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

Track

Mechatronics — Topic 01

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.

This project aims to develop a robust, lightweight and adaptable end-of-arm tooling solution designed to handle products weighing up to 50 kg. The main objective is to design, size and validate a robotic gripper for heavy-duty palletizing and depalletizing applications. The gripper shall 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 functional analysis and specification: study industrial gripping principles; identify target product families, dimensions, mass range, contact surfaces and operating constraints; and establish the functional and technical specifications.
• Develop the gripper architecture and detailed 3D models in SolidWorks, including 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.
• Perform mechanical sizing and strength calculations covering gripping forces, structural loads, load paths, stresses and deflections. Account for product mass, gripper mass, centre of gravity and relevant safety factors.
• Perform Finite Element Analysis studies in SolidWorks Simulation for relevant load cases, assess stress distribution, deformation and safety margins, and optimize geometry and material choices based on simulation results.
• Prepare the Bill of Materials, detailed drawings, assembly drawings, manufacturing information, component references and technical dossier, including 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