FAQ

For sensitive, irregular plastic parts, soft or adaptive gripper solutions such as suction cups with customized form cushions, bellows or vacuum cushions, or soft gripping fingers are suitable. Alternatively, needle or internal bellows grippers offer advantages when localized or internal pickups are necessary. Selection criteria include surface quality, weight, required gripping force, accessibility of the gripping point, and cycle time; testing benches and prototype tests are recommended before series approval.

Compatibility is ensured through mechanical interfaces (flange dimensions, mounting points), payload and center of gravity calculations, as well as electrical and pneumatic connection specifications. Standardized flange dimensions (e.g., ISO 9409) and quick connect couplings for electrical and pneumatic connections facilitate integration. Additionally, the communication protocols and I/O pins for sensors and actuators should be checked. Adapter plates or modules can be designed constructively to accommodate deviations.

The development time varies with complexity: for simple adjustments, a few weeks are typically realistic, while complex special grippers may require several weeks to several months. The process includes requirements gathering, concept design, CAD modeling, prototype fabrication, initial testing, and optimization. Additional time may be needed for testing under series conditions, material approvals, or regulatory certifications.

Essential steps: clarification of mechanical interfaces and fastening, testing of load capacity and center of gravity, coordination of electrical/pneumatic connections, definition of control and I/O signals, creation of CAD/electrical drawings, implementation of safety functions, as well as testing and commissioning phases including functional, cycle, and load tests. Documentation and training of operating personnel are part of the integration.

Maintenance intervals are based on operating time, load, environmental conditions, and type of gripper. Recommended measures include regular visual inspection for wear, tightening screws, checking seals and hose connections, inspecting sensors and valves, lubricating moving parts according to specifications, and testing functions at set intervals. For critical applications, a spare parts kit and a documented maintenance plan are advisable.

Standard components are generally available for short-term delivery (days to a few weeks), while custom parts may have longer delivery times. Availability depends on inventory management, manufacturing capacity, and the supply chain situation. For production-critical applications, it is recommended to keep critical spare parts on hand or to have a service agreement with defined response times.

Warranty services vary depending on the provider; typically, warranty periods range from several months to two years for new devices. The lifespan depends on usage, maintenance, operating environment, and materials used. Fatigue-resistant design, regular maintenance, and replacement of wear-critical components significantly extend the service life.

For bend-sensitive or thin-walled parts, special gripping concepts are recommended: needle or pin grippers (for point contact), vacuum grippers with large contact areas or flexible mounts, adaptive grippers with pressure-distributing pads, as well as force or path control to limit gripping force. Additional measures include process damping, slow approach movements, active compensation using sensors, and potentially part fixation during transport.

Magnet grippers are useful for ferromagnetic workpieces (steel, cast iron) with suitable surface and load-bearing geometry. Limitations: not applicable to non-magnetic materials (aluminum, plastics), effectiveness reduced with thick coatings or large air gaps, temperature influences can affect magnetic field strength, and residual magnetism can complicate rework. Safety shutdowns and redundancy should be considered in safety-critical applications.

For porous surfaces, suction cups with soft sealing lips, membrane or bell solutions, and large-area vacuum cushions are suitable to minimize leaks. Using multiple small suction cups combined with vacuum buffers or decentralized vacuum generators increases reliability. Additionally, vacuum sensors help monitor and active venting systems enable quick solutions.

Pneumatic grippers: Advantages are simple construction, high speed, robustness, and lower costs; disadvantages are limited positioning accuracy, compressed air requirement, and less precise force control. Electric grippers: Advantages are precise positioning/force-controlled gripping, easy integration into control systems, and energy efficiency; disadvantages are higher initial costs, potentially more complex maintenance, and lower robustness in harsh environments. Selection depends on the requirement profile (accuracy, force control, cleanliness, operating costs).

Required gripping force is determined by the weight of the component, acceleration and deceleration profiles, lever arms (moments), as well as safety factors for process uncertainties. Dynamic forces during startup/shutdown, center of gravity position, and surface are considered. For critical applications, calculations are supplemented by tests under real conditions and safety factors depending on the risk (typically 1.5–3 times the minimum load).

Essential quality criteria: precise manufacturing tolerances, form- and position-accurate assembly, wear-resistant materials, suitable surface treatments, reliable seals, and tested functionality of sensors and actuators. Traceability of components, material testing, as well as stress and sealing tests are part of quality assurance.

Retrofit includes inventory, interface measurement, definition of target requirements, selection of upgradable components (grippers, sensors, controls), mechanical and electrical modifications, and testing. The goal is minimal production downtime through planned installation windows, staging, and gradual commissioning. Safety and compliance with standards must be ensured throughout the entire process.

The machine directive, EN ISO 12100 (risk assessment and safety requirements), EN ISO 10218 (industrial robots), and ISO/TS 15066 for collaborative applications are to be considered, among others. Safety functions such as safe protective devices, emergency stop, safety-oriented controls, and suitable sensing are to be defined. A documented risk assessment and operating instructions are required.

Reducing cycle times through shortened gripping and return paths, use of lighter tools, parallel processing steps, faster vacuum or pressure buildup times, optimization of robot trajectories, and now adaptive control of gripping forces. Also, reducing takt changes through buffer cells or feeder systems contributes to increased efficiency.

ROI calculation includes the measurement of investment costs (acquisition, integration, training), ongoing costs (energy, maintenance, spare parts), as well as benefits in the form of labor time savings, increased output, improved quality, reduced error costs, and lower accident rates. Payback period is calculated by dividing investment costs by annual savings. Sensitivity analyses for utilization and downtime improve the reliability of the results.

Recommended are functional tests, cyclic endurance runs under real load, load and safety tests, measurement of gripping forces and positioning accuracy, FMEA for risk minimization, as well as pilot runs with series material. Documentation of the results and, if necessary, adjustments to design or process are part of the validation scope.

Environmental conditions determine material selection, protection classes (IP ratings), sealing types, and necessary protective measures. In dusty environments, easily cleanable surfaces, protective covers, and filters for pneumatic systems are important. High temperatures require heat-resistant materials or cooling measures; humidity can affect electrical components and requires suitable protective enclosures. Corrosion-resistant materials extend the lifespan in aggressive environments.

Sensors provide feedback on process stability and enable adaptive control: force sensors prevent exceeding or falling below defined forces, position sensors ensure positioning, vacuum sensors monitor the suction state and prevent part losses. Combining with control logic enables error routines, process documentation, and quality assurance.

Mechanical assembly is carried out using standardized flanges or custom adapter plates; dimensionally accurate drilling templates and mounting points must be used. Electrical and pneumatic connections are made via quick couplings, plug-in cables, or secured connectors, often with defined cable routes and strain reliefs. Prior to assembly, CAD interfaces and cable/hose management for movement freedom should be checked.

Important training contents: safe operation and emergency procedures, basic control and adjustment parameters, maintenance and cleaning measures, replacement of consumable parts, diagnosis and troubleshooting, as well as documentation and record-keeping. Practical hands-on units and written instructions enhance safety and availability.

Included documentation ideally comprises: CAD/STEP data, assembly and connection diagrams, electrical circuit diagrams, pneumatic schematics, parts list (BOM), user manual, maintenance schedule, test protocols, as well as certificates/material certificates. These documents facilitate integration, maintenance, and spare parts procurement.

Quality assurance includes dimensional and form inspection (measurement reports), material testing, leak and pressure tests, functional tests under load, endurance and cycle tests, as well as electrical tests for sensors. Additionally, process controls such as 100% testing of critical dimensions, sampling inspection, and batch traceability are meaningful.

Possible causes: inappropriate grasp geometry, incorrect grasp point, contaminated or moist surfaces, insufficient gripping force or incorrect force profile, wear on sealing lips, incorrect alignment or dynamic stress. Remedies: adjustment of the grasping concept (different grippers, suction cups or pads), cleaning or surface pre-treatment, force regulation and sensor integration, increase in contact area, use of positive fitting features or mechanical part fixation, as well as regular maintenance and material inspection.

We develop, produce, and deliver modular gripper systems and automation solutions for robots. Our modular system allows grippers to be quickly and flexibly adapted to various applications.

Our systems are used, among other things, in the automotive industry, in plastic injection molding, in the packaging industry, and in many other areas.

With the modular system, users can assemble custom grippers from standardized components. This saves time, costs, and allows flexible adjustments.

Yes. Our engineering team assists customers in selecting the right components or develops complete, ready-to-use gripper solutions.

Our components and gripper solutions are available in the online shop: shop.ags-automation.de.

Yes. In addition to standard components, we also develop custom special solutions that are precisely tailored to the specific application.