Manipulator selection requires coordinated checks of load, working radius, lifting stroke, end tooling and installation method. Load assessment includes both workpiece and tooling, with allowance for eccentric loading and safety margin. The working envelope must cover the handling path, lifting stroke must accommodate height changes, and tooling and mounting structures must suit the workpiece and site.
Selection essentials
Assess the parameters together: load determines load-bearing requirements; the working envelope determines whether pickup and placement points can be reached; lifting stroke accommodates height changes; tooling affects grip stability and workpiece surface protection; and installation determines the relationship between the equipment and workstation layout.
For automotive parts, cartons, panels, motor stators, hot castings, tyres and machine loading or unloading, select equipment according to workpiece weight and dimensions, handling route, cycle time and site environment. Assess structural and protective configurations separately for special conditions.
1. Applicable workstations and handling tasks
Pneumatic industrial manipulators assist with repetitive pickup and placement, machine loading and unloading, orientation changes and assembly positioning in factories. End tooling can be configured for the workpiece and task.
Manual handling of automotive seats, battery-compartment parts, motor stators, cartons, panels and hot castings may involve high physical effort, unstable positioning or impact damage. The manipulator arm and custom tooling work together to assist operators in gripping, transferring and placing these workpieces.
| Suitable Applications | Description |
|---|---|
| Heavy Workpieces | Manual handling is difficult and requires special design according to the workpiece and workstation. |
| High Handling Frequency | Stations involving repeated pickup and placement, machine loading and unloading, or assembly assistance |
| Damage-Sensitive Workpieces | Requires stable clamping, smooth transfer, and gentle positioning |
| Turning or rotation required | For example, panel turning, automotive interior-part turning and workpiece orientation adjustment |
| Limited Workstation Space | Manual handling is awkward, and floor-level interference must be reduced |
| Irregular Workpiece Geometry | Custom gripper jaws, vacuum cups, hooks, or dedicated tooling are required |
| Flexible Operation Is Required | Multi-station sharing, production line changes or temporary handling tasks |
2. When other handling methods may be appropriate
Match the equipment type to the process task. Other handling methods may also be compared for the following conditions:
| Condition | Potentially more suitable solution |
|---|---|
| The workpiece is lightweight and already easy to handle manually | Simple tooling or manual operation is sufficient |
| The transfer distance is particularly long | Conveyor lines, AGVs, and track systems may be more suitable |
| Motion is fully fixed and the required cycle rate is extremely high | An industrial robot or dedicated automatic machine is more suitable |
| Only simple vertical lifting is required | A jib crane or intelligent hoist may be more economical |
| No stable compressed-air supply is available on site | Consider an electric solution or provide an air-supply system |
Compare suitability in light of physical effort, operating risks, handling frequency and the site workflow.
3. Total load and workpiece centre of gravity
Start load assessment with the maximum workpiece weight, and record the tooling and motion conditions as well:
- Maximum workpiece weight
- Tooling Weight
- Workpiece centre-of-gravity position
- Is the load eccentric?
- Turning requirements
- Handling frequency and operating intensity
- Is it necessary to reserve a safety margin?
For example, an 80 kg workpiece and 15 kg tooling give a combined load of approximately 95 kg. Selection must also account for eccentric loading, turning motions and safety margin; the equipment configuration cannot be determined solely from nominal workpiece weight.
AUREK selects equipment for the project's operating conditions. Load-bearing configuration considers workpiece weight, tooling self-weight, centre of gravity, eccentric loading, handling cycle time and safety factor. Structures and tooling are assessed separately for light loads, heavy loads and special conditions.
State both the load and the actual handling motions when requesting a quotation, so load-bearing, balancing and operating conditions at the workstation can be assessed.
4. Working radius and handling path
The working radius must cover the pickup point, transfer route and placement point. Checking load alone while overlooking these positions may produce equipment that can lift the workpiece but lacks the effective reach or space needed for convenient placement.
Determine the working envelope from pickup-to-placement distance, slewing range, obstacle-clearance space, operating inertia and structural stability. Cover the complete handling path while accommodating operators and the site layout.
5. Lifting stroke and pickup/placement space
Lifting stroke is the effective vertical travel of the end tooling. Check it against the following handling tasks:
- Picking from a floor-level pallet and placing on a workbench
- Picking a part from a bin and placing it in a machine fixture
- Picking cartons from a conveyor and placing them in a stacking area
- Removing a workpiece from a machine and transferring it to an inspection station
- Moving panels, seats, or sheet-metal parts into assembly position
In addition to workbench height, check workpiece height, tooling height, gripping space and safety margin to assess the required lifting space:
Calculation: lowest pickup height + workpiece height + tooling clearance + safety margin = required lift space.
Configure the stroke from the lowest pickup point, highest placement point, installation height, workpiece dimensions, tooling length and motion path. Large height differences or complex movements require application-specific design considering the structure and safety requirements.
6. Tooling type and workpiece compatibility
The manipulator and end tooling perform the handling task together. Tooling must suit workpiece shape, material, surface condition, centre of gravity and required motions, and match the manipulator's load capacity and motion range.
Tooling assessment covers grip stability, workpiece surface protection, ease of operation and maintenance needs.
Vacuum gripping may be assessed for cartons; panels may combine vacuum gripping with a turning mechanism; automotive seats require dedicated tooling matched to their structure; and motor stators may use jaw or internal-expanding tooling. Hot castings also require checks of contact-part temperature resistance, thermal insulation and protection.
| Tooling type | Suitable Workpieces/Applications |
|---|---|
| Vacuum Gripper | Cartons, panels, sheet-metal parts and products with relatively flat surfaces |
| Jaw tooling | Irregular, metal and structural parts |
| Hook Tooling | Workpieces with holes, lifting points, or attachment points |
| Internal-Expansion Gripper | Cylindrical or bored workpieces, including some motor stators |
| Flipping Tooling | Workpieces requiring 90° or 180° turning |
| Thermally insulated tooling | High-temperature castings, die castings, and heat-treated workpieces |
| Dedicated Custom Tooling | Custom workpieces with special dimensions, geometry, or orientation |
Custom tooling and handling systems can be designed from workpiece drawings, process requirements and site conditions.
7. Installation type and workstation layout
In addition to load and tooling, installation configuration must be considered. The AUREK ARK series has three principal configurations: ARK-S column-mounted, ARK-M mobile, and ARK-O overhead-mounted.
1. ARK-S Column-Mounted Pneumatic Industrial Manipulator
Column-mounted equipment suits fixed workstations and can be secured to the floor or installed using embedded foundation fixings. It is commonly used for permanent handling, machine-loading and assembly-assistance stations.
2. ARK-M Mobile Pneumatic Industrial Manipulator
Mobile equipment suits shared use across stations, production-line changes and temporary handling tasks. A mobile or counterweighted base allows repositioning between stations while unloaded. After positioning, secure the base according to the project design before loaded operation.
3. ARK-O Overhead-Mounted Pneumatic Industrial Manipulator
Overhead-mounted equipment suits limited floor space, densely arranged machinery or stations requiring a larger coverage area. It can be integrated with overhead steelwork, rails or trusses to reduce floor-level interference.
| Type | Suitable Applications | Typical uses |
|---|---|---|
| ARK-S Column-Mounted | Fixed workstations for machine loading and unloading or assembly assistance | Machine loading/unloading, workpiece handling, and assembly positioning |
| ARK-M Mobile | Multi-station sharing, production line adjustment, temporary handling | Flexible production, multiple pickup/placement points and movement between workstations |
| ARK-O Overhead-Mounted | Limited floor space, densely arranged equipment or a large coverage area | Rail-based handling, transfers between stations and machine-loading assistance |
8. Selection parameters and configuration items
The following table lists parameters and configuration items to check during design assessment.
| Selection Parameter | Assessment basis |
|---|---|
| Load Capacity | Determined from workpiece weight, tooling self-weight, centre of gravity, eccentric loading and safety factor |
| Working Radius | Based on pickup and placement distance, required clearances, and travel path |
| Lifting Stroke | Based on the lowest pickup point, highest placement point, workpiece height, and tooling clearance |
| Drive Type | Select pneumatic or electric drive to suit the operating conditions |
| Mounting Configuration | Column-mounted, mobile, overhead-mounted or rail-mounted |
| End tooling | Vacuum cups, jaws, hooks, turning tooling or dedicated custom tooling |
| Air-supply conditions | For a pneumatic solution, confirm that a stable compressed-air supply is available on site |
| Operating environment | Consider temperature, humidity, dust, high-temperature exposure, hazardous-area requirements, and cleanliness |
General reference values in this guide: rated operating air pressure 0.5–0.8 MPa (5–8 bar), operating temperature −15 to 50 °C, relative humidity <90%, and pneumatic or electric drive options. For a specific unit, check its nameplate, contracted configuration and dedicated operating instructions.
9. Selection priorities for representative workpieces
Application 1: Automotive seat handling
Automotive seat assemblies are often irregularly shaped and may have an offset centre of gravity. A manipulator with dedicated seat tooling can assist gripping, lifting, translation and assembly positioning. Check the following conditions:
- Is the workpiece center of gravity offset?
- Is assembly alignment required?
- Could the tooling leave pressure marks or damage the seat surface?
- Is mobile equipment needed to serve multiple workstations?
Application 2: Carton or Box Handling
Vacuum gripping may be assessed for cartons or boxes according to surface condition and structural strength, for packaging, case packing, transfer and stacking stations. Check the following conditions:
- Is the surface of the carton flat?
- Is the box easily deformed?
- Is handling frequency high?
- Is mobile equipment required for flexible switching between workstations?
Application 3: High-Temperature Casting Handling
Handling hot castings requires assessment of weight, temperature and protection together. Tooling may incorporate heat-resistant contact parts, thermal insulation or cooling-air circuits. Check the following conditions:
- Workpiece temperature range
- Does the tooling material withstand the required temperature?
- Do pneumatic components need protection?
- Safe distance between operator and heat source
10. Information for quotations and engineering assessment
Organize the workpiece, motion and site information in the following table when submitting a design request:
| Information | Description |
|---|---|
| Workpiece Photographs or Video | Used to assess workpiece geometry, gripping faces and operating orientation |
| Workpiece weight | Maximum and typical weights |
| Workpiece dimensions | Length, width, height, center of gravity, and whether the geometry is irregular |
| Required Motion | Required lifting/lowering, rotation, turning and translation |
| Pickup and placement positions | Pickup point, placement point, height difference, and distance |
| Site environment | Floor space, overhead structure, surrounding equipment, and access routes |
| Frequency of use | Handling cycles per hour and operating hours per day |
| Utilities | Availability of compressed air and electrical power, and whether electric assist is required |
| Special requirements | High-temperature, hazardous-area, cleanliness, scratch-prevention, or deformation-prevention requirements |
For non-standard workpieces, also provide site video, workstation photographs and workpiece drawings so the structure, tooling, installation method and control logic can be checked.
11. Design comparison and configuration priorities
Compare load capacity, effective working envelope, lifting stroke, tooling compatibility and installation conditions together. Avoid selecting equipment on the basis of a single parameter.
For a fixed workstation, consider a column-mounted configuration first. For shared use across multiple workstations, consider a mobile configuration. Where floor space is limited or equipment is densely arranged, consider an overhead-mounted or rail-mounted solution.
For heavy, irregular, easily damaged or turned workpieces, or complex spaces, first assess whether a standard structure is suitable, then determine the required customization from the workpiece and site conditions.
AUREK can provide custom solutions combining pneumatic industrial manipulators, custom tooling, vacuum gripping, jib cranes and industrial handling systems. For more information, see the official website: https://www.aurek.cn/
Frequently Asked Questions
1. Can a pneumatic industrial manipulator handle heavy or special workpieces?
Design assessment can be undertaken for the specific application. Supply workpiece weight, dimensions and centre of gravity, tooling self-weight, working radius, handling path, safety factor and site conditions.
2. Is a larger manipulator always better?
Load, radius and stroke should match the workstation. Excessive radius may increase operating inertia and affect stability; aim for appropriate coverage of the handling path.
3. What if the workpiece has no regular gripping surface?
Compare jaws, internal-expanding tooling, hooks, contoured tooling or combined tooling. For irregular workpieces, determine the gripping method from drawings, permitted contact areas and site motions.
4. Can the manipulator flip a workpiece?
Turning can be configured according to the workpiece's centre of gravity, tooling structure and control method. Common motions include 90° turning, 180° turning and orientation adjustment.
5. Can a pneumatic industrial manipulator be used at a site without an air supply?
If no stable compressed-air supply is available, assess electric drive or a dedicated air-supply system. Determine the solution from load, cycle time, operating environment and the site's utility conditions.
6. How do I choose among column-mounted, mobile, and overhead-mounted configurations?
For a fixed workstation, prioritize a column-mounted configuration. For shared use across multiple workstations or a frequently reconfigured line, consider a mobile configuration. Where floor space is limited, equipment is densely arranged, or broad coverage is required, consider an overhead-mounted configuration.
7. How does a pneumatic industrial manipulator differ from a jib crane?
Jib cranes mainly serve conventional lifting tasks. Pneumatic industrial manipulators combine load balancing, orientation control and custom tooling for operator-guided pickup and placement, turning and assembly assistance.
8. How do I choose between a pneumatic industrial manipulator and an industrial robot?
Pneumatic industrial manipulators suit operator-guided assisted handling, flexible workstations and custom-tooling applications. Industrial robots suit repetitive motions, fixed cycle times and processes with greater automation requirements.
