Handling Systems
Precise Handling, Safe Movement
Precision and Safety in Motion – Intelligent Drive Technology for Handling Systems
Maximum Precision and Safety in Dynamic Motion Sequences
Handling systems move workpieces, tools and assemblies throughout automated production processes. They pick, position, lift, rotate, transfer and place components, often within extremely short cycle times and with a high degree of repeatability.
At the same time, motion must be not only fast but also safe. A gripper must not release a component unintentionally. A vertical axis must reliably hold a load even in the event of a power failure.
And if a robot arm or transfer axis encounters an obstacle, a collision should not automatically result in extensive machine damage.
Modern handling systems therefore combine dynamic performance with protective functions. Couplings, brakes and actuators play key roles by transmitting torque, securing positions, limiting overloads and supporting controlled motion sequences. In this way, individual axes, grippers and modules become a reliable handling solution.
Wenn jede Bewegung sicher ankommen muss
Mönninghoff-Komponenten können in unterschiedlichen Handlingsystemen zum Einsatz kommen, zum Beispiel
- in Pick-and-Place-Systemen für das schnelle Aufnehmen und Ablegen von Bauteilen
- in Robotikachsen und Greifermodulen
- in vertikalen Hub- und Positionierachsen
- in Transfer- und Montageanlagen
- in automatisierten Zuführ- und Sortiersystemen
- in Palettier- und Depalettiersystemen
- in hochdynamischen Umsetz- und Verpackungsprozessen
- in Prüf- und Messsystemen mit wiederholgenauen Bewegungen
- in kollaborativen oder besonders kompakten Automationslösungen
Die Aufgaben reichen dabei von kurzen, schnellen linearen Bewegungen bis zu komplexen rotativen Achsbewegungen. Manche Anwendungen benötigen eine hohe Positioniergenauigkeit. Andere verlangen nach einer zuverlässigen Haltefunktion oder einem definierten Verhalten bei einer Kollision.
Gemeinsam ist allen Einsatzfällen – Die Antriebstechnik muss zur Bewegungslogik der Maschine passen und auch bei hoher Dynamik zuverlässig reagieren.
Die Anforderungen an Kupplungen und Bremsen
Handlingsysteme stellen an ihre Antriebskomponenten besondere Anforderungen
- Hohe Positionsgenauigkeit Werkstücke und Werkzeuge müssen zuverlässig an der vorgesehenen Stelle ankommen.
- Kurze Reaktionszeiten Bewegungsbefehle sollen ohne unnötige Verzögerung umgesetzt werden.
- Hohe Wiederholgenauigkeit Auch nach vielen Zyklen muss die Bewegung stabil und reproduzierbar bleiben.
- Sicheres Halten Vertikale Achsen, Hubmodule und Greifer müssen Lasten auch im Stillstand zuverlässig sichern.
- Schutz vor Kollisionen und Blockaden Überlasten sollen möglichst schnell erkannt und mechanisch begrenzt werden.
- Kontrolliertes Abbremsen Dynamische Bewegungen müssen ohne unnötige Schwingungen oder harte Anschläge zum Stillstand kommen.
- Geringes Verdrehspiel Für präzise Positionierung und synchronisierte Achsen ist eine spielfreie Kraftübertragung wichtig.
- Kompakte Bauform Besonders an Roboterachsen und Greifmodulen ist Bauraum knapp.
- Energieeffizienz Halte- und Bremsfunktionen sollen möglichst wenig Energie benötigen.
- Hohe Lebensdauer Automatisierte Systeme arbeiten oft im Dauerbetrieb mit sehr vielen Bewegungszyklen.
Gute Integration in Steuerung und Sensorik: Schalt-, Halte- und Überlastzustände müssen mit dem Gesamtsystem zusammenspielen.
Das Ziel ist eine Bewegung, die schnell genug für den Prozess und kontrolliert genug für Mensch, Maschine und Werkstück ist. Oder kurz: Dynamik mit Sicherheitsgurt.
Engage, Hold and Protect
Mönninghoff develops clutch and brake systems for handling systems that are tailored to motion profiles, torque, speed, loads, installation space and safety requirements.
Overload Couplings
An overload coupling can limit or disconnect power transmission when a predefined torque threshold is exceeded. This protects downstream components when a gripper becomes jammed, a workpiece misaligns or an axis encounters an obstacle.
Potential applications include
- Protection of robotic and handling axes during collisions
- Safeguarding gripper modules and tooling
- Protection of transfer and feeding systems against blockages
- Limitation of load peaks during dynamic motion
- Faster return to operation following a fault
Depending on the application, disengagement torque, reset characteristics and integration with the control system can be customised. As a result, overload protection becomes a planned element of machine functionality rather than an unexpected leading actor when something goes wrong.
Electromagnetic Tooth Holding Brakes
Electromagnetic tooth holding brakes positively lock axes and can provide reliable holding functionality even during power failures. They are particularly suitable for vertical axes, lifting modules and gripper arms where loads must remain securely supported when stationary.
Typical applications include
- Vertical robot and handling axes
- Lifting modules in assembly and transfer systems
- Gripper arms handling sensitive or heavy workpieces
- Positioning axes used during maintenance and setup operations
- Holding functions within safety-critical motion sequences
Their compact design enables integration into axes with limited installation space. Correct specification of holding force, switching time, load conditions and safety requirements is essential.
Magnetorheological Fluid Brakes
Magnetorheological fluid brakes provide continuously adjustable braking torque and variable damping characteristics. They are particularly suitable where movements must be decelerated in a controlled manner to protect delicate workpieces or mechanical systems.
Possible applications include
- Soft-stop functions on dynamic axes
- Controlled deceleration of grippers and slides
- Damping under varying load conditions
- Sensitive motion control in precision assembly processes
- Variable deceleration for different products or tooling
Particularly during high-speed movements, a gentle stop can make all the difference. The workpiece should arrive precisely where intended, not develop a life of its own after landing.
Electromagnetic Tooth Clutches
Electromagnetic tooth clutches provide positive-locking engagement with high repeatability. They are suitable wherever drive branches, tools or axes must be connected and disconnected in a defined manner.
Potential applications include
- Engaging and disengaging drive systems
- Defined tooling and format changeovers
- Synchronisation of rotary movements
- Switching operations involving high torque
- Applications requiring minimal backlash
The positive-locking connection creates a clearly defined mechanical engagement state and can support precise positioning and system synchronisation.
Voice Coil Actuators
Voice coil actuators are ideally suited for highly dynamic linear movements. They can perform short-stroke actuation, positioning and switching tasks whenever direct, repeatable movement is required within a compact installation space.
Potential applications include
- Fast gripper and locking movements
- Compact tool actuation systems
- Linear positioning in assembly equipment
- Rapid switching functions in feeding and inspection modules
- Short stroke movements in highly dynamic handling axes
They enable rapid linear movements wherever larger mechanical solutions would be unnecessary or incompatible with the axis design concept.
Handlingsysteme, die Bewegung beherrschen
Ob Pick-and-Place, Greifmodul, Roboterachse, Transferstation oder automatisierte Montage: Mönninghoff entwickelt Kupplungen, Bremsen, Überlastsysteme und Aktuatoren für Handlingsysteme, die präzise, sicher und dauerhaft zuverlässig arbeiten.
Sie entwickeln ein neues Handlingsystem, möchten eine Robotikachse absichern oder suchen eine kompakte Lösung für präzises Halten und dynamisches Bremsen? Sprechen Sie mit unseren Experten über Drehmoment, Kraft, Zykluszeit, Überlastschutz, Haltekraft und Bauraum. Gemeinsam bringen wir alles sicher an seinen richtigen Platz.
Reliable Technology for Critical Handling Applications
Precision Is a System-Level Requirement
A handling system consists of more than a single axis. Motors, gearboxes, couplings, brakes, actuators, sensors and control systems must function as an integrated whole. Even small deviations can affect positioning accuracy, tool life and process quality when operating at high cycle rates.
The following parameters may be considered during system design
- Torque and speed
- Linear force and stroke
- Acceleration and deceleration
- Mass and inertia of moving assemblies
- Cycle time and switching frequency
- Required positioning accuracy and repeatability
- Load profiles and potential collision scenarios
- Holding and braking torque
- Backlash and torsional stiffness
- Available installation space and connection geometry
- Sensor, control and diagnostic requirements
- Temperature, vibration and other environmental influences
Mönninghoff develops solutions that not only meet individual performance criteria but can also be integrated into the actual motion sequence of the handling system.
Safety for People, Machines and Workpieces
In handling systems, faults can have a variety of consequences. A blocked gripper can damage the workpiece. An uncontrolled vertical axis can endanger both equipment and personnel. A collision can lead to costly downtime.
For this reason, the following questions should be considered during the design stage
- How should the axis respond to an unexpected obstacle?
- At what point should overload protection disengage?
- Should disengagement be communicated to the control system?
- How will a vertical load be held during a power failure?
- How can a dynamic motion sequence be brought to a controlled stop?
- How can the system be safely reset and restarted?
- Which conditions must be detected by sensors and control systems?
- How can the safety function be integrated into the overall system?
A good solution protects more than the mechanics. It also supports clear and efficient fault handling procedures.
Test Early, Integrate Faster
Prototypes and functional test assemblies help integrate components into handling systems at an early stage and validate their performance under realistic conditions. This is particularly valuable for highly dynamic axes, where interaction between mechanical systems and motion control is critical.
Potential test criteria include
- Switching times and response behaviour
- Positioning accuracy and repeatability
- Holding force under static and dynamic loads
- Soft-stop and damping performance
- Behaviour during collisions, blockages and overload conditions
- Vibration and noise characteristics
- Thermal loading during continuous operation
- Effects of high cycle rates on wear and functionality
- Integration with controls, sensors and diagnostic systems
- Behaviour during emergency stops and restart procedures
Early testing enables components to be optimised for the specific handling concept from the outset. This reduces later modifications and provides a solid foundation for successful series production integration.
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