In robotic palletizing, the spotlight often shines on the robotic arm. Yet the true hero operates at the point of contact: the gripper.
This End-of-Arm Tool (EOAT) directly influences efficiency, product integrity and overall ROI. The wrong gripper creates operational bottlenecks and product damage. The right gripper, managed by intelligent software, transforms productivity metrics overnight.
Critical gripper selection factors for optimal performance
Choosing the right gripper requires methodical evaluation of several key factors.
a. Product characteristics drive everything
The product dictates your gripper choice – not the other way around. Size, weight, shape and surface properties determine viable options. Fragile items require vacuum grippers with controlled pressure settings. Rigid boxes favor mechanical grippers with precise clamping force.
b. Throughput requirements set the pace
Your production targets and the relevant speed determine whether single-item, multiple-item or layer grippers make sense. High-volume operations benefit from layer and multi-item handling capabilities. Lower-volume operations prioritize flexibility over raw speed.
c. Environmental conditions cannot be ignored
Temperature extremes, dust levels and moisture affect gripper performance dramatically. Cold storage requires specialized materials and seals. Dusty environments often render vacuum systems ineffective without proper filtration.
d. Flexibility determines long-term value
Multiple product types require adaptive gripper designs or tool changers. Evaluate whether single-purpose or multi-function grippers better serve your operation.
e. Robot compatibility ensures seamless operation
The gripper must work within your robot’s payload capacity. Mounting interfaces and communication protocols must align perfectly. Confirm compatibility before finalizing your selection.
f. Software integration unlocks full potential
Modern palletizing software simplifies gripper configuration and control dramatically. The trend favors intuitive interfaces over complex programming requirements.
Palletizing gripper types: Finding your perfect match
All grippers share common components – actuators, sensors and structural frames. But their operational principles differ significantly.
Vacuum grippers: The versatile standard
Vacuum grippers lift items using suction applied to top surfaces. They handle sealed boxes, cartons, and items with smooth surfaces excellently.
Components and operation
These systems combine suction cups, vacuum generators and control valves. Single or multiple cups distribute force across the product surface, while multi-chamber vacuum models enable the partial activation of the gripping surface. Specialized materials accommodate varying temperatures and product types.
Three key variants
- Foam vacuum grippers excel with irregular top surfaces
- Suction cup arrays feature multiple cups with independent zone control
- Layer vacuum grippers handle entire product layers simultaneously
Benefits
Vacuum systems offer gentle handling and operational simplicity.
Considerations
They struggle with porous surfaces and dusty environments. Moreover, energy consumption can become a consideration in large installations.
Industry vacuum gripper examples
- Schmalz FXCB and SPZ vacuum grippers offer excellent versatility
- OnRobot VGC10 & VGP20 deliver precise vacuum control
- Piab CPT offer energy-efficient operation for various applications
Parallel grippers: Precise and powerful
Parallel grippers use jaws, plates or fingers to clamp products from the sides. They excel with regularly shaped items requiring firm, controlled gripping.
Benefits
Modern electric versions offer precise force and position control. Some integrate vacuum gripping for auxiliary slip sheet handling. Their strong grip ensures product security during rapid movements.
Considerations
These grippers typically handle one item at a time. Irregular shapes present challenges for standard designs. Uncontrolled force can damage products without proper configuration.
Industry parallel gripper examples
- OnRobot 2FGP20 and RG2-FT provide versatile gripping solutions
- Zimmer Group GPP5000 offers precision force control
- Schunk PGN-plus-P series combines strength with flexibility
Fork grippers: Support from below
Fork grippers slide beneath products, often with top clamps for stability. They shine with open-top containers and items unsuitable for top gripping.
Benefits
Fork designs provide stable support for delicate or unstable loads, such as trays with multi-product arrays. They often handle pallets without tool changes or accommodate clean surface heavy items with characteristics extending beyond vacuum capabilities.
Considerations
These systems require specific conveyor configurations allowing fork entry. The sliding action can reduce cycle times slightly. Mechanism complexity may affect maintenance requirements.
Industry fork gripper examples
- Körber Handle Fork Gripper GR25 offers robust performance
- TRAK Group Robot Fork Palletising Gripper suits heavy-duty applications
- Robot EOAT SF-100 side fork gripper is suitable for open top boxes and compressed bags
Specialized grippers: Custom Solutions
Some applications require custom-engineered gripping solutions. These address unique product characteristics or multi-tasking requirements effectively. Hybrid designs may combine vacuum and mechanical elements in one tool.
Cost-Benefit Analysis
Custom solutions optimize performance only for the specific applications they have been designed for. Development time and cost exceed standard options significantly. However, operational gains often justify the investment for challenging applications.
Seamless integration: The communication layer
Effective palletizing requires smooth interaction between gripper, robot, and software.
Physical Connections
Standardized flanges like ISO 9409-1 simplify mechanical mounting. Power requirements vary between electric and pneumatic systems. Signal connections range from simple digital I/O to sophisticated networks.
Communication Protocols
IO-Link has emerged as a vital standard for gripper connectivity. This protocol enables dynamic parameter adjustment and diagnostic data exchange. It supports Industry 4.0 initiatives through enhanced data visibility.
Software Orchestration
Modern palletizing software translates tasks into coordinated robot and gripper actions. It manages configuration of physical dimensions and operational parameters.
Future trends: The evolution continues
The progress on gripper technologies follows the increasing manufacturing needs. Breakthroughs happen when they are controlled by new generation robotic palletizing software.
Manufacturing and Weight Optimization
3D printing enables lighter, more efficient gripper components. Reduced weight improves robot performance and energy efficiency. Custom geometries address application-specific challenges cost-effectively.
AI and Vision Integration
Smart grippers increasingly incorporate vision and AI for adaptive operation. These technologies enable optimal grip point identification for diverse products. They prove especially valuable for mixed-load handling scenarios.
Adaptive Materials and Designs
Soft robotic principles are entering industrial applications gradually. Variable stiffness materials conform to irregular shapes automatically. Bio-inspired designs handle previously challenging products effortlessly.
Conclusion: A strategy for operational excellence
Selecting the ideal palletizing gripper requires careful application analysis. No universal solution exists for all palletizing challenges. Understanding and combining product characteristics, throughput needs and space limitations will lead to optimal choices.
The greatest performance gains come from pairing advanced grippers with intelligent software. Modern solutions manage diverse gripper types through intuitive interfaces.
At Progressive Robotics, we develop technology that make robots operate smarter, like our most intuitive and easiest-to-deploy robotic palletizing software.
Just send us a message here to book your free live demo session.