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160 mm
Handling
Handling
▼
Machining
Assembly
Organisation
47,3 mm
Pneumatics
Pneumatics
▼
Electronics
Mechanics
Sensorics
Software
88,5 mm
Hesse Grippers and their applications
Hesse
Grippers and
their applications
including vacuum devices
158,5 mm
English
Chinese
English
▼
French
German
Russian
195 mm
Spanish
Blue Digest
Blue Digest
on Automation
053 435
225 mm
Hesse
Stefan Hesse
Grippers and
their applications
including vacuum devices
Blue Digest
on Automation
Blue Digest on Automation
All texts, representations, illustrations and drawings included in this book are
the intellectual property of Festo AG & Co. KG, and are protected by copyright
law. All rights reserved, including translation rights. No part of this publication
may be reproduced or transmitted in any form or by any means, electronic,
mechanical, photocopying or otherwise, without the prior written permission
of Festo AG & Co. KG.
It has been a long held dream by man to one day be free of the drudgery
Foreword of manual labour through the use of automatic devices. Needless to say, this
vision always depends on the technical components available at the time.
The automatic production lines of the twenties used by the English company
MORRIS MOTORS had to be mechanically controlled to a large extent, which
was not very successful. Not until the sixties did a new basic technology become
established: The NC machine and the industrial robot. Both are computer-aided
and therefore freely programmable as far as movement is concerned.
For the user, it is becoming increasingly difficult to take in the now wide range
of gripper technology. This is the reason why this brief introduction has been
published. Above all, it is intended to provide advice and ideas to practical
users, since the selection of the right gripper is by no means a trivial task. As
with other technologies, there is a risk of making the wrong decision. Nowadays,
however, most gripper tasks can be accomplished using standard grippers.
Therefore, special grippers are only developed for exceptional cases. A sound
basic knowledge of grippers and their use is always a good investment for the
future.
Stefan Hesse
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table of contents
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Technical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1 Workpiece
5
2 Magazine
3 Clamping device A
4 Gripper
5 Magnetic gripper
S G
Fig. 1-2:
How can a workpiece
be picked up?
a) External gripping
b) Internal gripping
c) Combination of internal
and external gripping
a) b) c)
Fig. 1-3:
The right choice of
gripping point can affect
the positioning error during
assembly
a) Gripping a component
by its body
b) Gripping
by connecting wires
a
b
a) b)
Workpiece handling does not in itself create added value. Only in assembly
Is a controlled gripper operations or when used to guide tools can an industrial robot add value to a
necessary at all? workpiece. It is therefore a welcome advantage if handling devices can be
simplified or even eliminated altogether. Example – a user wishes to feed work-
pieces to a clamping device (Fig. 1-4).
1 Clamping point
2 Simplest type of gripper
(mandrel or plug gripper)
3 Supply magazine
2
1
There are many workpieces which can withstand the necessary gripping force
High point loadings can without sustaining damage. But there are other workpieces which are for
damage workpieces example polished, thin-walled, soft, brittle or super-finished and which can be
damaged during gripping, especially by clamp-type grippers which impose a
point loading (See Fig. 1-5).
a) Area/area
b) Line/area
c) Point/area
d) Double line/area
a) b)
c) d)
Point loading is the contact force per unit gripping area which results from
clamp gripping. Deformation occurs at the point of contact. Contact force should
not, however, be assumed to be the same as the closing force of the gripper.
V-shaped grippers, for example, spread forces. Gravity may also be a factor,
depending on the orientation of the gripper, as may the coefficient of friction µ.
When it comes to the fine positioning of objects, the average person relies on
Problems with accuracy eye/hand coordination and manages without difficulty, for example, to thread
a needle. Mechanical gripping must be just as precise and trouble-free.
Fig. 1-6:
Unambiguous pick-up points
ensure reliable gripping
a) Inaccurate workpiece
position
b) V-shaped template
centres workpiece
a) b)
Workpieces are not aligned to the gripping centre, since the gripper closes in an
arc and operates with workpieces of different diameters. The gripping centre,
also known as the tool centre point (TCP), is however the value entered in the
programming of the handling machine. Deviations of this kind may causes
problems with close-tolerance assembly operations. This type of problem is
shown in Fig. 1-7 [1]. This effect is not encountered with parallel-jaw grippers.
Fig. 1-7:
Gripper devices which close in
an arc may cause a shift of the
gripping centre 1
1
2
a) Scissors-type gripper
with 2 different work-
2
pieces 1 and 2
b) Parallel-jaw gripper
δx
a) b)
Fig. 1-8:
Centre deviation resulting
from workpiece form errors
δx
δy
δx
Standard grippers have reached a high level of development and can be used
for many applications, not just the classic applications. There are also gripper
systems for special applications. Rails and adapter plates can be used, for
example, to create double grippers, multi-position grippers and multi-workpiece
grippers. We will illustrate this with a few selected examples.
3-point grippers are the preferred type for handling cylindrical workpieces.
Workpiece handling These grippers give both good centring and a high degree of reliability [1]. Care-
with standard grippers ful design of the gripper fingers can provide a certain measure of adaptability
to different workpiece dimensions. Fig. 2-1 shows an example, using hardened
gripper pins for the internal gripping of small workpieces. These pins can if
desired be repositioned in other bores provided in the gripper fingers. The result
is an enhanced gripper range, albeit with the need for manual resetting. The
gripper pins need not be used concentrically – it may be better to arrange them
at gripping points in accordance with the internal contours of the workpiece,
for example in order to grip a housing with a rectangular aperture (Fig. 2-1c).
It is also possible to grip into hole patterns extremely effectively using gripper
pins.
Fig. 2-1:
Using a 3-point gripper
a) b) c)
The minimum effective length of the pins should be 5 mm. This also applies to
mechanical gripper fingers.
Fig. 2-2:
Multi-point gripper
for long workpieces
The centre of gravity of the workpiece should be placed at the exact midpoint
between the grippers. When single grippers are used, the centre of gravity
should be as close as possible to the gripping point.
Fig. 2-4:
Multi-workpiece gripper
for assembly operations
New technology, such as video recognition systems, has led to new demands
being placed on gripper systems. One example of this is the insertion of chocola-
tes into a blister pack. This also falls under the broad heading of “assembly”
work. Fig. 2-5 shows a solution in which several suction cups are used to pick-up
the rectangular chocolates from a conveyor belt.
The suction cups are fitted to single-acting standard cylinders which are
protected against torsion. Each suction cup is able to move forward indepen-
dently at high speed. Once the recognition system system has detected a work-
piece and determined the coordinates and the orientation of the workpiece
(longitudinal axis), the gripper adjusts its angle accordingly. The suction cup now
advances, picks up a workpiece from the moving belt and returns to its initial
position. Once all the suction cups have picked up workpieces, the robot swivels
to the packing conveyor belt and sets down all the workpieces simultaneously in
the nests of the blister packs. Since all workpieces are already correctly aligned
relative to the grippers, their alignment with the packaging is also correct.
6 5
Fig. 2-6:
Methods of holding a work-
piece (example: ball bearing)
1 Enclosure
only without clamping
2 Partial enclosure
combined with clamping
force
3 Clamping force only
(force-locking connection)
4 Holding with suction
(force field) 1 2 3
5 Holding
with magnetic field
6 Holding with adhesive
layer, such as grease
4 5 6
a) Gripping an egg
with the human hand [2]
b) Gripping a workpiece and
holding it during assembly
c) Attitude of gripper hand
during feed motion
m.g m.g
a)
b)
c)
Fig. 2-8:
Gate feeder using
a parallel-jaw gripper
1 Parallel-jaw gripper
2 Sliding gate
1 2
Sliding gates have been fitted in place of the gripper fingers. These should
be as short as possible, as is usually the case in gripping applications, to avoid
overload of the linear guides of the gripper jaws and reducing their service life.
This solution is worth considering only for the feed of small workpieces, since
other solutions are available for large heavy workpieces [3]. In order to reduce
the load acting on the feed slide, a stepped track has also been developed
which enables a proportion of the load due to workpiece build-up to be
supported by the step.
Depending on the application in question, a hand axis may be of interest for the
following motions. Rotation > 360°, swivelling < 360°, thrust motions (generally
with short strokes) and screwdriving motions, particularly for the insertion of
screws. The most typical motion is, however, swivelling, which is why gripper
manufacturers almost always offer compatible swivelling units. Fig. 3-1 shows
a two-axis module which can swivel between 0 and 270° and provide a linear
thrust stroke of up to 100 mm. The positions are finely adjustable, with a
cushioned approach. But what exactly can we do with this motion capability?
Fig. 3-1:
Three-point gripper combined
with a swivel/linear unit
Let us first consider the term “degrees of freedom”. A workpiece can have
Degrees of freedom a maximum of 6 degrees of freedom, expressed as 3 linear motions on the
of the hand 3-dimensional axes x, y and z and 3 rotary motions α1, α2 and α3 about the
axes x, y and z. Handling machines, by the way, can have more than 6 degrees
of freedom. We then speak of degrees of mechanical freedom or travel freedom.
1 Vertical up-down
2 Forward/backward
3 Lateral left/right
α1 Pitch, tilt
α2 Roll, twist
α3 Yaw, turn.
As you will know, the closing motion of the gripper jaws is not considered as a
degree of freedom, since this motion has no influence on the motion path of the
gripper.
Fig. 3-2:
The human hand can execute
motions with 6 degrees
of freedom
(according to Bejczy)
1
a) Biological
b) Technical
2
α1
α2
3 G
α3
a) b)
Fig. 3-3:
Double gripper designed
as a crown turret
a) Radial gripper
b) Axial gripper
a) b)
Fig. 3-4:
Shaft gripper
1
1 Connecting flange
2
2 Cushioned stop
3 Set screw
4 Parallel-jaw gripper 3
5 Pneumatic cylinder
5
Fig. 3-5:
Handling module
for assembly of small
workpieces
1
1 Swivel cylinder
2 Lifting cylinder 2
3 Adapter plate
4 Standard gripper
5 Transfer system
6 Workpiece for insertion
7 Receiver workpiece
3
8 Gripper finger
9 Magazine 4
5
7 8
9
Simple handling modules can also be quickly and easily assembled using
standard suction cups and semi-rotary actuators (Fig. 3-6). An additional short-
stroke axis would turn this combination into a pick-and-place device. A hollow
flange shaft can be used as a throughfeed for the vacuum line. The actuator can
operate at switching frequencies of up to 3 Hz.
Fig. 3-7:
Inverting workpieces
1 Gripper jaw
2 Standard gripper
3 Semi-rotary actuator
4 Workpiece
5 Conveyor belt
Fig. 3-8:
Triple gripper installed on a
special machine with double
stations
G Grippers
S Clamping points
Fig. 3-9:
Picking up ferromagnetic
sheets from a stack using
a suction-cup/lifting module
1 Suction cup
2
2 Standard cylinder
with hollow piston rod
3 Frame 3
1
4 Magnetic rollers
5 Roller conveyor
4
6 Sheet metal stack
7 Lifting table
6 5
Fig. 3-10:
Simple specimen shaker
made from standard
components
This shaker has been created using a standard cylinder, a swivel unit with a
hollow flange shaft and a standard gripper and adapter. It would also be
possible to create an array of shakers or provide other motion combinations.
The critical factor is to create a quick, inexpensive assembly, without the need
for a great deal of preparatory work.
1 Adapter
2 Force generator
3 Force conversion
4 Force transmission, Holding
with finger as transmission Interface
system
components
5 Gripper jaw
as gripping component
Actuation Kinematics
It is essential when designing gripper jaws to know the points at which the
workpiece is to be gripped. Technical parameters naturally also have an certain
influence. Fig. 4-2 illustrates this with the example of a two-finger gripper. Area
contacts are generally preferable to line or point contacts.
Fig. 4-2:
The contour at the gripping
point of the workpiece
determines the jaw shape
used, 1, 2 or 3.
1 2 3
Conditions are not always ideal. If we consider the case of “parallel flat sur-
faces”, we see that some workpieces are not in fact parallel at all; for example,
plastic mouldings may have slight moulding bevels. If the deviations from
parallel are small, it may be sufficient to fit the gripper jaws with a compliant
rubber covering. It is, however, sometimes better to provide pendulum jaws,
of which three types are shown in Fig. 4-3.
Fig. 4-3:
Gripper jaws
with compliant surfaces
1 2 3
Fig. 4-4:
Jaw shape with centring effect
for scissor-tong grippers
D
R2
α
R R1
A A
C1
D1 + D2
D=
2
0.5 · R
A=
tan(α · 3.14/180)
B = 0.5 · R
0.5 · R
R1 = – 0.5 · D
sin(α · 3.14/180)
0.5 · R
R2 = + 0.5 · D
sin(α · 3.14/180)
Fig. 4-5:
Gripping several workpieces
simultaneously, using
a pressure distributor to F F
compensate for tolerances
δx
φ1
...
φ3 30 x
0. mm
.. 7
φ7 0 mm
0.
.. 1
00m
m
50 mm 50 mm
A
B
B
C
C
D
Grippers can be designed for many special applications [3]. There are, for
Jaws for special example, grippers with rotary jaws, which can turn a workpiece through 90°.
applications One jaw is passive, while the other is equipped with a rotary actuator. Attempts
are, however, always made to use a normal basic gripper before developing a
special gripper. Fig. 4-8 shows some examples of special grippers.
Fig. 4-8:
Variants of jaws
for parallel grippers
1 Moulding jaw
with lamellar assembly
2 Width-adjustable jaw
3 Jaw of combination gripper
1 2 3
The moulding jaw incorporates thin movable metal plates. When the gripper
closes, the plates are pressed against the workpiece, forming an impression
of it’s contour. The entire lamellar assembly is then clamped into place.
The impression is reversible, i.e the lamellae can be reset. Gripper jaws can
also be provided with serrated adjusters, allowing the gripping width, but not
the stroke, to be matched to the workpiece dimensions. The jaws can also be
used turned through 180°. In order to grip several workpieces simultaniously
Fig. 4-9:
Mobile gripper jaws lift the
workpiece out of the V-shaped
recess in the magazine
1 Gripper housing
2 Finger
3 Mobile jaw
4 Rotary axis
5 Support surface
6 Torsion spring
7 Workpiece
Fig. 4-10:
The type of approach affects
the required opening Radial approach Axial approach
b b
a a
c c
This means that force and counter-force are in equilibrium. A simple experiment
to demonstrate this is shown in Fig. 5-1a. A rod is subjected to a tensile load. In
the first case, one end of the rod is clamped, while in the second case a person
pulls on each end. The tensile force in the rod in each case is not 400 N as
you might think but only 200 N. If we apply this to the parallel gripper shown in
Fig. 5-1b, this is subject to the same prin-ciple. It makes no difference whether
only one finger moves and applies a gripping force of 200 N or whether two
opposed fingers each generate 200 N. The two grippers shown are equivalent
in terms of force.
FG FG FG
Fig. 5-2:
Forces acting on gripped
object (state of rest)
FR FR
1
1 Finger
2 Gripper jaw
3 Workpiece
FG FG
µ Coefficient of friction
2
µ µ
G
3
G = FG · µ · n
m·G
FG =
µ·n
Variables in formula:
FG = Minimum required gripping force in N
G = Weight force of gripped object in N
g = Gravitational acceleration in m/s2
m = Workpiece mass in kg
n = Number of fingers or gripper jaws
µ = Coefficient of friction between gripper jaw and object.
As we can see, allowance is made in the formula for the number of fingers, since
of course a friction force FR is created at each gripper jaw. With 3 contact points,
n = 3. There are several possible variants for the 3-point solution. Fig. 5-3 shows
a “true” three-finger gripper and a solution based on a two-finger gripper. In this
latter case, the gripping force is split at the V-jaw into the contact forces FKi.
Fig. 5-3:
Plan view
of 2 gripper situations FG
a) Two-finger gripper
with V-jaw FK2
b) Three-finger gripper
FG
α
FG β FG = FK1
α
FG
FK3
G = Σ FKi . µ G = FG . µ . 3
If, in the case of the two-finger gripper, a V-jaw angle of 120° is selected, the
same as the finger positioning of a three-finger gripper, the two grip-pers will
be the same from the point of view of holding forces. There will be differences
with other V-jaw angles. In these cases, we must refer to the contact angles,
which can be determined by the following formula if random V-jaw angles are
permissible:
G · sinα1
FKi =
µ · (sinα1 + sinα2 + sinα3)
in which
i = 1, 2, 3
and
α1 = 180° – α23
α2 = 180° – α13
α3 = 180° – α12
Fig. 5-4:
Calculation of contact forces
for a gripper with a V-jaw on
one side
FR1 α13
FG = FK1
FR3
FR2
FK3
α12 α23
FK2
Fig. 5-5 shows the mathematical relationships governing gripping force during
an upward motion in the case of the commonly-used V-jaw grippers with
3- or 4-point object contact. A distinction can be made between 3 variants
of gripping:
α1 α2 FK2
FG
Positive locking
with friction locking
FR1 a FR2
m(g + a)
FK1 =
2cosα1
m(g + a)
FG FG FG = tanα · S
2
m(g + a)
FK1 FK2 FK2 =
2cosα2
α1 α2
m .g
FR
a FR
FK1 = m(g + a)tanα2
FG=
FK1 FG FG = FK1 · S
m(g + a)
FK2 =
FK2 2cosα2
90° α
m .g
a
FG
m(g + a) m(g + a)
FR FK FK = FG = sinα · S
4µ 2µ
2α
FG
m .g
The equations given in Fig. 5-5 incorporate allowances for certain factors which
we have not yet mentioned:
It may be, in the case of a multi-axis handling machine, that the force situation
Check the motion cycle changes from time to time during a motion cycle. It may be possible to counter-
act certain forces which occur by using positive-locking gripping (lateral
motions), while other forces may call for a higher coefficient of friction. It is
therefore a question of identifying the motion phase requiring the highest
holding force and selecting a gripper on this basis. Fig. 5-6 shows a number
of typical motions and the forces operative during these.
Fig. 5-6:
Force situations
during gripper motion
v v
FR FR FR FR FR FR
a) Rest state
b) Upward motion v=0
c) Downward motion
d) Lateral motion FB
e) Inclined upward motion
FB
FG FG FG FG FG FG
a) G b) G c) G
v v
FR FR FR FR
FB FB
FG FG FG FG
d) G e) G
FB = m · a
FB = m · r · ε
Fig. 5-7:
Example of handling task P2
P3
P1
P4
Mass = 1 kg
Fig. 5-8:
Examples of torque created
as a result of gripped work-
pieces 1 2 3
a b l l
c c
FK1 FK2 FK2
G
FK2 FK1 FK1
G G
G(l + c) –G · c
FK1 = and FK2 =
l l
Fig. 5-9 shows the forces which occur. In accordance with the law of levers
(force times force arm equals load times load arm), the gripping force FG pro-
duces tilting forces in the finger guide. These in turn produce increased friction.
Part of the generated gripping force is thus counteracted by friction forces in the
guide. Moreover, wherever friction occurs, wear will soon follow. The higher the
tilting moments in the guide, the higher the load. If the permissible limits are
exceeded, the gripper will not achieve either its specified service life or the
desired gripping force.
Fig. 5-9:
Eccentric forces acting
on a gripper finger
v
FNy
y
FNx
FG
Fig. 5-10:
Gripping force FG as a
function of gripper stroke h
a) Angle gripper
b) Parallel gripper
Q Tensile force
h Gripper stroke
Any use of grippers must start with a study of the planned application. This will
reveal what grippers are required to do, and what loads they must withstand. If
studies of this kind are carried out inadequately, over-hastily and incompletely,
the result is likely to be annoyance – if grippers are the wrong choice, they may
fail quickly and thus not provide the expected performance. Never try to talk
someone into using a particular gripper – the choice must be taken on the basis
of the degree to which the requirement profile and the gripper performance
coincide.
52 6 Technical properties
Fig. 6-1:
Characteristic data Characteristic data for grippers
for grippers
• Type designation
• Design
• Size
6 Technical properties 53
Only idealised handling operations run perfectly smoothly. If we take a closer
Accuracy of gripping look, we will see that it is always necessary to accommodate tolerances on all
axes. Theoretically this is true, the only question is the order of magnitude of
the resulting errors. Fig. 6-2 shows an exaggerated form of the general situation.
The workpiece feed is subject to errors, the robot motions are imprecise and the
target position, for example a basic workpiece to which others are to be fitted, is
also subject to tolerances.
Only an analysis of the tolerances will show whether the situation is critical
or not. Roughly one-third of all assembly applications are a question of inser-
ting pins into holes. Some of these operations can be regarded as precision
assembly, with clearances of only a few hundredths of a millimetre. In cases of
this kind, it may occur that the repetition accuracy of the gripper and industrial
robot used exceeds the permissible limit. The repetition accuracy of a gripper is
defined as the variation in the jaw end position during 100 successive gripping
operations (closing motions). This figure may, for example, be ± 0.02 mm in the
case of a parallel gripper.
Fig. 6-2:
General model of a 1 2
handling operation
1 Workpiece store
on suspended conveyor
2 Industrial robot
on a mobile unit
3 Assembly carriers
on a transfer line
In order to carry out close-tolerance assembly, all the following measures must
be adopted:
Joining mechanisms are devices placed ahead of the gripper which are designed
to compensate for angular and positioning errors between the connecting part
held by the gripper and the connecting axis defined by the basic assembly part.
A distinction is made between active (IRCC = instrumented remote centre com-
pliance) and passive joining mechanisms (RCC = remote centre compliance).
In the interests of simplicity, most are are of the RCC type. These can easily
54 6 Technical properties
compensate for position deviations of 2 mm with an orientation error of 2°, and
a permissible clearance between the two joining parts of as little as 0.01 mm.
In order for these devices to operate, guide chamfers are required on the basic
assembly part (bore) and/or the joining part to be added (pin), a factor which
should not be forgotten. Fig. 6-3 shows the principle of an RCC unit. Compliance
can be provided by using a special configuration of elastomer components or
leaf springs. The inner pair of joints correct angular errors, while the outer pair
of joints compensate for positioning errors. The apparent (remote) pivot point of
the joining part to be inserted lies at the tip of this. It is not necessary for users
to make their own joining mechanisms; these are commercially available in a
range of sizes.
Fig. 6-3:
Joining mechanism
with combined lateral and
angular compensation
1 Lateral (position)
compensation
2 Angular compensation
4
3 Apparent pivot point 1 2
for angular compensation 5
4 Gripper support plate
5 Parallel gripper
6 Gripper jaws 6
7 Joining part 7
8 Basic assembly part 3
8
The problem of fitting a pin into a hole is similar to the problem encountered
in feed motions of inserting a workpiece into a clamping device. There is little
fundamental difference between these two operations. We shall consider this
type of operation next.
The gripper and handling device are pressed in the direction of the clamping
axis, which is in effect an overload. There is a brief force-locking connection
between the handling device and the machine to which the workpiece is being
fed. A flexible flange plate on the gripper can help prevent damage
6 Technical properties 55
Fig. 6-4:
Situation in which an overload
of the gripper and handling
device can occur if no com-
pensation is provided.
a)
a) Feed to a clamping device
b) Axial correction during
closing of clamping device
b)
Force closure
Fig. 6-5:
Picking-up a workpiece
from a magazine pallet
a) Axial misalignment x
during approach
to position
b) Compensation
during gripping operation
a) b)
56 6 Technical properties
The situations here are more than the grippers can cope with. Attention must be
paid to axial misalignment.
6 Technical properties 57
It can be seen from the number of remedies available that this is a problem
which needs to be taken seriously.
Fig. 6-6:
Gripper combined
with a pressing element
1 Pressure spring
2 Gripper
1
3 Pressure plate
4 Workpiece 2
5 Gripper jaws
4 5
Fig. 6-7 shows a very simple device which can be used to assist assembly
operations. The gripper is mounted on a cone able to tilt by about 15°. This
makes the gripper flexible in the x, y and z directions in cases where the joining
part misses its destination and rests on the basic assembly part. In these cases,
the cone lifts slightly, creating some “breathing space” in the x-y plane.
The gripper is now able to deflect in the appropri-ate direction. It is, however,
necessary for the mating parts to have guide chamfers.
Fig. 6-7:
Simple joining mechanism
for vertical assembly
1
1 Centring cone
2 Connector plate for gripper 2
3 Gripper
4 Gripper jaw
5 joining part 7
6 Basic assembly part 3
7 Arm of handling device
4
z
5 y
6 x
58 6 Technical properties
Grippers are final effectors, which is to say that they are positioned at the end
Protection of a kinematic chain (free-arm robots) and thus have the greatest radius of
against collision action of all the robot components. This in turn means that grippers are subject
to the greatest risk of collision. The more complex and delicate a gripper is,
the greater the chance of damage in the case of a collision. Collision-protection
devices (or shut-off devices) have thus been developed to prevent this. These
devices are fitted between the gripper and robot arm and complement the
gripper control system. The protective devices are triggered when an adjustable
load threshold is exceeded and generate a shut-off signal. In the case of the
device shown in Fig. 6-8, a pneumatically-pressurised chamber is used to keep
the device stiff. In the case of a collision, the cushion of compressed air is
depressurised and the mechanism becomes “soft”, i.e. slightly flexible.
Fig. 6-8:
Collision protection
with adjustable parameters
for a gripper, showing α
reaction capability z
a) Rotational
b) Vertical
c) Horizontal β
F Triggering force
F
z Vertical impact path
α Angle of deflection F
resulting from collision
β Angle of tilt F
a) b) c)
There are also spring-loaded mechanisms in which the gripper disengages under
overload and recoils from an obstacle. These, however, offer little convenience
in the form of adjustment but are very simple in design. The deciding factor is
of course the application in question and the probability that unexpected ob-
stacles will be encountered. This will indicate whether it is necessary to protect
a gripper against collisions. If there are no obstacles anywhere near the gripper,
collision protection will certainly not be required.
6 Technical properties 59
Every gripper requires space to operate. The route to the gripping point requires
Gripper working area a gripper working area or feed channel which must be free of obstructions.
The minimum size of this area is governed by the contour of the gripper with
open jaws or with a workpiece if this projects beyond the edges of the gripper.
As the result of this, it may prove better to use a parallel-jaw gripper instead
of an angle gripper. This is illustrated in Fig. 6-9. It has been assumed that the
workpiece to be press-fitted into a basic assembly part needs to be picked up
by a gripper making a positive-locking connection in the insertion direction.
This can, however, also be achieved by using a parallel gripper, with the ad-
vantage that this will permit the storage locations on the magazine pallet to
be positioned more closely together. This increases storage capacity, which is
generally desirable.
Fig. 6-9:
When working with three-
dimensional object configu-
1
rations, consideration must be
given to the clearance contour
of the gripper
a) Radial gripper
b) Parallel gripper
1 Clearance edge
2 Pitch circle of gripper jaws
3 Workpiece
4 Flat pallet 2
5 Open gripper jaws 3 5
x Distance between
storage locations
x x
a) b)
If the gripper is kept as light as possible, this means a higher payload for the
Load-bearing capacity handling device and minimum impairment of dynamic machine characteristics.
and dead weight Fig. 6-10 shows the relationship between the nominal load of the handling
device and the tool load, with grippers often being regarded as tools. The nomi-
nal load specification refers to the interface between the robot arm and the
connector flange of the gripper.
If a handling device is operated with the maximum possible load, speed and
acceleration must be reduced. This may affect one motion axis or several.
The handling cycle will thus become slower. This is not a problem if the process
times are significantly longer than the cycle time for a handling operation.
It is therefore worth considering in appropriate cases whether an increased
handling-device load can be used.
60 6 Technical properties
Fig. 6-10:
Specifications of load capacity Nominal load
for industrial robots
Tool load Working load
Additional load
Maximum load
6 Technical properties 61
The excellent flexibility of an industrial robot from both the mechanical and
7 control technology points of view and the speed of a pick-and-place device can
Application areas provide a practical benefit only if the selected gripper meets the requirements of
and gripper types the application in question. The applications of a given gripper are not, however,
subject to any rigid definition – with a little imagination, modifications can
always be found to provide the optimum solution to a gripper application.
The aim of this article is to provide some suggestions for this.
One of the main uses of industrial robots and insertion devices is without doubt
machine-feed and assembly applications. Both these areas may involve require-
ments and customer wishes which go well beyond the “aver-age case”. It may
also be the case that a single gripper module is required to deal with objects of
widely-varying geometry. Each individual gripping task must be thought through
thoroughly before a recommendation is made.
Dimension 20 ... 50 mm
50 ... 300 mm
300 ... 1000 mm —
> 1000 mm — —
Internal gripping — —
Surface Smooth
Rough —
Porous
Sensitive — —
Short cylinder
Shaft/Rod — — —
Prisms Block —
Flat/short —
Flat/long — — —
Plastics —
Textiles — — — —
Foil — — — —
Glass
Pottery
The size of the workpiece to be handled need not necessarily dictate the size of
the gripper. If, for example, a gripper is required for large integrated circuits (ICs)
with 40 pins, this gripper will almost always need to be capable of executing
a powerful closing motion, since with large IC’s considerable force is required
to bend the numerous “legs”. As Fig. 7-3 shows, the reason for this is that the
gripper must adjust the legs to a precise spacing during its closing motion.
The IC legs are prebent to an angle of approximately 15°, allowing them
to conform to the correct spacing in the gripper.
Fig. 7-3:
ICs have splayed pins which
are aligned to the desired
spacing during the gripper
motion
Applications such as the feed of automatic machine tools and the removal of
processed workpieces may require 2 workpieces to be picked up simultaneously.
Special multiple grippers can be designed for this purpose, but it is sometimes
possible to use a slightly modified simple parallel gripper for this purpose. This
is shown in Fig. 7-4. It is, however, then necessary to use suitable gripper jaws
to suit the distance between the workpieces.
There are cases where the clamping point of a machine is not freely accessible
Feed gripper to the gripper due to the fact that passage is obstructed by tools, safety or test
as special solution equipment, etc., leaving only a certain “feed channel”. In cases of this kind, the
clearance contour of the gripper when holding a workpiece is a critical factor in
the selection process. Fig. 7-5 shows a solution in which a workpiece is gripped
parallel to the main axis of a 3-point gripper. The gripper has been fitted for this
purpose with specially adapted gripper jaws. The workpiece should be gripped
close to its centre of gravity to prevent unnecessary moments which would have
the effect of rotating the workpiece out of the jaws.
Fig. 7-5:
Handling lengths of bar
material with a 3-point
gripper
1 open
1 Arm of a handling device
2 Three-finger gripper
3 Gripper jaw
clamped
2
Fig. 7-6:
Gripping a rectangular
workpiece
a) 2-point gripper
b) Exploitation
of geometrical features
c) Corner-to-corner a) b)
clamping y
d) 4-point gripper
x
c) d)
Great progress has been achieved in recent years in the automation of assembly
Grippers for assembly work at all technological levels. For example, automatic machines have been
applications developed for the assembly of electronic components which allow cycle times
well below 1 second. This cannot be achieved by industrial robots, but these
play a valuable role in flexible assembly systems for short-run assembly work.
Assembly robots are without doubt an essential element of the “factory of the
future”.
The changer system provides a mechanical coupling and connections for signal
and power-supply lines, for example for compressed air. Each individual gripper
must be equipped with a lower changer system. Automatic changing (setting
one gripper down and picking up another) takes approx. 5 seconds. The purpose
of the joining mechanism is to provide automatic compensation for axial offset
and small anglar deviations. A collision protecting device can also be valuable,
particularly in cases where it is necessary to protect a complicated and costly
gripper from damage. If the gripper is overloaded, the collision protection device
disengages, triggering an emergency stop of the handling device.
6
5
The gripper system consists in this case of a suction gripper and parallel-jaw
gripper. These are independent and are activated individually. It is perfectly
possible to produce this combination gripper from standard components.
In accordance with the assembly sequence shown in Fig. 7-10, the joining part
is first picked up by the suction gripper. The basic assembly part is then gripped
by the parallel gripper. The joining process is carried out while the effector
travels to the set-down position. This operation can also be carried out during
set-down, by inserting the joining part into the basic assembly part. This method
can be used, for example, to place lenses in mounts. The advantage is that no
external assembly device is required.
Fig. 7-10:
Sequence for assembly
within a gripper
a) Approach
to pick-up position
b) Gripping the joining part
c) Lifting the joining part
d) Approach to
2nd pick-up position
e) Gripping the basic a) b) c) d)
assembly part
f ) Joining process
g) Module assembled
h) Set-down of
completed module
e) f) g) h)
Up to the present time, no uniform guidelines have been developed for the
design and sizing of grippers. If a variety of workpieces need to be handled,
the selection of grippers will be determined chiefly by object and process para-
meters and other parameters under the user's control. There is at the moment
no universal algorithm to determine the structure of gripper systems and the
design of grippers. Programs are, however, avail-able for the calculation of
technical/physical parameters.
Shape
Form of Grösse
und size
of object to be Berechnung von Kräften
der Greifobjekte Calculation of forces Berechnung der
Calculation of
gripped und Momenten, die
and moments Flächenpressung
contact pressure an
während der Bewegung
which occur during der Griffstelle
at gripping point
Mass and des Teils im Raum
Masse und Eigen- 3D motion of object
properties auftreten
schaften der
of objects
Objekte
Definitionder
Festlegen of drive
Antriebs-
Werkstoff und
Material and parameters
parameter für Greifer-
Oberfläche
surface of des for gripper
antrieb drive
gripping object
Greifobjekts
Bewegungsfolge
Axis motion Bestimmen des
Determination
insequence
den Achsen Berechnung der auf den Greifergetriebes
of gripper gearing
Calculation of forces
Greifer wirkenden
acting on gripper during
Kräfte bei Bewegungen
robot motion
Geschwindigkeit des Roboters
Speed and
und Beschleuni- Kontrollrechnung und
Checking calculation
acceleration of
gung Optimierung der
and optimisation
robotdes
perRobo-
axis
ters je Achse Greiferkonstruktion
of gripper design
Gripper flange
Greiferflansch
and type of Auswahl des
Selection Typs des
of type Design
Konstruktion
und Energieart
power source Greiferantriebs
of gripper drive of gripper connection
Greiferanschluß
With complicated workpiece shapes, the procedure must start somewhat earlier
with a search for suitable gripping surfaces on the object. This process is shown
in Fig. 8-2. We must be aware that any change in grip-ping points will have
effects on the dynamic behaviour of the gripper and must be recalculated for
a given gripper. If a workpiece has recesses or shoulders which can be used to
create a positive-locking connection with the gripper, these should be used.
This will allow the gripping force to be reduced.
Finding a gripping
Griff-Fläche
surfacesuchen
on the object
Calculation
Berechnung:of
--Force
Kraft Provisional
vorläufiger
--Moment
Moment location of gripper
Greifort
--Moment of inertia
Trägheitsmoment
Abmessungen
Estimation of von Verschieben
Relocation of der
Werkstückabsätzen
workpiece dimensions gripper plane
Greifebene
Dokumentieren
Documentation
der
Ergebnisse
of results
A number of attempts are being made to produce programs which will allow
the automatic planning of handling systems, including grippers. The procedure
used here, too, is to identify all possible gripping surface pairs on the object to
be manipulated (relating to two-jaw grippers, i.e. parallel surfaces). The contact-
free regions (gripping zone) are then defined. We then determine all the grippers
able to work within the defined gripping zones. There must be adequate coinci-
dence between the object gripping surfaces and gripper surfaces (gripper jaws).
The decision as to whether a gripper is able to grip a workpiece by the pair of
gripping surfaces selected is then taken in a process which takes into account
various physical and other parameters. Once all possible types of grippers have
been identified, an optimisation process is started to identify the best gripper
(type and variant).
The flow chart shown in Fig. 8-3 can be used to select an individual gripper.
Each activity can be correlated to typical questions. These can help in a
discussion with users to arrive at a binding list of technical characteristics.
Intuitive selection of a gripper on the basis of gripping force alone, as is
still done in many cases today, can easily lead to error and should be avoided
at all costs.
Abklärung aller
Determination of Bedingungen (Masse,
all conditions (mass, Größe,
size, Form)
shape) am Greifobjekt,
applying to the
der Bewegungssequenz
gripped und einschränkender
object,the motion sequence Randbedingungen
and any limiting factors 1 to 5 5
1 bis
originating in the process or its environment
von Prozeß und Umgebung
Definition of gripper
Festlegung principle:
des Single, Einzel-,
Greifprinzips: multible Mehrfachgreifer,
or special grippers,
6 6tobis
12 12
holding system, kinematics
Sondergreifer, or force fields
Haltesystem, Kinematik bzw. Kraftfelder
no
nein Can the load
Kann beBelastungssituation
die successfully handled in
in jeder
every
17
17tobis
21 21
direction of motion?
Bewegungsrichtung beherrscht werden ?
ja
yes
DesignGestaltung
of gripper jaws, sensor equipment,
der Greiferbacken, media Ausstattung,
sensorische 27
27tobis
32 32
throughfeeds and mounting
Medienführung und Befestigung
no
nein Does the concept
Entspricht das conform
Konzepttoden
theAnforderungen
requirements
as expressed in theAufgabenstellung
problem description? 33tobis
33 3535
gemäß ?
ja
yes
Evaluation and selection of gripper model
Bewertung und Typauswahl (monetär sowie nichtmonetär) 36
36tobis
3939
(financial and nonfinancial factors)
Outsourcing,
Realisierungspecial
durchexternal
Zukauf,manufacture or in-house
Fremdvergabe oder Eigenbau 40 40
Stop
Stopp
1. Are the object properties, especially mass, size, fragility and surface quality,
sufficiently well known or are further tests required?
2. Is there good access to the gripped object (gripper freedom “feed channel”)?
3. Has the gripper application (handling cycle) been defined in a detailed
and binding way or are changes likely?
4. Is a single gripper required to handle both blanks and ready-machined
workpieces (radical changes in shape during working cycle)?
5. Are all working conditions known (pressure, temperature, object condition,
cycle time, dust generation, oil mist, humidity, coefficient of friction,
mass, etc)?
The Festo gripper selection tool (GST) can be used to make a selection on the
basis of technical/physical parameters.
Programs of this kind do not of course provide all the answers but they relieve
users of time-consuming calculations and provide more time for an examination
of all the other parameters. Technical/physical parameters governing fit and
clearances have first priority in nay case in the gripper selection process.
Suction cups are a popular and simple solution for repetitive gripping appli-
cations of the “pick up, move, set down” type, provided that the workpieces in
question have flat non-porous surfaces. A further advantage is that suction cups
can be used with non-magnetic materials such as glass, ceramics and wood.
We can make a general distinction between 2 types of suction-cup applications:
Fig. 9-1 shows the most important functions of a suction cup. Not all these
functions will be used in every application.
Suction cups are suitable for a large number of handling operations, such as
sorting, feeding, clamping, turning and stacking, and are used as grippers with
lifting devices, balancers, feed devices, stacking systems, packing machines and
production lines. Suction cups are particularly convenient when workpieces have
the following features:
• Awkward dimensions
• Susceptible to deformation
• Non-magnetic
• Surfaces sensitive to scratching (ground, polished, painted)
• Undulating but non-porous surfaces.
1
F = (po – pu) · A · n3 · η · z ·
S
Fig. 9-2:
Force conditions with
vertically-moving suction cup FS
pu
po
F
With high-speed motions, allowance must also be made for forces resulting from
weight, mass moment of inertia and centrifugal force. This results in different
lines of action for the overall force. Furthermore, the centre of gravity of the
gripped object may not coincide with the centre of the suction cup. Fig. 9-3
shows the resulting typical load cases and the calculation of the required
suction cup force FS.
Fig. 9-3:
Typical force situations 1 v FS Fs ≥ n1 · F
at suction cup
F Sum of all forces producing detachment and shift
FS Force produced by vacuum
S
n1 Safety coefficient against shift
F
2 v FS
Fs ≥ F(n1 · cosα + n2/µ · sinα)
µ
Fs ≥ n1 · Fz + n2/µ · Fx
FX
n2 Coefficient of protection against shift
S α µ Coefficient of friction (suction cup/workpiece)
FZ F
3 FS Fs ≥ n1 · k1 · F
v
k1 = 1 + r/R
S k1 Coefficient of eccentricity of line of force action
r Distance between force action and suction-cup axis
r R
F R External radius of suction cup
4 v FS
Fs ≥ n1 · k1 · Fz + n2/µ · Fx or
µ Fs ≥ F(n1 · k1 · cosα + n2/µ · sinα)
S
FX α Angle between force action and vertical
r
α S Centre of gravity of gripped object
FZ F
5 FS
Fs ≥ n1 · k1 · Fz + n2/µ · k2 · Fx or
µ
Fy Fs ≥ F(n1 · k1 · cosα + n2/µ · k2 ·sinα)
S
k2 = 1 + r/R + Fz/Fy · µ
R α F
r k2 Coefficient of eccentricity of line of force action
FZ
6 v
Fs ≥ n2 · F/µ
In the case of oiled or greased sheet metal, which often requires handling during
shaping processes, problems may be encountered due to the fact that the speci-
fied coefficient of friction between the steel and rubber no longer applies. The
coefficient will be considerably lower, since in most cases the lips of the suction
cup will not penetrate the oil film. In situations of this kind, it is the law of fluid
friction which applies and not Coulomb’s law of friction. Tests should always be
made in cases of this kind before a suction cup is selected.
Suction cups used in handling systems operate with rough vacuum, which
How can the necessary ranges from 105 to 102 Pa. Other ranges include fine, high and ultra-high
vacuum be achieved? vacuum. 70% vacuum is the value generally used with suction cups. This means
0.7 bar vacuum or 0.3 bar absolute pressure.
Fig. 9-4:
Methods of producing
a vacuum
c) d)
The disadvantages are the higher purchase cost and the cost of further
accessories, such as air reservoirs. Some companies, for example light-bulb
manufacturers, use not only a central compressed-air supply but also a central
vacuum supply. In these cases, decentral vacuum generators are not required.
Fig. 9-5:
Comparison of performance
-0,9
of typical vacuum generators
-0,8
-0,6
in barin bar
-0,5 Ejector
Ejektor
Vacuum
-0,4
Vakuum
-0,3
-0,1
0
0 100 200 300 400 500 600 700 800 900 1000
Suction capacity
Saugvermögen in l/min in l/min
• Very simple design, with no moving parts and low purchase cost
• No additional equipment required; fast response time
• Extremely reliable.
The disadvantages are the higher operating cost resulting from the consumption
of compressed air and the need for silencers. These vacuum generators must
be sized for peak load, since no reservoir is used. Suction air is generated in
the ejector as compressed air passes through the restricted cross-section at the
drive nozzle. This restriction produces an increase in flow velocity. Following this,
the air expands and exits via the receiver nozzle. If the exhaust-air duct is shut
off (Fig. 9-6b), an ejector pulse effect is produced.
The venture principle is named after Giovanni Battista Venturi (1746 to 1822), an
Italian physicist. Venturi's main work was concerned with hydrodynamics and
hydraulics and he invented the nozzle with flow restrictor which bears his name
today. This nozzle is also used as a measuring nozzle to determine flow rate in
accordance with the Bernoulli formula.
a) Suction 4
b) Ejection
5
1 Shut-off valve
2 Receiver nozzle 6
3 Driver nozzle
4 Compressed air supply
5 Suction cup a) b)
6 Workpiece
Fig. 9-7:
Vacuum generators
in a series circuit
p Pressure p
V Vacuum
Adhesive suction cups are merely pressed onto the workpiece to force out the
air they contain; a vacuum is then created by the resilience of the suction cup
material or by weight forces. It is virtually impossible to compensate for leakage
losses. The suction surfaces must be smooth and non-porous.
Fig. 9-9:
Example of a vacuum circuit
based on an ejector 1 2 3 4
6 7
The line diameter in the vacuum circuit should not be undersized, since this will
increase flow resistance, but should not be oversized that suction times become
too long. We see in nature that trees need to feed vital liquids to the very last
leaf tip, which has resulted in the evolution of appro-priate distribution systems.
Fig. 9-10:
Correct choice of tubing
diameter is important in the
distribution of suction air 1
1 Suction cup
0,35.D
2 Line
The elasticity of suction cups means that handling applications in general cannot
achieve positioning accuracies of better than ±1.0 mm. Additional technical
measures are therefore required if the positioning error is to be reduced further.
Fig. 10-1:
A small selection of the major
types of suction cup
9 10 11
Despite its relatively simple design, type A exhibits good results for all criteria.
Its comparatively large flexibility in the vertical direction as the vertical force
increases, makes it suitable for use in all but a few applications. Type B allows
very high vertical forces, since the vacuum chamber stays in shape even under
high vacuum thanks to spacers and the small narrow sealing lips. In the case of
type C, the double seal results in a very low residual volumetric flow rate. The
complex seal system, however, takes up more space, thus reducing the effective
diameter of the suction cup. Type D is characterised by the low maximum
vertical forces which it can transmit, its lack of geometrical stability under the
action of lateral forces, and its very large elastic vertical stroke. This rules this
type out for a variety of handling applications.
Fig. 10-2:
Evaluation of various Criteria Transmittable Transmittable Flexible Residual
types of suction cups vertical horizontal vertical volumetric
force force stroke flow rate
Design
Very good
Ideal A
Suitable
Suitable in certain cases
— Not applicable
— —
Fig. 10-3:
Freedom of movement
of suction cups
4 5 6
Spring-loaded suction cups can also cushion the impact of workpiece contact
and compensate for height differences. The spring tension also offers the
advantage that the suction cup comes into contact with the workpiece before
the handling device stops. This reduces the time taken to build up the required
vacuum in the end position.
Fig. 10-4:
Suction-cup array fitted to
rods allowing longitudinal
movement and used to pick up
workpieces of constantly
varying contours [2]
Let us at this point once again mention deep suction cups (bell-shaped), which
have the adaptability to handle concave and convex workpieces very well, as
shown in Fig. 10-5.
Fig. 10-5:
Deep suction cups can adapt
well to curved surfaces
a) b)
Fig. 10-6:
Vacuum gripper with very
large freedom of movement
of suction components
1 Suction cup
2 Workpiece
3 Magazine plate
Fig. 10-7:
Standard suction cups are not
very suitable for use with thin 1
foil material
3 4
Fig. 10-8:
Low-pressure gripper
equipped with porous plastic
or perforated plates
We accordingly use centring aids, insertion guides and support stops. In the
case of electronic components for fitting to PCBs, which require gripping from
above, it can improve accuracy to grip the components a second time after they
have been aligned mechanically.
a) Fine positioning 1
during gripper contact v
2 6
b) Stop to reduce displace
ment during lateral motion 3 4 5
c) Alignment by spring- 7
loaded stops before
gripper contact a) b)
1 Centring mandrel
2 Spring 8
3 Suction cup
4 Workpiece
10
5 Magazine feed
6 Arm
11
7 Support 9
8 Vacuum connection
9 Roller conveyor
10 Tapered guide
11 Spring-loaded c)
guide wedge
The needless discharge of suction air means a waste of energy and usually also
Workpiece-controlled indicates a gripper malfunction. Attempts are therefore made to equip suction
activation of suction air cups in such a way that they activate vacuum generation only when they reach
the workpiece surface. There is a further problem: When several suction cups
are used in an array, it may occur that not all the suction cups are covered by
the workpiece, for example during the handling of packages of varying sizes in
positions which are not always precisely defined. Any suction cups which remain
uncovered must be deactivated in order to prevent the vacuum from collapsing.
The basic concept is illustrated in Fig. 10-10.
Fig. 10-10:
Automatic deactivation
of uncovered suction cups
1
1 Vacuum 2
2 Basic body
3
3 Airborne ball bearing
4 Suction cup 4
5 Workpiece
5
Fig. 10-11:
Circuit diagram for a suction
head fitted with vacuum 1
efficiency valves
2
1 Vacuum generator
2 Exhaust air 3
3 Distributor
4 Vacuum efficiency
valve with filter
5 Flat suction cup 4
It also takes some organisation to activate a suction cup at the right moment.
Sensor valves are often used for this purpose, as are proximity sensors.
Fig. 10-12 shows a number of variants. Sensor valves are installed in the vacuum
line and act directly on this, while external sensors supply an electrical signal
which is used to activate directional control valves. With the solution shown
in Fig. 10-12b, the handling device travels towards a stack whose height is of
course constantly changing. Once the workpiece has been reached (topmost
sheet), the lowering motion is stopped and the vacuum is activated. In the case
of Fig. 10-12d, a “positive signal” triggers the vacuum by actuating a directional
control valve.
Rapid ejection of workpieces from suction cups is just as important for fast
Ejector systems machining cycles as a fast pick-up. There are various ways of achieving this.
If a vacuum generator is used to produce the vacuum, it has become standard
practice to fill a small reservoir with compressed air during vacuum generation.
When the compressed-air supply to the generator is switched off, vacuum gene-
ration ceases and at the same time the compressed-air reservoir discharges
abruptly. This creates a positive pressure in the suction chamber, ejecting the
workpiece from the suction cup (Fig. 10-13).
Fig. 10-13:
Circuit diagram for a vacuum
generator with an ejector
pulse system
p Input pressure
V Vacuum
Fig. 10-14:
Vacuum head with “short-
circuit” hole to atmosphere
It is of course also possible to switch straight from suction air to compressed air,
and this is done in practice. An example of this is shown in our last illustration,
Fig. 10-15. By the way, precise ejection at the desired point is particularly
important with fragile or very light workpieces, since these could otherwise
stick to the suction cup momentarily and then fall at a greater height from the
handling device during its return stroke and possibly suffer damage.
Fig. 10-15:
Circuit diagram for a suction
gripper with a vacuum
generator and compressed-
air ejector system
p Supply pressure
V Vacuum
p
Fig. 11-1:
Some typical applications
of bellows suction cups
1 Picking up inclined
workpieces
2 Leveling of an inclined
formed part
3 Limiting suction force
4 Highly-flexible 1 2 3
suspension for undulating
workpieces in random
orientation
5 Picking up stepped
workpieces
6 Gripping formed parts
with undulating surface
7 Picking up flat workpieces
from magazine
8 Separating and picking up 4 5
flat workpieces
p1 p1 p2 p2
p1 > p2
6 7 8
Fig. 11-2:
Picking up thin panels
with a suction cup 1
a) Undulating effect 2
b) Air nozzle to assist
separation
1 Suction cup
2 Blast nozzle
3 Indexing motion
4 Lifting device to raise stack
3
4
a) b)
In Fig. 11-2a, the suction cups do not merely lift the panel but first generate
undulations along the length of the panel to detach any second panel which
may be adhering to the underside of the first. Only then is the panel lifted. Each
lifting cylinder must accordingly be controlled separately. “Peeling” effects can
also be produced by combining spring-loaded suc-tion cups with a non-spring-
loaded suction cup at the edge of the panel. In this case, the panel is lifted at
the edge while still being held down at other points by the spring force of the
suction cups. It is also possible to equip flat suction cups with a separator
insert, which is a fixed support within the suction chamber. When vacuum is
present, the panel picked up by the suction cup bends slightly around the sepa-
rator insert, due to the upward motion of the soft suction-cup lips. This effect
can be exploited with thin sheet metal up to approx. 3 mm.
When panels are picked up which are slightly porous, such as chipboard, a
“through-suction” effect may be encountered, also resulting in two panels being
lifted from a stack at the same time. The remedy here is to increase the suction
area (by using more suction cups) and reduce the vacuum level.
Fig. 11-3:
Combination gripper for hand-
ling thin ferritic sheet-metal
V
workpieces
1
1 Electromagnetic coil
2 Suction-cup lip made
of soft cellular rubber 2
V Vacuum
200 mm
Double lifting of small blanks can be rectified by using a second suction cup to
remove the second workpiece, which is held less firmly than the first workpiece
and can thus be “vacuumed” away and set down at another place. The first
gripper can swivel away from the second suction cup or else rotate, as shown
in Fig. 11-4. The two grippers rotate synchro-nously in opposition. The suction
forces are adjusted to different levels. A second workpiece is picked up along
with the first, carried along and then ejected into a set-down tray.
Fig. 11-4:
“Vacuuming” second work-
pieces away with a rotating
suction cup
1 Blanks magazine 1
2 Suction cup
for second workpiece
3 Set-down tray
for second workpieces
4 Rotary gripper 2
5 Feed device
for production machine
3
Fig. 11-5:
Workpieces removed from
stack using a suction cup
and spreader magnets
2 mm
1
1 Suction cup
2 “Floating” sheet 2
at top of stack
3 Permanent magnet 3
4 Stack of sheet-metal
work pieces
Fig. 11-6:
Forced bowing of thin blanks
at magazine outlet prevents
double pick-ups
1
1 Vertical magazine
2 Toothed insert
3 Spring-loaded ratchet
4 Suction cup
Fig. 11-7:
Feeding station
for thin sheet metal
1 Lifting cylinder 1
2 Suction
3 Pick-up rollers
4 Contact point 2 3
5 Workpiece stack
Fig. 11-8:
Feed system
on a packing machine 1
1 Vertical magazine 2
2 Distributor
3 Suction cup
4 Rotary indexing table
5 Lifting cylinder
6 Tub (workpiece) 3
7 Production machine
4
6
5
7
Fig. 11-9 shows the feeding of food containers on a filling line. Retaining brushes
on the magazine ensure that only one container is removed at a time.
The gripper arm carries a suction cup and is able to reach down between the
two conveyor belts and set down the deep-drawn foil container. Only when this
has been transported onwards can the arm swivel back into its pick-up position.
A rotary pneumatic cylinder can be used as a drive or, as shown here, a rack-
and-pinion gear unit with a linear cylinder.
1 Retaining brush 1
2 Stack of containers 2
3 Magazine rod 3
4 Spindle-driven lift ram
4
5 Limit switch
11
to monitor feed
6 Double conveyor belt 10
7 Lateral guide
8 Suction-air line
9 Gripper arm drive
10 Swivel arm
11 Suction cup
5
6 7 8
9
Suction cups are also frequently used in combination with other grippers to
provide auxiliary functions. This is illustrated in the example, Fig. 11-10 showing
the stacking of spools of textile thread. These spools are gripped internally by a
mandrel gripper and placed on a pallet. The auxiliary function to be provided
by the handling device, is to insert a separator board between each layer. The
device picks up the separators from another stack via suction cups which are
advanced into their working position specifically for this operation. In this way, it
is possible to operate without a gripper-changing system. Combinations of this
kind can be produced relatively easily by using pneumatic cylinders with hollow
piston rods.
Fig. 11-10:
Multi-layer stacking
of textile thread spools, 1
using a combination gripper
1 Gripper connection
2 Lifting cylinder
2
3 Hollow piston rod
4 Separator
5 Mandrel gripper
6 Gripper thread spool 5 3
7 First stack layer
8 Transport pallet 4
6
7
Fig. 11-11:
Feeding station
for glass bulbs
5
1
1 Swivel magazine
2 Handling device
with suction cup 6
3 Forked carrier in feed chain
4 Glass bulbs
5 Filling area 2
6 Magazine rail
8
3 7
A Accuracy of gripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Adapter rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adhesive suction cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Alignment effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Angle gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 51
Angular compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assembly gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Assembly mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Axial alignment error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Axis gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
B Ball-and-socket head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Bellows suction cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 99
C Centre deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Centring aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Changing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Characteristic curve for gripping force . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Characteristic data for grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checklist for grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Clamping force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clamping marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clamping safety margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Clamping zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clearance contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Coefficient of friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45, 80
Collision-protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Combination gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 66, 100, 105
Compensate for tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Compliance device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Contact force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13, 43
Contact sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Crown turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cushioned stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
D Deceleration force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Deep suction cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 92
Degrees of freedom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Degrees of transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Diameter of the interference circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Distribution with suction cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Double gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Double-lip suction cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Duplex machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
G Geometrical error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Gripped object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Gripper finger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Gripper fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Gripper jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 37
Gripper module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Gripper pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gripper selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Gripper selection tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Gripper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Gripper types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Gripper working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Gripping centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gripping force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 43
Gripping point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 17
Gripping stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Gripping surface pairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Gripping zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 72
Guide wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
I Inertia force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Interference circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Internal gripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
IRCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
J Jaw shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Jaw-type gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
K Knee-lever gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
M Magazine pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Maximum load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Moulding jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Multiple suction-cup gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Multi-point gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Multi-stage ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Multi-workpiece gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
N Nominal load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Non-slip covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Normal force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Q Quick exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
S Safety factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Scissors-type gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
T TCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Third law of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Three-finger gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Three-point gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thruster device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Tool centre point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 35
Triple turret gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Turning workpieces over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Turret gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Twin-workpiece gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Two-finger gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33, 43
Type of approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
U Universal jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Uses of grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
V Vacuum blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Vacuum circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Vacuum efficiency valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Vacuum generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Vacuum management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Vacuum switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Vacuum technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Venture-type vacuum generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Venturi nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Vertical magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Vice-type gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
V-jaw gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
W Wide-range gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14