Design and Development of an Energy-Efficient Pneumatic Gripper for Palletizing Applications

Palletizing automation plays a vital role across industries, requiring the selection of suitable robotic grippers to improve product quality and cost efficiency. However, issues such as carton drops, and misalignment often caused by inconsistent air supply can compromise gripper performance. Pneumatic grippers, in particular, face limitations such as low deformation resistance, leading to bending during carton handling. To overcome these challenges, pneumatic gripper pincers were designed with an integrated pressure-feedback mechanism to enhance reliability. Anti-slip rubber pads and FlexiForce sensors were incorporated to prevent carton slippage and monitor gripping force. Simulation analyses and hardness tests validated the effectiveness of tungsten carbide pincers, confirming improved durability and grip stability. The developed pneumatic gripper system demonstrated enhanced palletizing performance, with fewer operational issues and reduced production downtime. These improvements increased system reliability and availability while also enhancing energy efficiency by minimizing idle periods, reducing wasted power during stoppages, and ensuring more consistent productive operation.