How to choose an industrial manipulator for handling
An industrial manipulator takes over repetitive handling and protects operators from strain injuries. This guide explains gripping principle, reach and load balancing plus the right capacity and mounting in line with EN ISO 10218.
View manipulatorsWhich gripping principle suits the load?
The gripping principle depends on the shape, surface and weight of the load. The main options are vacuum grippers, mechanical jaw grippers and mandrel or clamp grippers. A wrong choice lets loads slip and creates exactly the operator strain the manipulator is meant to prevent.
Vacuum grippers suit smooth, non-porous surfaces such as sheet metal, cartons or glass and usually run on around 6 bar of compressed air at the ejector. Mechanical grippers hold cylindrical or irregular parts by form fit, while mandrel and clamp grippers lift rolls, drums or sacks.
How do you size reach and layout?
Reach and layout follow the work area the operator has to cover. Column-mounted manipulators cover a circle up to roughly 4 m radius, ceiling mounting frees up floor space, and rail systems serve long, linear paths.
- Column jib: fixed base, 1 to 4 m radius, ideal for single workstations.
- Ceiling mount: keeps the floor clear and widens the swing area.
- Rail and gantry systems: serve several stations along one line.
- Include stacking height and pallet dimensions in the reach, not just the pick point.
How to combine manipulator, bench and traffic routes ergonomically.
Read the guideHow does load balancing protect the operator?
Load balancing holds the load almost weightless in any position, so the operator can guide it with only a few newtons of force. Pneumatic systems adjust the pressure automatically, while mechanical spring balancers are low-maintenance. This keeps back and shoulder strain well below the critical values of EN 1005 and the key indicator method.
EN 1005‑2 sets base values around 25 kg for repetitive manual lifting, which frequency, grip height and trunk posture can quickly push below 10 kg. A manipulator decouples the load weight from the guiding force and makes even heavy parts safe to handle all day.
Which figures belong in the spec sheet?
Selection hinges on rated load, gripper dead weight, centre of gravity, cycle rate and the energy supply. Always add the gripper weight to the payload, because a 40 kg workpiece plus a 15 kg vacuum beam gives a 55 kg system load.
- Treat rated load plus gripper weight as the system load.
- Check air quality and supply (typically 6 bar, filtered and lubricated or oil-free).
- Match the gripper swivel and rotation angles to the placing task.
- Document CE conformity and compliance with EN ISO 10218 and the Machinery Directive.
- Plan maintenance intervals for valves, springs and vacuum filters.
Frequently asked questions
At what weight is a manipulator worth it?
As soon as repetitive loads reach the EN 1005‑2 base values of about 25 kg, or below that at high frequency, a manipulator relieves the back and shoulders and stabilises cycle time.
Vacuum or mechanical gripper?
Vacuum suits sealed, smooth surfaces such as sheet and cartons, mechanical grippers suit cylindrical or irregular parts. Porous surfaces need a mechanical form fit.
What happens if the air supply fails?
A check valve in the pneumatic circuit holds the load in place so it does not drop. This safeguard is mandatory for suspended loads.
Do I add the gripper weight to the capacity?
Yes. Payload and gripper weight together form the system load, which must stay within the rated capacity of the manipulator.
Looking for the right manipulator?
We supply column, ceiling and rail manipulators with vacuum, jaw and mandrel systems including load balancing - engineered to EN ISO 10218.
Standards-based
Engineered to EN ISO 10218 and the Machinery Directive.
Ergonomic
Load balancing keeps strain below EN 1005 limits.
Safe
Check valves secure suspended loads.
Expert advice
Our specialists size grippers and reach.