Installation procedure for industrial manipulator in a factory (practical and safety standards)

A high-quality industrial manipulator doesn't operate smoothly by chance. It requires correct placement, proper structural attachment, precise load balancing, and alignment with the actual movements of the user. This is why the installation of a manipulator must be performed meticulously and according to standards.

In this article, Vietmani will guide you through each step of the factory installation process, based on practical experience and core technical requirements. Let’s get started!

Step 1 – Site Installation Survey

If you simply eyeball the location, measure a few basic parameters, and proceed immediately to installation, it is very easy to end up with equipment that fails to deliver the desired performance. Therefore, a thorough site survey is essential.

Here are the 3 basic survey checklists you need to complete:

Surveying the Foundation or Ceiling Structure

For floor-mounted manipulators, you must consider:

• Thickness and quality of the concrete.
• Location of reinforcement bars (rebar) and underground pipes.
• The moment bearing capacity is when the arm is fully extended.

For ceiling-mounted manipulators, you need to examine:

• The long-term dynamic load-bearing capacity of the beam system.
• The durability of the rail system to ensure no deflection (sagging) occurs during use.

Surveying the Workspace

• The actual required operating radius.
• Surrounding obstacles: machinery, conveyors, lighting, and ventilation ducts.
• Traffic paths for workers moving around the area.

Surveying Human Operations

Since the manipulator is installed for human use, this is the most critical part of the survey.

• Worker positioning when performing lifting/lowering tasks.
• Frequency of lifting/lowering per shift.
• Other movements involved: twisting, reaching, etc.

Although a thorough survey might take a few extra hours, it helps you avoid years of fatiguing operation and safety risks later on.

Step 2 – Selecting the Appropriate Configuration

After the site survey, engineers will meet to research and propose a design for the manipulator and the appropriate end-effector (gripper). This step isn't just about choosing a model; it's about defining the right configuration for the space and the people.

Choosing the Mounting Style: Floor, Ceiling, or Mobile

• Floor-mounted (Column): Suitable when the floor is thick enough, high stability is required, and operations are repetitive at a fixed location.
• Ceiling-mounted / Overhead Rail: Frees up floor space, suitable for long production lines, but requires a sufficiently rigid roof structure.
• Mobile Base: Flexible, but only safe on flat floors with moderate loads.

Note: Each mounting style has different requirements for foundations, structure, and safety. Selection cannot be arbitrary; it must be calculated and reviewed carefully.

Determining Working Radius and Lifting Stroke

• The larger the reach radius, the higher the moment (torque) applied to the base or ceiling.
• The lifting stroke must be sufficient for the task without being excessive or bulky.
• Goal: Design a manipulator with a working range that ensures convenience for the worker, thereby maximising performance.

Choosing the Assistive Mechanism and End-Effector

• Power source: Pneumatic, electric, or hydraulic must match the available infrastructure.
• End-effector (Gripper): Must be designed based on the specific product; avoid "one-size-fits-all" solutions.

If the survey step helps you understand the factory, this configuration step ensures the manipulator becomes an integral part of the production process, not just a device placed there for the sake of it.

Step 3 – Site & Technical Infrastructure Preparation

Once a suitable solution is defined, the next phase is preparing the site for construction and installation.

Preparing the Foundation or Suspension Structure

For floor mounts:

• Concrete floor must be thick and hard enough to withstand long-term dynamic loads.
• Drilling positions for bolts must avoid rebar, water pipes, or underground cables.
• Floor surface must be flat, with no cracks or peeling.

For ceiling mounts:

• Beams and purlins must be tested for actual load-bearing capacity.
• Reinforcement plans must be in place if the existing structure is insufficient.
• Clearly define suspension points, spacing, and allowable deflection.

Preparing Energy Sources

• Pneumatic: Stable pressure, clean and dry air (avoid moisture that jams valves).
• Electric: Suitable power supply, safe grounding, no temporary wiring.
• Routing: Pipes and cables must be arranged neatly so they do not obstruct operations.

Preparing a Safe Installation Area

• Clearly cordon off the installation zone.
• Post warning signs and restrict unauthorised personnel from moving or working in the area.
• Ensure full Personal Protective Equipment (PPE) for the installation team.

Step 4 – Mechanical Installation

At this stage, all drawings and calculations are brought to reality. This step determines whether the manipulator will run smoothly or drift, and whether it will reduce worker fatigue or add to it.

The installation process for mechanical components is as follows:

Installing the Base and Anchor Bolts

• Position the base precisely according to the survey drawings.
• Drill holes to the correct diameter and depth.
• Completely clean the drill holes before inserting bolts (chemical or mechanical).
• Tighten bolts to the specified torque (do not tighten based on "feeling").

Levelling and Alignment

• The manipulator axis must be absolutely vertical relative to the floor.
• Use a spirit level or precision measuring device to check.
• Use shims for alignment before the final tightening.

Assembling the Arm and Moving Joints

• Assemble in the correct sequence from the main column to the arm.
• Apply adequate lubrication to all joints.
• Avoid strong impacts that could deform or scratch working surfaces.
• Crucial: Ensure every joint rotates lightly, evenly, and without friction. If a joint is stiff during installation, operation will never feel "weightless" later.

Step 5 – Connecting Assistive & Safety Systems

Connecting the power and safety systems determines whether the manipulator is truly light, safe, and easy to control when put into use.

Connecting the Assistive System

For Pneumatic Manipulators:

• Connect air lines in the correct direction and at the correct working pressure.
• Install the air preparation unit (filter/regulator) in a visible position for maintenance.
• Check for leaks at all connection points.
• Note: Pressure too low makes the lift weak/hard to balance; pressure too high causes jerky movements and safety risks.

For Electric or Hybrid Manipulators:

• Check for a stable power supply.
• Ensure safe grounding.
• Cable management should be neat, ensuring no tension when the arm rotates or extends.

Setting and Calibrating Assist Force

• Adjust lifting force based on the actual weight of the load, not theoretical specs.
• Test at various heights to ensure the arm does not drift on its own.
• Check the ability to stop at any position in space.

Checking Safety Mechanisms

• Anti-drop system in case of power loss.
• Load retention mechanism during sudden stops.
• Prevention of load release while the object is still suspended.
• These details often go unnoticed during installation but are life-savers in emergencies.

Step 6 – Test Run & Standard Verification

Do not rush to put the manipulator into production immediately after mechanical and system connections. The test run and calibration phase is a necessary safety buffer to detect small deviations before they become major operational risks.

No-Load Test Run

• Operate the manipulator through its full range of motion.
• Check movements: lifting, lowering, rotating, and extending.
• Observe smoothness, latency, and stopping capability at each position.
• If the manipulator jerks, jams, or makes unusual noises without a load, it will definitely be worse with a load.

Real Load Test Run

• Attach a load matching the actual working weight.
• Test operations exactly as a worker would during a shift.
• Observe for arm drift, misalignment, or slight vibrations.
• This is where small calibration errors reveal themselves, especially at full extension or maximum height.

Fine-Tuning

• Re-adjust pressure and balance force if necessary.
• Calibrate lifting/lowering speeds to match user pace.
• Ensure the arm stops completely and does not slowly drift.

Safety Scenario Testing

• Simulate power loss (air or electricity).
• Check the reaction of the anti-drop system.
• Ensure the load does not free-fall in any scenario.

Step 6 doesn't add new features, but it protects people and equipment throughout the lifecycle. A thorough test run is always cheaper than stopping the production line to fix errors later.

Step 7 – Operation Training & Handover

Installation and testing are not the end of the project. The manipulator only delivers value when humans understand and master it. This is the time to guide the future operators.

Training Direct Operators

Training should be concise but focused:

• Basic safety principles: Never stand under the load, do not yank the manipulator.
• Proper technique: How to clamp and centre the load correctly.
• Operation sequence: Lift – Move – Lower.
• Prohibited actions: What absolutely not to do during operation.
• Result: Workers should operate smoothly and easily.

Guide to Start-of-Shift Checks

• Check air pressure/power status.
• Inspect hoses, cables, and the gripper head.
• Quick test of lift/lower functions and the Emergency Stop button.
• This habit helps detect small issues early before they become accidents.

Technical Handover and Documentation

• Operation and basic maintenance manuals.
• Allowable load information.
• Acceptance and test run minutes.
• Recommended periodic inspection schedule.

Step 7 is the bridge between technology and people. Doing this well ensures the manipulator becomes a familiar, safe, and durable tool in every production shift.

Conclusion

A standard industrial manipulator installation process ensures the equipment fits the space, the task, and the people using it every day. When every step is performed meticulously—from surveying and configuration to site prep, testing, and training—the manipulator will deliver the true value it was created for.

Contact Vietmani for professional installation support. Hotline: 0931 782 489