How Industrial Manipulators Optimize Complex Material Handling Processes

In industrial manufacturing, lifting and moving materials with heavy weight, special shapes, eccentric loads, or requiring precise positioning often poses many difficulties for operators. Traditional lifting methods can meet the load-bearing capacity but are not optimal when it comes to moving, rotating, and placing materials accurately within confined workspaces.

Assistive lifting arms are a solution to help control loads more flexibly, combining lifting, moving, rotating, and positioning capabilities with direct operation by the user. Thanks to this, complex material handling processes can be performed more smoothly, accurately, and stably.

How do assistive lifting arms optimize the process?

Assistive lifting arms do not only help lift heavy materials but also support the entire lifting – moving – rotating – positioning – placing process. By combining a power-assisted mechanism, a mechanical arm, and suitable tooling, the device helps simplify operations that traditional lifting methods struggle to address.

Reducing physical effort when lifting and moving loads

Zero Gravity technology creates a state of balance between the load weight and the assistive force, helping operators control the load with significantly less applied force. With VIETMANI's HA Series, the Auto Balancer – Zero Gravity system can adjust the balancing force according to the load and working pressure.
As a result, lifting and moving heavy loads becomes easier, while also reducing dependence on manual labor for repetitive tasks.

More stable load control during positioning

Unlike methods using cables or chains that can create a pendulum effect, the structure of the assistive lifting arm helps control the load more stably during movement. This is especially useful when handling eccentric loads or when needing to insert materials into installation positions in confined spaces.
Operators can actively steer the load instead of constantly exerting force to hold, maintain, and align the materials.

Supporting rotation and changing material orientation

For processes requiring changes in product direction or orientation, the lifting arm can be integrated with a Rotary Union and appropriate tooling. VIETMANI's HA Series offers 330° and 360° Rotary Union options, allowing connection with tooling and supporting the rotating movement of the load.

Thanks to this, the process can be condensed from many separate operations into a more continuous sequence of actions.

Customizing tooling for each type of material

Tooling is the component in direct contact with the product and plays a decisive role in the ability to handle loads with different shapes, sizes, and characteristics. Assistive lifting arms can be combined with suitable clamping, gripping, or suction solutions instead of using a fixed lifting mechanism for every application.

Expanding the range of operation in the production line

Lifting arms can be installed in various configurations depending on the layout and movement requirements of the factory. With a configuration suspended on a KBK rail system, the device can expand its operating range and is suitable for production lines that need to move loads between multiple positions.

For the HA Series, the standard configuration has a load capacity from 80–1,000 kg, a maximum working radius of 4,000 mm, and a standard lifting stroke of 200–1,800 mm, allowing for the selection of a configuration suitable for each handling requirement.

Thus, the value of an assistive lifting arm lies not only in the ability to "lift heavy loads" but also in the ability to turn a complex material handling operation into a smooth, flexible, and more controllable process.

Measurable benefits (ROI)

Investing in assistive lifting arms not only brings benefits in safety and ergonomics but can also be evaluated through specific operational indicators. Depending on the application, businesses can track changes before and after implementing the equipment.

Reducing manual labor

Zero Gravity technology helps significantly reduce the force that operators must use to lift and control loads. Many projects implemented by Vietmani have recorded a labor reduction of up to 80% in suitable applications.

This indicator can be evaluated through the number of people needed to participate in a stage, the level of operator fatigue, and the ability to maintain stable operations throughout the shift.

Shortening cycle time

When the lifting, moving, rotating, and positioning operations are performed continuously by an assistive system, businesses can reduce the time spent on intermediate steps.

Some vacuum lifting systems can shorten the "Suction – Lift – Release" cycle to just a few seconds, showing a clear improvement in handling speed for suitable applications.

For each production line, ROI can be measured by the average processing time per product, cycles/hour, and output before and after applying the device.

Reducing costs related to workplace injuries

Reducing manual lifting operations and improving ergonomics can contribute to limiting risks related to musculoskeletal disorders. Businesses can use indicators such as the number of accidents, days off due to injury, medical costs, and compensation costs to evaluate investment efficiency.

Increasing productivity and process stability

When operators can control loads more easily and accurately, the material handling process can achieve higher stability, especially with stages repeated many times a day. Vietmani's assistive lifting arms are designed to support operators in moving loads quickly, safely, and contribute to increasing productivity at the workplace.

Indicators that can be tracked include:

• Output/hour.
• Cycle time.
• Defect rate or damaged product rate.
• Downtime of the stage.
• Number of workers required for each operation.

Evaluating payback period

From the above indicators, businesses can convert operational efficiency into economic value and calculate the payback period of the equipment. The evaluation formula can be simplified to:

Payback Period = Investment Cost / Savings or Added Value per Period

However, the actual ROI of an assistive lifting arm depends on the load, frequency of operation, cycle time, equipment configuration, tooling, and characteristics of each line. Therefore, instead of applying a fixed ROI figure, businesses should evaluate based on the actual data of each application.

With VIETMANI, the HA Series has many load configurations from 80–1,000 kg, along with the ability to customize the system according to handling requirements, helping businesses choose a solution suitable for their operational problems instead of investing in a configuration that exceeds their needs.

Practical applications of assistive lifting arms

Thanks to the ability to combine power-assisted mechanisms and specialized tooling, assistive lifting arms can be designed for many different material handling stages in the factory. In particular, the device is effective in positions requiring frequent lifting, changing orientation, or precise product positioning.

• Lifting and positioning electrical cabinets, switchboards.
• Lifting shafts, tubes, and mechanical parts.
• Lifting, rotating material rolls.
• Gripping and assembling automotive and motorcycle components.
• Lifting wheels, tires, and component assemblies.
• Moving materials between stages on a production line.
• Pick & Place products with sensitive surfaces using vacuum technology.

The important point is that assistive lifting arms do not necessarily have to use a fixed configuration for every application. Load, product shape, center of gravity, operating direction, and workspace will determine the suitable arm configuration and tooling, thereby creating a material handling solution that is close to the actual process of each factory.

Conclusion

In modern production processes, material handling not only requires the ability to lift large loads but also requires the ability to move, rotate, change orientation, and position accurately. Assistive lifting arms help solve these requirements by combining power-assisted technology, lever mechanisms, and tooling suitable for each type of load.

When selected and configured correctly for the application, assistive lifting arms can help reduce labor, shorten operation time, increase load control, and improve process stability. This is not just a lifting support solution but also a plan to optimize material handling operations in the factory.

Each material handling process has different characteristics in terms of load, size, center of gravity, operating direction, and workspace. Therefore, an effective solution needs to be designed and configured based on the actual application.

VIETMANI provides assistive lifting arm solutions, tooling, and industrial lifting systems upon request, from equipment configuration selection to designing gripping mechanisms suitable for each type of product.

Are you encountering difficulties in lifting, moving, rotating, or positioning materials in your production line?

Contact VIETMANI for consultation and proposals for an assistive lifting arm solution suitable for your business's actual process.

Hotline: 0931 782 489