 Version History
| Version | Date | Revision Details | Prepared/Approved By |
|---|---|---|---|
| V1.1 | 2026-06 | Standardized structural-component terminology, parameter descriptions, safety requirements, maintenance and inspection items, troubleshooting content, and formatting; added a structural diagram and numbered reference table. | Engineering/After-Sales Service |
0.2 Equipment Nameplate and Project Record
| Item | Details | Item | Details |
|---|---|---|---|
| Customer name | Project number | ||
| Equipment model | Serial number | ||
| Rated load | kg | Maximum working radius | mm |
| Lifting Stroke | mm | Air-Supply Pressure | MPa |
| Tooling type | Mounting Configuration | □Column-mounted □Mobile □Overhead-mounted □Other | |
| Delivery date | After-sales contact |
01Safety instructions
Only trained and qualified personnel may operate, maintain or repair the equipment. Before starting work, they must understand site risks, rated parameters, tooling logic and emergency-stop/unloading procedures. Incorrect operation may cause accidents.
| SPECIAL WARNING Never connect or disconnect the air supply, close the air-supply shutoff valve, or make unauthorized pneumatic-circuit adjustments while the equipment is operating, gripping a workpiece, or supporting a suspended load. Before restoring the air supply/electrical power, you MUST confirm that the tooling is at its lowest safe position and is not gripping a workpiece. The tooling may move suddenly when the air supply/electrical power is restored. |
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1.1 Warning Levels
| Signal Word | Meaning | Potential Consequences | Required Action |
|---|---|---|---|
| DANGER | An immediate, severe hazard exists. | May result in serious injury, death, or major equipment damage. | Stop work immediately. Do not continue until the hazard has been eliminated. |
| WARNING | A significant hazard or risk of incorrect operation exists. | May result in personal injury or equipment damage. | Follow the specified procedure strictly; contact the manufacturer when necessary. |
| CAUTION | A condition may affect stable equipment operation or service life. | May result in minor injury, product damage, or malfunction. | Inspect, maintain, and document as required. |
1.2 Prohibited Practices
| No. | Prohibited Practice | Risk |
|---|---|---|
| 1 | Never overload the equipment or lift a workpiece that exceeds the rated load on the equipment nameplate. | Overloading may cause failure of the arms, cylinder, connections, or tooling. |
| 2 | Personnel must not stand or pass beneath the load or main arm, or within the tooling travel path. | Unexpected descent or swinging of the load or tooling may cause personal injury. |
| 3 | Never leave a suspended load unattended. | Air-supply fluctuations, incorrect operation, or tooling leakage may cause the load to fall. |
| 4 | Do not make unauthorized modifications to pneumatic circuits, valve manifolds, regulators, end stops, brakes, or tooling structures. | Doing so may compromise balance control and loss-of-air protection. |
| 5 | Do not weld, cut, strike, or forcibly drag a suspended load. | Doing so may cause structural damage, load swing, or tooling failure. |
| 6 | Keep hands, clothing, and tools away from rotating joints, gripper jaws, cylinders, and other moving parts. Never reach into these areas. | Contact may cause pinching, entanglement, or component damage. |
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 combine pneumatic balancing, rigid arms and custom tooling to assist workpiece handling, machine loading and unloading, assembly, turning and positioning, and transfers between stations, reducing the handling load supported directly by personnel.
2.1 Intended Applications
Equipment is selected for light loads, heavy loads or special conditions, for production tasks requiring assisted support, lifting, turning and alignment.
Typical industries include automotive components, new energy batteries, general manufacturing, logistics handling, electronics manufacturing and aerospace.
Typical workpieces include automotive seats, sheet-metal parts, headliner trim, motor stators, cartons/enclosures, panels, tires, high-temperature castings, and roller products.
End tooling is designed for workpiece shape, weight, surface condition, gripping faces and motion path. Options to compare include vacuum cups, jaws, hooks, internal-expanding tooling and air-expanding shafts.
2.2 ARK-Series Installation Configurations
| Series | Installation Configuration | Suitable Applications | Main Features |
|---|---|---|---|
| ARK-S | Column-Mounted / Floor-Fixed | Fixed-workstation handling, machine loading/unloading, and assembly assistance. | Stable structure with a clearly defined footprint; customizable for workpiece weight, radius, and path. |
| ARK-M | Mobile / Counterweighted Base | Shared use across multiple workstations, frequently reconfigured lines, and temporary workstations. | Can be repositioned manually or with electric assistance while unloaded. Loaded operation is permitted only after the equipment reaches the workstation and its base is secured as specified. |
| ARK-O | Overhead-Mounted / Ceiling-Fixed / Rail-Mounted | Applications with limited floor space, dense equipment layouts, or a large coverage area. | Saves floor space and can be integrated with a truss or rail system. |
2.3 Equipment design and delivery process
| Stage | Core Activities | Deliverables/Approval Points |
|---|---|---|
| Analysis | Confirm workpiece weight, dimensions, gripping surfaces, cycle time, motion path, site space, air-supply conditions, and safety risks. | Requirements list, site-survey record, and preliminary solution. |
| Design | Develop the structural concept, tooling concept, pneumatic-control logic, 3D CAD design, simulation verification, and any required prototype review. | Concept drawings, three-dimensional models, pneumatic/electrical design, and quotation scope. |
| Review | Confirm workpiece compatibility, operating method, installation configuration, maintenance space, safeguards, and acceptance criteria with the customer. | Approved drawings, technical agreement, and review record. |
| Production | Fabrication and assembly, pneumatic installation, factory testing, packaging and shipment, on-site installation and commissioning, and training. | Factory inspection record, acceptance form, operation manual, and maintenance record form. |
03Structure and main components
The equipment typically comprises a base/column, rotary joints, main arm, secondary arm, lifting cylinder, air reservoir, pneumatic control box, operating handles, brakes, tooling connection flange and custom tooling. Arm length, joint count, braking method, tooling structure and pneumatic logic are configured for the project conditions.
| No. | Component | Function |
|---|---|---|
| 1 | Fixed Mounting Base | Secures and supports the complete equipment assembly to ensure stable manipulator installation. Depending on the project, the equipment may be floor-mounted, installed on a mobile base, or connected to a steel structure. |
| 2 | Load-Bearing Column | Supports the complete equipment weight and provides the supporting structure for the upper rotary assembly, arms, and pneumatic system. |
| 3 | Main Rotary Joint | Allows the manipulator to rotate horizontally, extending the workpiece pickup and placement coverage area. |
| 4 | Lower Lift-Cylinder Support | Secures the lower end of the lift cylinder, maintains stable cylinder loading, and provides a reliable connection to the arm mechanism. |
| 5 | Safety Air Receiver | Provides reserve air during supply fluctuations or a brief loss of air for the safe unloading or slow descent sequence specified in the project design. Verify the supported actions and duration against the configuration of this equipment. |
| 6 | Pneumatic Control Enclosure | Houses the principal pneumatic-control components, pressure-regulation components, and protection modules for convenient commissioning, maintenance, and fault inspection. |
| 7 | Lift Cylinder | Provides vertical assist for unloaded/loaded balance and raising/lowering motion. |
| 8 | Main-Arm Support | Connects the column to the main arm, carries main-arm motion loads, and provides the main arm's mounting and load-support point. |
| 9 | Main Arm | Carries handling motion within the principal operating radius and is the main structure that defines horizontal coverage. |
| 10 | Intermediate Rotary Joint | Connects the main arm and secondary arm, enabling multi-angle steering and flexible pickup and placement. |
| 11 | Secondary arm | Extends the operating range and improves access to workpieces and flexibility when transferring between workstations. |
| 12 | Front Rotary Joint | Connects the front-end actuation structure and supports tooling-direction adjustment, orientation control, and workpiece positioning. |
| 13 | Front Connection Arm | Connects the control handle, front joint, and tooling interface for compatibility with different end effectors. |
| 14 | Control Handle | Held by the operator to control raising, lowering, gripping, release, flipping, braking, and other equipment functions. |
| 15 | Tooling Connection Flange | Connects custom tooling and end effectors such as vacuum cups, hooks, grippers, and internal-expansion mechanisms. |
3.1 Operating Principle
The equipment uses pneumatic balancing and a lever mechanism. A cylinder provides load-balancing force through the arm, while a precision regulator sets and stabilizes cylinder pressure, allowing the operator to guide lifting, translation, turning and positioning. Control logic switches between unloaded and loaded states; air-loss protection, joint brakes and tooling interlocks reduce the risk of unintended actions.
3.2 Tooling-to-Machine Interface
- Tooling must suit the workpiece's centre of gravity, gripping faces, surface material, permitted indentation, handling motions and cycle-time requirements.
- Vacuum tooling should include a vacuum generator/pump, vacuum gauge or switch, filter and any necessary protection against loss of vacuum.
- For jaw tooling, verify clamping force, contact materials, slip prevention and surface protection, stops, clamped-position confirmation signals and release interlocks.
- For hot-workpiece tooling, verify insulation materials, hose temperature resistance, personnel separation distance and the effects 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
| Project design basis The table lists parameters to confirm during design assessment and does not define fixed product capacities. AUREK equipment is configured for each project. Final load, radius, stroke, tooling, installation method, drive system and safety configuration follow the project drawings, nameplate and acceptance documents. |
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4.1 Project customization parameters
| Parameter | Normal operating conditions | Heavy loads / Special conditions | Description |
|---|---|---|---|
| Rated load | Assessed for the workpiece and tooling together. | Application-specific structural design. | Confirm from workpiece weight, tooling weight, eccentric loading, and the safety factor. |
| Working Radius | Configured for the pickup and placement distance. | Designed for the available space and handling routes. | Assess site space, slewing range, operating inertia and load together. |
| Lifting Stroke | Customized to Pick-and-Place Heights | Designed for the motion path. | Actual stroke depends on installation height, tooling length, and workpiece orientation. |
| Rated Operating Air Pressure | 0.5–0.8 MPa | Confirmed against the drive configuration. | A stable supply of clean, dry compressed air and a filter-regulator are recommended. |
| Operating Temperature | -15–50 °C | Designed for the operating environment. | High-temperature, low-temperature, cleanroom, hazardous-area, and other special applications require dedicated engineering. |
| Relative Humidity | ＜90% | Designed for the operating environment. | Avoid prolonged exposure to condensation, corrosive gases, and dust. |
| Drive Type | Pneumatic or Electric | Configured for the application. | Normal applications primarily use pneumatic balancing; special cycle-time or operating requirements can be addressed through custom design. |
4.2 Basic and optional configurations
| Category | Feature | Description |
|---|---|---|
| Basic configuration | Multiple Rotary Joints | Provides pickup and placement over a broad area and supports transfer and positioning between workstations. |
| Basic configuration | Joint Brakes | Brakes/end stops can be provided as required at the main, intermediate, and front joints. |
| Basic configuration | Backup Air Supply / Air Receiver | Provides reserve air during a main-supply fault for the slow descent or safe unloading sequence specified in the project design. Verify its capabilities against the configuration of this equipment. |
| Basic configuration | Protective Enclosure / Pneumatic Control Enclosure | Protects precision pneumatic components and simplifies maintenance. |
| Optional | Extended/Widened Arm | Extends the operating radius or clears equipment interference. |
| Optional | Lift End Stop / Loss-of-Air Brake | Improves safety at travel limits and under loss-of-air conditions. |
| Optional | Counterweights / Counterweighted Base | For heavy loads, mobile bases, or tooling with an eccentric load. |
| Optional | Special Coating / Stainless-Steel Structure | For clean, humid, corrosive, or brand-color-specific applications. |
| Optional | Air Compressor / Mobile Base | For insufficient on-site air supply or flexible use across multiple workstations. |
4.3 Application information required for selection
| Category | Information to Confirm |
|---|---|
| Workpiece Information | Weight, dimensions, center of gravity, material, surface condition, permitted gripping/vacuum points, and susceptibility to deformation. |
| Motion Requirements | Pickup and placement heights, transfer distance, flipping angle, rotation direction, cycle time, and required positioning accuracy. |
| Site Information | Space around the equipment, aisle width, foundation conditions, overhead steel structure, air/electrical supply, temperature and humidity, dust, and oil contamination. |
| Safety Information | Personnel traffic areas, hazards beneath the load, emergency-stop/brake requirements, tooling loss-of-pressure protection, and secondary restraints. |
| Delivery Information | Site access route, installation window, acceptance criteria, intended trainees, spare parts, and maintenance plan. |
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.
- When returning equipment to service after prolonged storage, complete each item in the pre-start checks and maintenance checklist.
5.2 Unpacking Inspection
| Inspection Item | Inspection Details | Corrective Action |
|---|---|---|
| Product Identification | Verify the equipment model, customer project, drawing revision, and nameplate data. | If the model does not match, stop installation and contact AUREK. |
| Appearance and Structure | Inspect the arms, column, base, cylinder, pneumatic control enclosure, and tooling for shipping damage. | Record photographs and assess the extent of damage before taking corrective action. |
| Accessories | Verify that fasteners, air tubing, fittings, the filter-regulator, documentation package, and spare parts are complete. | Supply missing items in accordance with the packing list. |
| Drawings and Documentation | Verify the operation manual, pneumatic schematics, electrical schematics, acceptance records, certificates, and other documents. | Missing documents must be supplied before the equipment is released for use. |
06Installation and commissioning
| Installation Responsibility Installation, relocation, foundation reinforcement, overhead suspension, and rail/gantry connections MUST be performed by qualified professionals. The equipment must not enter production before installation is complete. |
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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 assembly, foundation, pneumatic and electrical drawings and the approved project drawings.
6.2 Column-Mounted Foundation Requirements
Column-mounted manipulators are generally secured to the foundation with expansion anchors or chemical anchors. The general 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.
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
| Step | Action | Acceptance Criterion |
|---|---|---|
| 1 | Inspect all load-bearing bolts, pins, flanges, cylinder connections, and tooling connections. | All fasteners are secure, with no looseness, cracks, or abnormal deformation. |
| 2 | Connect a supply of clean, dry compressed air and slowly open the main air-supply valve. | The filter-regulator reads normally and the pneumatic circuit has no obvious leaks. |
| 3 | Adjust unloaded-balance pressure with no load attached. | The arms raise and lower easily without unintended rapid upward or downward movement. |
| 4 | After gripping a test workpiece, switch to the loaded state and adjust loaded balance. | The load remains stably balanced/suspended, operating force is low, and the tooling does not slip. |
| 5 | Test raising/lowering, rotation, brakes, pickup, release, flipping, and other functions. | The action sequence is correct, and end stops and interlocks operate effectively. |
| 6 | Complete a full handling-cycle test at the actual workstation. | No interference or abnormal noise, and no pulling or kinking of air tubing. |
| 7 | Provide and document safety training for operators. | Operators understand prohibited practices, daily inspection, and troubleshooting procedures. |
07Operating procedures
| Pre-Operation Check The first operator on each shift MUST complete the pre-start inspection. If abnormal noise, an air leak, rough motion, loose tooling, a cracked weld, insufficient air pressure, or brake failure is found, remove the equipment from service immediately and report the condition. |
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7.1 Pre-Start Inspection
| Inspection item | Acceptance Check |
|---|---|
| Air Supply | Pressure meets project requirements and the compressed air is clean and dry. Condensate in the filter-regulator bowl is below the level mark. |
| Load-Bearing Connections | Base, column, arms, cylinder, flange, and tooling connections have no looseness, cracks, or deformation. |
| Air Tubing/Cables | No bulges, cracks, kinks, or wear, and no interference with rotary joints or moving parts. |
| Tooling | Gripper jaws, vacuum cups, hooks, and internal-expansion elements are undamaged; gripping surfaces are clean; fasteners are secure. |
| Brakes/End Stops | Joint brakes, lift end stops, mechanical end stops, and interlocks function correctly. |
| Work Area | The load path is free of personnel, obstructions, and unsecured items; the floor is clean. |
7.2 Typical Operating Sequence
| Step | Operation | Precautions |
|---|---|---|
| 1 | Open the main air supply and confirm that the pressure gauge/indicator is within its normal range. | Do not open the valve abruptly. If abnormal leakage occurs, close it immediately. |
| 2 | Move the unloaded manipulator to the pickup position. | Keep both hands on the control handle or in the specified positions, clear of joint pinch points. |
| 3 | After confirming correct contact between the tooling and workpiece, perform the pickup operation. | For vacuum tooling, confirm the required vacuum level; for jaw tooling, confirm that the required clamped position has been reached. |
| 4 | Switch to the loaded-balance/Load state. | Do not press Load when no workpiece is present. Do not move rapidly until the load is stable. |
| 5 | Raise, lower, rotate, transfer, flip, or position at a smooth, controlled speed. | Keep the workpiece in view at all times. Never move a load over personnel. |
| 6 | At the placement position, seat the workpiece securely and transfer its weight to the support. | Release the tooling only after the workpiece is fully supported and stable. |
| 7 | Release the tooling and confirm that the workpiece is secure; return unloaded or move to the parking position. | At the end of the shift, lower the tooling to its lowest safe position and shut off the air supply. |
7.3 Control Functions
Button names and quantities depend on the tooling, turning mechanism and interlock configuration. Identify control functions from the equipment-panel labels and pneumatic/electrical diagrams. The following table explains common controls.
| Control | Function | Operating Precautions |
|---|---|---|
| Brake Knob/Button | Engages or releases the brake at the column, main joint, or designated joint. | Before moving, confirm that the brake is released; lock it as required when parked. |
| Pickup/Grip | Actuates gripper clamping, vacuum gripping, or the internal-expansion mechanism. | You MUST confirm that the workpiece is correctly positioned. |
| Load / Loaded Balance | After gripping the workpiece, switches the system to the loaded-balance state. | Do not operate this control without a workpiece. |
| Release | Releases the tooling after the workpiece is moved to the specified position. | Do not release the workpiece until it is stable. |
| Raise/Lower | Controls vertical direction or assists with fine height adjustment. | Do not hold the drive against an end stop for an extended period. |
| Flip/Rotate | Controls tooling orientation by flipping, rotating, or positioning it at an angle. | Confirm that the surrounding area is clear of personnel and interference. |
| Emergency stop | Stops motion immediately when personnel or equipment safety is at risk. | Do not reset or resume production until the fault has been corrected. |
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 moves upward or downward without a command, drifts rapidly, or requires substantially increased operating force, stop production immediately and recheck balancing and the air supply.
08Maintenance and inspection
Maintenance personnel must be trained and familiar with the equipment structure, pneumatic logic, tooling movements and potential hazards. Before any maintenance, remove the workpiece from the tooling, lock the arms, shut off the air/electrical supplies and release residual pressure. Periodic maintenance identifies and corrects abnormalities affecting equipment operation.
8.1 Routine Maintenance
| Item | Maintenance Requirement | Recommended Frequency |
|---|---|---|
| Filter-Regulator / Air-Preparation Unit | Drain condensate, inspect the filter element for contamination, and maintain a dry compressed-air supply. Add upstream filtration if air quality is poor. | Inspect daily during the first month of service; thereafter, set the interval according to air-supply quality. |
| Air Tubing and Fittings | Inspect around rotary joints for wear, kinking, aging, or leaks. Prevent debris and foreign objects from abrading or cutting air tubing. | Visual inspection daily; detailed inspection weekly. |
| Load-Bearing Connections | Inspect bolts, pins, and welds at the base, column, arms, cylinder, and tooling connections. | Inspect carefully every week. |
| Tooling | At the end of the shift or before an extended shutdown, unload the workpiece, secure the tooling, and retract it to the minimum radius or designated parking position. | At the end of every shift. |
| Brakes/End Stops | Confirm reliable operation of joint brakes, lift end stops, mechanical end stops, and interlock switches. | Daily functional check. |
| Cleaning | Remove dust and oil contamination from tooling, suction cups, guides, and the control panel; keep labels legible. | Daily / According to site contamination. |
8.2 Detailed Equipment Inspection Checklist
| Category | Inspection Item | Inspection Details | Daily | Weekly | 1 Month | 6 Months |
|---|---|---|---|---|---|---|
| Rails/Suspension Connections | Fasteners | No loose or detached components | ● | ● | ||
| Rails/Suspension Connections | Welded Areas | No cracked or failed welds | ● | |||
| Rails/Suspension Connections | Rotation/Travel | Rotates or travels freely, with no binding | ● | |||
| Rails/Suspension Connections | Safety pin / Retaining device | Securely locked; retaining device effective. | ● | |||
| Manipulator Body | Welded Areas | No cracked or failed welds | ● | |||
| Manipulator Body | Vertical and Rotary Motion | Smooth and free of binding or abnormal noise | ● | |||
| Manipulator Body | Fasteners and End Stops | Fasteners are not loose; end stops are securely attached | ● | |||
| Arms and Joints | Welded Areas | No cracked or failed welds | ● | |||
| Arms and Joints | Main-Arm Rotation | Reaches the stop position accurately; brake is effective | ● | |||
| Pneumatic Control System | Wear at Moving Parts | No abnormal wear or excessive clearance | ● | |||
| Pneumatic Control System | Air-Preparation Unit / Filter | No leaks; pressure meets project requirements; condensate drained | ● | |||
| Pneumatic Control System | Air Tubing | No bulges, cracks, or kinks, and no abrasion against moving parts | ● | |||
| Tooling System | Tooling Operation | Connections are secure; valves shift and reset freely | ● | |||
| Tooling System | Cylinder/Actuator | Connections are secure; motion is smooth and free of stick-slip | ● | |||
| Safety System | Emergency Stop / Interlock / Loss-of-Air Protection | Operates correctly; test records are complete | ● | ● |
Inspection responsibilities: the operator on the first shift of each day performs the daily visual/functional checks; the maintenance team or designated responsible person performs weekly, 1-month and 6-month checks. Record abnormalities and track corrective-action outcomes.
8.3 Lubrication and Air-Supply Requirements
- Moving parts are lubricated before delivery or use lubrication-free components. Perform maintenance during service according to the project 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, immediately follow the emergency-stop procedure specified for this equipment. Do not disconnect air hoses or interrupt the air supply indiscriminately as a substitute for emergency stopping.
- After completing the load stabilization, unloading or other safe response specified for this equipment, isolate the main air supply and prevent unintended restoration. During maintenance, follow site requirements for isolation and tagging.
- Report the fault to the site supervisor and record the symptoms, time of occurrence, 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
| No. | Symptom | Possible Causes | Inspection and Corrective Action |
|---|---|---|---|
| 1 | Manipulator Will Not Rise | Air supply not open; air-supply pressure too low; loaded-state switching not completed; air tubing kinked or fitting disconnected; load exceeds rated capacity. | Open the air supply; check main supply pressure and adjust the filter-regulator; check the Load module; straighten or replace air tubing/fittings; operate within the rated load. |
| 2 | Manipulator Will Not Descend | Air-supply pressure has fallen or air was unexpectedly lost during operation, activating a safety device; module is not operating correctly. | Check that the air supply is stable; repair the loss-of-air or leak point; check for pilot air at the control port; confirm the safety-device reset conditions. |
| 3 | Manipulator Rises or Falls on Its Own | Unloaded- or loaded-balance pressure is incorrectly adjusted; workpiece weight does not match the preset load; valve leakage. | Readjust unloaded/loaded balance; verify workpiece weight; inspect the regulator, directional valve, and cylinder seals. |
| 4 | Arm Will Not Rotate or Brake Will Not Release | Brake fault; related air tubing is kinked; end stop has been reached; debris is binding the joint. | Straighten or replace air tubing and fittings; inspect the control valve and brake mechanism; adjust the end stop; remove debris. |
| 5 | Gripper Does Not Hold / Vacuum Tooling Does Not Grip | Insufficient air pressure/vacuum; worn suction cup or contaminated gripper contact surface; workpiece surface is incompatible with the current tooling; damaged seal. | Check the air/vacuum supply; clean or replace suction cups/gripper pads; verify tooling compatibility with the workpiece; replace seals. |
| 6 | Slow Motion or Abnormal Noise | Insufficient air flow; blocked filter; inadequate joint lubrication or joint wear; cylinder stick-slip. | Check main-line flow and the filter element; clean and service as required; inspect joint bearings and the cylinder; contact the manufacturer for service. |
| 7 | Air Tubing Wears Frequently | Incorrect tubing routing; bend radius too small; missing protective sleeve or supports. | Reroute the tubing; add a cable carrier/protective sleeve/supports; provide sufficient movement allowance. |
| Service Notice If a fault involves a load-bearing structure, cylinder, valve manifold, loss-of-air protection, emergency-stop interlock, or tooling safety logic, do not dismantle or modify the equipment yourself. Contact AUREK Technical Support/After-Sales Service. |
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10Shutdown, relocation and disposal
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, steelwork, lifting plan, dismantling and 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.
Appendix A Contact and Service
| Item | Details |
|---|---|
| Company Name | Jiangsu AUREK Intelligent Technology Co., Ltd. |
| English name | Aurek Intelligent Technology |
| Address | No. 1 Tongzhou Road, Guannan Economic Development Zone, Lianyungang, Jiangsu, China |
| Telephone | +86 190 5120 6661 |
| sales@aurek.cn | |
| Official Website | www.aurek.cn |
| Service Scope | Custom pneumatic industrial manipulators, application-specific tooling, vacuum lifters, articulating jib cranes, intelligent hoists and industrial material-handling systems. |
