Structure and Operating Principle of Vacuum Assist Manipulators

In a factory, lifting and moving loads require equipment that is both powerful and flexible. The structure of a vacuum assist manipulator is therefore designed with multiple coordinated components such as the manipulator arm, lifting arm, rotary union, fixture, and vacuum suction unit.

So, what is the role of each component and how do they coordinate with each other? Let's join Vietmani to explore in detail the structure and operating principle of this solution.

What is a vacuum assist manipulator?

A vacuum assist manipulator is a lifting solution that combines an industrial manipulator and a fixture integrated with a vacuum suction unit. The manipulator assists in lifting, moving, and positioning the load, while the vacuum suction unit holds the object through the contact surface.

Depending on the requirements of each application, Vietmani can combine the HA Series with various types of grippers/tooling to meet the characteristics of each type of lifting object.

Thanks to this combination, operators can handle loads more conveniently while maintaining good control over the lifting – moving – positioning – releasing process in the production line.

Structure of a vacuum assist manipulator

A vacuum assist manipulator is a system comprising multiple coordinated components to perform lifting, moving, and positioning of loads. With Vietmani's HA Series configuration, the system can combine the manipulator with various grippers/tooling depending on the specific requirements of each application.

Column and fixed mounting system

The column is the main structural part used to secure the manipulator to the factory floor, acting as a fulcrum for the entire manipulator mechanism. With the Fixed Column version of the HA Series assist manipulator, the column is firmly anchored to the floor, helping the equipment operate stably within the workspace.

Depending on the configuration, Vietmani also provides an installation option on the Aluminum KBK system to expand the equipment's movement range.

Lifting arm and moving joints

The lifting arm is the component that directly creates the manipulator's operating range. The system consists of arm segments linked together via moving joints, allowing for lifting, lowering, moving, and positioning objects within the working area.

The HA Series has a working radius of 750–4,000 mm and a standard vertical lifting stroke of 200–1,800 mm, depending on the configuration.

Pneumatic Controller System

The Pneumatic Controller plays an important role in controlling and balancing the manipulator. The HA Series features the following modes:

• M – Manipulator: lifting and lowering via push buttons.
• T – Balance: Zero Gravity balance for the arm and tooling when unloaded.
• A – Auto Balancer: Zero Gravity balance for both unloaded and loaded states.
• AC – Collaborative: Auto Balancer/Zero Gravity mode that supports button-free operation based on equipment configuration.

Rotary Union – Tooling connection swivel joint

The Rotary Union is the part that connects the third arm segment with the tool gripper, while allowing the tooling to rotate during operation. This design helps prevent twisting of the air hoses when the gripper rotates.

The HA Series offers Rotary Union options of 330°, 360°, and 360° with a brake, featuring an air inlet/outlet port system depending on the configuration.

Fixture – Gripper/Tooling

The Gripper/Tooling is the part that directly connects to the object to be lifted. This is also the component selected based on the characteristics and processing requirements of each load type.

In practical applications, the manipulator and gripper are combined into different solutions customized according to the requirements of each application. Therefore, the tooling configuration can change depending on the lifting object and the manipulation method.

Vacuum suction unit

In a vacuum assist manipulator configuration, the vacuum suction unit is integrated into the tooling to create contact points and hold the lifting object using suction force.

It should be noted that the provided HA Series documentation does not detail each component of the vacuum suction unit, such as the suction cup type, vacuum generator, or vacuum parameters. Therefore, these parameters need to be determined based on the actual tooling configuration of each application, rather than applied universally across the entire HA Series.

Braking system and safety functions

The braking system and safety mechanisms help control movement and minimize risks during operation. They perform functions such as:

• Safety lock in case of pressure loss.
• Preventing release while the object is moving.
• Interlock design.
• Some Rotary Union configurations feature an integrated brake.

Thanks to the coordination between the manipulator, balancing mechanism, lifting arm, Rotary Union, tooling, and vacuum suction unit, the assist manipulator can support operators in performing lifting, moving, and positioning tasks tailored to specific production scenarios.

Operating principle of a vacuum assist manipulator

The vacuum assist manipulator operates based on the coordination between the manipulator mechanism, pneumatic balancing system, and vacuum suction unit. The manipulator assists in lifting, lowering, and moving the load, while the vacuum suction unit holds the object via the fixture.

1. Creating holding force with vacuum

• When the suction unit contacts the lifting object's surface, the vacuum system creates conditions for the suction cups to grip the object. The holding force is formed at the contact points between the suction unit and the load surface.

2. Activating the manipulator mechanism

• After the object is held by the tooling, the Pneumatic Controller system controls the manipulator mechanism. Depending on the configuration, the operator can use the Manipulator, Balance, or Auto Balancer mode to assist in lifting and moving the load.

3. Lifting and moving the load

• The supporting force from the pneumatic system combined with the moving joints helps the operator bring the load to the desired position. With the HA Series, the manipulator has a maximum working radius of 4,000 mm and standard vertical lifting from 200–1,800 mm, depending on the configuration.

4. Rotating and positioning the object

• The Rotary Union allows the tooling to rotate as required by the operation, while minimizing air hose twisting when the gripper rotates. Depending on the configuration, the swivel joint can achieve 330° or 360°.

5. Releasing the object

• Once the load has been brought to the correct position, the operator controls the suction unit to release the object from the tooling. The manipulator then returns to a suitable position to continue the next operating cycle.

6. Safety mechanisms during operation

• The HA Series system is equipped with safety functions such as locking upon pressure loss, preventing release while the object is moving, and an interlock design. These mechanisms help control the load during operation.

Applications of vacuum assist manipulators in factories

Thanks to the combination of the Industrial Manipulator and vacuum suction fixture, the vacuum assist manipulator can be configured to handle various types of loads. Here are some common applications:

• Lifting and moving sheet materials: MDF wooden boards, steel plates, glass plates, etc.
• Lifting and moving materials packed in carton boxes.

You can watch the video below for a more detailed perspective on the equipment's applications.

Vietmani's vacuum assist manipulator solution

Each lifting and lowering scenario in a factory has different requirements regarding load weight, lifting object size, operation direction, and positioning method. Therefore, Vietmani does not apply a fixed tooling configuration for all applications. The HA Series can be combined with various grippers and solutions to meet the processing requirements of each load type.

With the vacuum assist manipulator solution, the manipulator takes charge of supporting the lifting, moving, and positioning, while the fixture integrated with the vacuum suction unit handles contacting and holding the object. The Rotary Union helps connect the tooling to the manipulator and supports rotational movement according to the equipment configuration.

Besides the tooling customization capabilities, the HA Series also features control configurations such as Manipulator, Balance, and Auto Balancer – Zero Gravity, helping to choose an operation method suitable for manipulation requirements. The system is also integrated with safety functions such as locking upon pressure loss and interlocks.

If you are looking for a vacuum assist manipulator solution suited for a specific load type or production stage, Vietmani can work with you to analyze requirements for load weight, lifting object, operation range, and tooling to select the appropriate configuration.

Contact Vietmani to discuss your lifting problem. Hotline: 0931 782 489.