- Before first assignment, complete training in equipment structure, tooling principles, permitted application limits and abnormal-condition response, with practice using the actual site workpieces.
- The standard sequence has eight steps: approach → grip → confirm → lift → transfer → lower → release → return. Complete at least one full handling cycle during training.
- You must remember the prohibited operations: overloading, diagonal lifting, impact, entering the danger zone, rapid arm swing, lifting without clamping, and adjusting the air pressure and tooling units without permission.
- The assessment must confirm that employees can independently complete one full, smooth handling cycle without hazardous actions and respond correctly to common abnormalities.
First-use training for a pneumatic industrial manipulator should center on the actual workstation. Identify the equipment and tooling structures, confirm the permitted workpiece range, then practice standard motions and abnormal-condition response. Operators may begin formal work only after completing the necessary training. Use the following content to organize initial training and record results with the confirmation checklist at the end.
01First understand the basic components of the equipment
The trainer should explain each component on the actual equipment and have the new employee identify it, emphasizing the relationship between components and operating actions:
- Column: The supporting foundation of equipment, usually fixed to the ground, base or track structure.
- Main arm / Secondary arm: Provide rotation, extension and transfer within the specified range.
- Joints: Connect the arm sections and allow movement within the specified range.
- Cylinder: The principal actuator in a pneumatic industrial manipulator, used for balancing, lifting or auxiliary motion.
- Tooling: Contacts the workpiece directly and may use jaws, suction cups, wraparound clamps, internal-expanding grips, magnetic grips or custom combinations.
- Control handle: Allows the operator to command gripping, lifting, lowering and release.
- Air supply system: Includes the air inlet, filter-regulator, hoses, fittings and pressure gauge, and directly affects motion stability.
02Clarify the scope of workpieces allowed to be transported
Before use, check the equipment's design load and tooling application range, then verify the current workpiece's weight, dimensions, center of gravity and surface condition. Determine whether handling is permitted from the equipment requirements, not an estimate based on experience.
- Look at the weight: The weight of the workpiece must be within the rated load of the equipment and the allowable load of the fixture. Overloading is strictly prohibited.
- Look at the size: Workpieces that are too long, too wide or irregularly shaped, even if the weight does not exceed the standard, may cause risks due to swinging, unbalanced loading or blocking of sight.
- Check the center of gravity: An offset center of gravity loads the tooling unevenly and may cause tilting, slipping or rotation after lifting.
- Check the surface: For vacuum tooling, assess whether the surface is flat, clean and dry, and check for oil, dust, holes or uneven texture. For jaw tooling, confirm sufficient strength at the gripping point and assess the risk of crushing the product or closing without engaging it.
Demonstrate custom-tooling use with actual site workpieces, clearly identifying designated gripping points and prohibited locations so that employees can judge whether a grip location meets the requirements.
03Check before starting: the first step for safe operation
Before each shift, operators should perform the following basic inspection, with periodic review by the team leader or equipment administrator:
- Check whether the air pressure is within the specified range - if the pressure is too low, it may not be clamped firmly or the lift may be weak, and if the pressure is too high, it may move too fast or damage the components.
- Check whether the pneumatic tubing is bent, aged, worn or leaking, and whether the joints are loose.
- Check whether the clamp structure is firm and whether bolts, pins, and buckles are missing or loose.
- Use the suction cup fixture to check whether the suction cup is damaged, deformed, or aged, and whether the vacuum pipeline is leaking.
- Check whether the limit device is effective and whether there are any obstacles within the action range of the manipulator.
- Confirm that the emergency stop button is in an operable position and that employees know how to use it.
- If the equipment has air supply processing components, check the water accumulation in the filter cup, the status of the lubricator and the pressure gauge reading.
04Standard Handling Sequence and Practical Training
Practice the following eight steps in order so that grip confirmation, a low-level trial lift and secure placement before release become fixed parts of every handling cycle:
- Step One · Approach the Workpiece: Stand in a safe position and slowly push the manipulator close to the workpiece to avoid collision with peripheral equipment and personnel.
- Second Step · Grip: Align the clamp at the designated clamping position to ensure that the clamping jaws, suction cups or positioning surfaces are in full contact with the workpiece.
- Step Three · Confirm: After gripping, check the clamping, vacuum or status indication. Confirm that the workpiece is not skewed, inadequately engaged or held only at an edge.
- Step Four · Lifting: Lift slowly, leave the table or pallet a small height first, and then continue to lift after confirming it is stable.
- Step Five · Horizontal Travel: Keep moving at a steady speed, without pushing hard, swinging arms, or turning suddenly.
- Step Six · Descend: After approaching the placement position, slowly descend to prevent crushing of the workpiece, tooling or hands.
- Step Seven · Release: After confirming that the workpiece has been stably positioned, release the clamp or release the vacuum.
- Eighth Step · Reset: Return the manipulator to the specified parking position and do not hang it in the passage or above the head of the person.
Have each employee complete at least one full handling cycle during training. The team leader should observe grip confirmation, transitions between actions and safe positioning, correcting hazardous habits promptly.
05Prohibited operations that must be remembered
The following actions are prohibited. During training, identify the corresponding hazardous areas and incorrect movements at the workstation:
- Overloading is prohibited: Do not handle workpieces that exceed the weight, size, or clamping range.
- Angled pulling and lifting are prohibited: Do not use the manipulator to drag a jammed workpiece.
- Impact operation is prohibited: Do not hit the workpiece, material rack or equipment with the clamp.
- Personnel are prohibited from entering dangerous areas: No one is allowed to stand under the workpiece, within the movement path or within the rotation area.
- Rapid arm swinging is prohibited: This includes sudden acceleration, abrupt stopping and large-angle swinging, particularly with a suspended workpiece.
- Do not lift before confirming a secure grip: If vacuum holding is unstable or the grip is skewed, place the workpiece back immediately.
- Unauthorized adjustments are prohibited: Air pressure, travel limits, balance valves, flow-control valves and tooling structures must be adjusted by the equipment administrator or the manufacturer's engineers.
Post the prohibitions near the workstation and verify compliance during daily safety inspections.
06On-site handling methods for common abnormalities
Abnormal-condition training should verify that employees can recognize fault symptoms, stop hazardous operation, and report and respond as required:
- Loss of air or significant drop in air pressure: Stop transporting immediately, keep personnel away from the workpiece, place the workpiece safely according to equipment requirements or wait for maintenance personnel to handle it.
- vacuum gripping is unstable: Do not continue to lift, put the workpiece back to its original position, and check the suction cup, workpiece surface condition and compressed-air supply.
- Workpiece slides: Do not lift it directly with your hands. You should first lower the height, stop moving, and notify the team leader.
- Manipulator binding: Do not pull forcibly. Check whether a travel limit has been reached, air hoses are entangled or joints are obstructed.
- Abnormal noise / air leakage / sudden fast and slow movements / automatic drift: Stop the machine immediately and report for repair.
- An emerging hazard: Operators must know how to use the emergency stop correctly and how to report, isolate and recover afterward.
07Ergonomics and safe positioning
Safe positioning must allow comfortable control and clear observation. Stand beside the workpiece or where the control handle is readily operated; never stand directly beneath the workpiece or in a crushing zone between the workpiece, manipulator and rack. Hold the control handle or designated grip. Keep hands out of clamping faces, landing areas and rotary joints. Maintain sight of the workpiece, tooling and placement location together. If visibility is obstructed, reposition first; blind operation is prohibited.
Before handling, confirm that the route is clear and maintain safe separation from equipment, aisles, containers, columns and other personnel. Plan the route in advance for large workpieces. When several people cooperate, appoint one main operator; others must not simultaneously push or pull the workpiece or manipulator.
08Shift handover inspection and daily inspection
At shift handover, communicate operating history and recheck equipment condition. The outgoing shift reports abnormalities, tooling changes and outstanding maintenance. The incoming operator uses the checklist to inspect pressure, hoses, fittings, tooling, suction cups, travel limits, emergency stops, bolts and overall operation.
The equipment administrator should regularly inspect critical fasteners, joint wear, air quality, tooling locators and safety markings, using inspection findings to plan maintenance. Safety staff can review operating requirements and abnormal-condition procedures during team activities.
09First training confirmation checklist
| Training topic | Training content | Proficiency |
|---|---|---|
| Equipment identification | Can identify columns, main arms, auxiliary arms, cylinders, joints, fixtures, control handles, and air supply systems | □Yes □No |
| Workpiece scope confirmation | Know the weight, dimensions, center of gravity and surface condition requirements for allowable handling | □Yes □No |
| Pre-start inspection | Can inspect air pressure, hoses, fittings, tooling, suction cups, travel limits and emergency stops. | □Yes □No |
| Standard operating procedures | Can operate according to the process of approaching, clamping, confirming, lifting, translating, descending, releasing and resetting. | □Yes □No |
| Prohibited operation identification | Be aware of prohibited behaviors such as overloading, diagonal pulling, impact, entering dangerous areas, and rapid arm swinging. | □Yes □No |
| Abnormal-condition response | Can recognize air loss, unstable vacuum gripping, slipping, binding, unusual noise and drift, and stop operation and report the fault. | □Yes □No |
| Ergonomics requirements | Understands safe positioning, hand placement, visibility and clearance from hazards. | □Yes □No |
| Shift handover inspection | Can complete shift-handover inspections and daily inspection records. | □Yes □No |
10Criteria for judging qualified training
Assessment should include oral explanation, practical operation and inspection. Employees must explain the equipment components and tooling functions, judge whether a workpiece is within the permitted range, and independently complete a full, smooth cycle without hazardous actions. They should actively confirm grip stability, name at least five prohibited actions, recognize unstable vacuum holding, workpiece slip, unusual noise and drift, use the emergency stop correctly, explain the shutdown-and-report process, and complete startup and shift-handover inspections as required.
When the station, tooling or product changes, provide targeted retraining. Recheck the permitted application range, gripping locations, motion path and operating method, then assess the employee's understanding of those changes.
