Design, Sizing and Validation of a Heavy-Duty Robotic Gripper or Industrial Palletizing Applications

Track

Mechatronics — Topic 01

Reference

MECHA001

Context and objective

Industrial palletizing operations often require the handling of large and heavy products with different dimensions and packaging characteristics. The reliability of the gripping tool is essential to ensure safe handling, repeatable cycles and effective integration with industrial robots.

The project aims to develop a robust, lightweight and adaptable end-of-arm tooling solution for handling products weighing up to 50 kg. The gripper must accommodate a defined range of product sizes, provide reliable retention during robot motion, and remain compatible with the payload and wrist-load limits of the selected industrial robot.

Main tasks

• Perform a functional analysis of industrial gripping principles.
• Identify target product families, dimensions, mass range, contact surfaces and operating constraints.
• Establish the functional and technical specifications.
• Develop the gripper architecture and detailed 3D models in SolidWorks.
• Design the gripping mechanism, adjustable elements, structural frame and robot-mounting interface.
• Select suitable materials and standard components based on strength, stiffness, mass, manufacturability, availability and cost.
• Calculate gripping forces, structural loads, load paths, stresses and deflections.
• Account for product mass, gripper mass, centre of gravity and relevant safety factors.
• Perform SolidWorks Simulation studies for relevant load cases.
• Assess stress distribution, deformation and safety margins.
• Optimise geometry and material choices based on simulation results.
• Prepare the Bill of Materials, detailed drawings, assembly drawings, manufacturing information, component references and a technical dossier.
• Include a cost estimation.

Expected deliverables

• Functional analysis and approved technical specification.
• Complete SolidWorks 3D assembly and native CAD files.
• FEA simulation report with identified load cases and results.
• Bill of Materials and component list.
• Technical manufacturing and assembly dossier.