How to Select a Pneumatic Industrial Manipulator
A Practical Guide to Load, Reach, Stroke, Tooling, and Installation
Knowledge Center / Selection Guide · Jiangsu Aurek Intelligent Technology Co., Ltd.
In brief: Select a Pneumatic Industrial Manipulator based on five factors—load, operating radius, lift stroke, end-of-arm tooling, and installation configuration. Load calculations must include workpiece weight, tooling weight, eccentric loading, and a safety margin. The radius must cover the pickup and placement points; stroke is based on the height difference; tooling is customized for the workpiece geometry and surface; and the installation configuration—column-mounted, mobile, or overhead-mounted—is selected for the available site space.
Abstract
Selection of a Pneumatic Industrial Manipulator is based primarily on five factors: workpiece load, operating radius, lift stroke, end-of-arm tooling, and installation configuration. Load determines whether the workpiece can be handled stably; radius determines whether the pickup and placement points are within reach; stroke determines whether the vertical range is sufficient; tooling determines whether the workpiece is held securely without damage; and the installation configuration—column-mounted, mobile, or overhead-mounted—is selected for the available site space.
For light-load, heavy-load and special working conditions such as auto parts, carton plates, motor stators, high-temperature castings, tires, and equipment loading and unloading, the Pneumatic Industrial Manipulator usually needs to be customized and designed based on the weight, size, transportation path, cycle time requirements and on-site conditions of the workpiece.
For more products and cases, see the AUREK official website: https://www.aurek.cn/
First: Which Workstations Are Suitable for a Pneumatic Industrial Manipulator?
A Pneumatic Industrial Manipulator is not merely lifting equipment. It is particularly suited to heavy-material handling, frequent pickup and placement, orientation changes, and assembly assistance in industrial facilities.
Workpieces such as automotive seats, battery-compartment components, motor stators, cartons, panels, and high-temperature castings are often strenuous to handle manually, difficult to position consistently, vulnerable to impact damage, and potentially hazardous. A Pneumatic Industrial Manipulator with custom tooling helps operators handle them with less effort and greater stability.
| Suitable Applications | Description |
|---|---|
| Heavy Workpieces | Manual handling is difficult and requires special design according to the workpiece and workstation. |
| High Handling Frequency | Repeated pickup and placement, machine tending, or assembly throughout the shift |
| Damage-Sensitive Workpieces | Requires stable clamping, smooth transfer, and gentle positioning |
| Tilting or rotation is required | Such as plate flipping, car interior parts flipping, workpiece attitude 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 |
Two. When Might a Pneumatic Industrial Manipulator Be Unsuitable?
A professional selection process does not recommend one type of equipment for every application. A Pneumatic Industrial Manipulator may not be the first choice in the following situations:
| situation | Possibly a 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 |
Selection must therefore consider whether the equipment genuinely addresses the site's heavy, hazardous, and repetitive work—not just the equipment itself.
Three. Start with the Load: More Than Workpiece Weight
The first step in selecting a Pneumatic Industrial Manipulator is to determine the required load. This is not limited to the workpiece weight; also consider:
workpiece maximum weight
Tooling Weight
workpiece center of gravity position
Is the load eccentric?
Does it need to be flipped?
handling frequency and usage intensity
Is it necessary to reserve a safety margin?
For example, if the workpiece weighs 80 kg and the tooling weighs 15 kg, the equipment carries nearly 95 kg. Eccentric loading, flipping motion, and a safety margin must also be considered; selection must not be based on the workpiece's nominal weight alone.
AUREK's Pneumatic Industrial Manipulator adopts project-based selection and does not use unified weight classification as the upper limit of product capabilities. The load capacity needs to consider the weight of the workpiece, the self-weight of the fixture, the position of the center of gravity, the eccentric load, the handling rhythm and the safety factor; light load, heavy load and special working conditions can be specially designed based on site conditions.
A word of caution: Don’t just ask “How many kilograms can this equipment lift at most?” You should also ask “Can this weight be lifted stably, effortlessly, and safely at my work station?”
Fourth: Working Radius Must Cover the Pick-and-Place Points
The operating radius determines the work envelope that the manipulator can cover. Focusing only on load and overlooking reach can result in equipment that can carry the workpiece but cannot reach the pickup point, or that makes placement awkward.
The operating radius is comprehensively customized based on the pick-and-place distance, rotation range, avoidance space, operating inertia and structural stability. There is no unified maximum value that applies to all projects. A reasonable approach is to allow the effective operating range to completely cover the pick-and-place path, while taking into account the operator's feel and on-site layout.
Section Five — Lifting Stroke: Use the Height Difference, Not the Equipment Height
Lift stroke is the effective vertical travel of the end-of-arm tooling. Common applications include:
Take materials from the floor pallet and place them on the workbench
Picking a part from a bin and placing it in a machine fixture
Take cartons from the conveyor line and place them in the stacking area
Take out workpiece from the equipment and transfer it to the inspection station
Moving panels, seats, or sheet-metal parts into assembly position
The lifting stroke should not only look at the height of the workbench, but also consider the height of workpiece, height of tooling, grab space and safety margin:
Calculation: lowest pickup height + workpiece height + tooling clearance + safety margin = required lift space.
The lifting stroke is customized according to the lowest pick-up point, highest discharge point, installation height, workpiece size, fixture length and action path; for working conditions with large height differences or complex movements, special designs will be combined with structural forms and safety requirements.
Six. Tooling Type: A Key Factor in Usability
The Pneumatic Industrial Manipulator provides the handling force, but end-of-arm tooling often determines whether the system is practical to use. Tooling must be designed for the workpiece geometry, material, surface condition, center of gravity, and required handling motion.
Tooling selection is not simply about whether the workpiece can be gripped. It must be held securely without damage, be easy for the operator to use, and remain serviceable over time.
For example, cartons are usually suited to vacuum gripping; panels may require vacuum gripping plus a flipping mechanism; automotive seats normally require dedicated tooling; motor stators may require a gripper or internal-expansion mechanism; and high-temperature castings require heat-resistant, insulated, and guarded tooling design.
| Gripper Type | Suitable Workpieces/Applications |
|---|---|
| Vacuum Gripper | Cartons, plates, sheet metal parts, products with smooth surfaces |
| Mechanical Gripper | Special-shaped parts, metal parts, structural parts |
| Hook Tooling | Workpieces with holes, lifting points, or attachment points |
| Internal-Expansion Gripper | Cylindrical parts, inner hole type workpiece, some motor stator products |
| Flipping Tooling | workpiece requiring 90° or 180° flip |
| Heat-Resistant Tooling | High-temperature castings, die castings, and heat-treated workpieces |
| Dedicated Custom Tooling | Custom workpieces with special dimensions, geometry, or orientation |
AUREK supports engineered, custom-engineered solutions ranging from a single tooling assembly to a complete line solution, designed to customer drawings, process requirements, and site conditions.
Section Seven — Selecting an Installation Configuration: Column-Mounted, Mobile, or Overhead-Mounted
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
Suitable for fixed workstations, usually installed through ground fixation or foundation embedded installation. The structure is stable and the floor space is clear. It is suitable for long-term fixed use of handling, loading and unloading and assembly auxiliary scenarios.
ARK-S Column-Mounted Pneumatic Industrial Manipulator
2. ARK-M Mobile Pneumatic Industrial Manipulator
Suitable for shared use across multiple workstations or lines that are frequently reconfigured. A mobile or counterweighted base allows the equipment to move between workstations for flexible production.
ARK-M mobile Pneumatic Industrial Manipulator
3. ARK-O Overhead-Mounted Pneumatic Industrial Manipulator
Suitable where floor space is limited, equipment is densely arranged, or broad coverage is required. It can be integrated with an overhead steel structure, rail, or gantry system to reduce floor-level interference.
ARK-O Overhead-Mounted Pneumatic Industrial Manipulator
| Type | Suitable Applications | Typical uses |
|---|---|---|
| ARK-S Column-Mounted | Fixed workstation, fixed loading and unloading, assembly assistance | Machine loading/unloading, workpiece handling, and assembly positioning |
| ARK-M mobile | Multi-station sharing, production line adjustment, temporary handling | Flexible production, multi-point pick and place, work station switching |
| ARK-O Overhead-Mounted | Tight ground space, dense equipment, and large coverage | Track handling, cross-station transfer, loading and unloading assistance |
Eight. General Parameter Reference Table
The following parameters are intended for preliminary selection. Final values must be confirmed for the workpiece, tooling, required cycle time, and site conditions.
| Selection Parameter | Reference content |
|---|---|
| Load Capacity | Determined based on workpiece weight, fixture weight, center of gravity, eccentric load 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-effector tooling | Vacuum cups, grippers, hooks, flipping tooling, or dedicated custom tooling |
| Air supply conditions | For a pneumatic solution, confirm that a stable compressed-air supply is available on site |
| Usage environment | Consider temperature, humidity, dust, high-temperature exposure, hazardous-area requirements, and cleanliness |
General parameters published on AUREK's website: rated operating air pressure 0.5–0.7 MPa (5–7 bar), operating temperature −15 to 50 °C, relative humidity <90%, and pneumatic or electric drive options.
Ninth: Three Typical Selection Scenarios
Typical Applications for Pneumatic Industrial Manipulators
Scene 1: Car seat handling
Automotive seat assemblies often have irregular geometry and an offset center of gravity. Manual handling is strenuous and can compromise assembly positioning. A Pneumatic Industrial Manipulator with dedicated seat tooling can support gripping, lifting, horizontal transfer, and assisted assembly. Key selection considerations:
Is the workpiece center of gravity offset?
Is assembly alignment required?
Will tooling crush the seat surface?
Do you need mobile equipment to accommodate multiple workstations?
Car seat handling application
Application 2: Carton or Box Handling
Cartons and box-shaped products usually have regular surfaces, making vacuum-cup tooling a practical option. Compared with repeated manual bending and lifting, vacuum handling reduces repetitive effort and is suitable for packing, case packing, transfer, and stacking stations. Key selection considerations:
Is the surface of the carton flat?
Is the box easily deformed?
Is the frequency of handling higher?
Is mobile equipment required for flexible switching between workstations?
Carton / Box handling Application
Application 3: High-Temperature Casting Handling
High-temperature casting handling requires consideration of not only weight, but also thermal insulation, safeguards, and personnel safety. These applications normally require heat-resistant tooling, thermal barriers, or cooled pneumatic-circuit design to reduce close operator exposure to heat sources. Key selection considerations:
workpiece temperature range
Is tooling material temperature resistant?
Do pneumatic components need protection?
Safe distance between operator and heat source
Tenth: Information to Prepare Before Requesting a Manipulator Solution
In order to judge the solution faster, it is recommended to prepare the following information before consultation:
| Information | Description |
|---|---|
| Workpiece Photographs or Video | Used to determine the shape, gripping surface and operating posture of workpiece |
| workpiece weight | Includes maximum and regular weights |
| workpiece size | Length, width, height, center of gravity, and whether the geometry is irregular |
| Required Motion | Do you need to lift, rotate, flip or translate? |
| Pick and place location | Pickup point, placement point, height difference, and distance |
| On-site environment | Floor space, overhead structure, surrounding equipment, and access routes |
| Frequency of use | handling times per hour, working hours per day |
| energy conditions | Availability of compressed air and electrical power, and whether electric assist is required |
| special request | High-temperature, hazardous-area, cleanliness, scratch-prevention, or deformation-prevention requirements |
For non-standard workpieces, provide site video, workstation photographs, or workpiece drawings so engineers can assess the manipulator structure, tooling type, installation configuration, and control logic more accurately.
Eleventh: Summary—Five Factors in Manipulator Selection
Load determines whether the workpiece can be carried; radius determines whether the required points are within reach; stroke determines whether the vertical travel is sufficient; tooling determines usability; and installation configuration determines whether the solution can be implemented on site.
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 a heavy, irregular, damage-sensitive, or flipped workpiece, or a complex site layout, purchasing only standard equipment is not recommended. Develop a custom solution for the workpiece and site.
AUREK can provide customized solutions around Pneumatic Industrial Manipulator, custom tooling, vacuum gripping, jib crane and industrial handling systems. For more information, see the official website: https://www.aurek.cn/
Frequently Asked Questions
1. Can the Pneumatic Industrial Manipulator handle heavy or special workpieces?
Yes. AUREK does not judge product capabilities based on a unified upper limit of weight. The specific project design needs to be based on the workpiece weight, size, center of gravity, fixture weight, operating radius, handling path, safety factor and site conditions.
2. Is a larger manipulator always better?
No. Load, radius, and stroke must match the workstation. Excessive radius can affect operating inertia and stability; appropriate coverage of the pickup and placement path is more important.
3. What if the workpiece has no regular gripping surface?
Grippers, internal-expansion tooling, hooks, form-fitting tooling, or hybrid tooling can be used. Tooling for irregular parts is normally customized from workpiece drawings and the required site motions.
4. Can the manipulator flip a workpiece?
Yes. Flipping capability depends on the workpiece center of gravity, tooling structure, and control method. Common functions include 90° flipping, 180° flipping, and orientation adjustment.
5. Can Pneumatic Industrial Manipulator be used without air supply?
If no stable compressed-air supply is available, consider an electric-drive solution or provide an air-supply system. The appropriate choice depends on load, cycle time, operating environment, and available site utilities.
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. What is the difference between a Pneumatic Industrial Manipulator and a jib crane?
A jib crane is primarily intended for conventional lifting. A Pneumatic Industrial Manipulator emphasizes human-guided operation, load balancing, orientation control, and custom end-of-arm tooling, making it better suited to precise pickup and placement, flipping, and assembly assistance.
8. How do I choose between a Pneumatic Industrial Manipulator and an industrial robot?
A Pneumatic Industrial Manipulator is better suited to human-guided operation, low-effort handling of heavy loads, flexible workstations, and custom tooling applications. Industrial robots are better suited to fixed cycle times, repetitive motion, and high levels of automation.