High-Efficiency Automation Gripper for Forklift Fuel Tank Assembly

An Automation Integration company, integrated HVR MAG automation gripper for the forklift manufacturing industry, offering magnetic gripper with robot arm to its assembly line. Previously, the company relied on a labor-intensive manual process where 3 to 4 operators used cranes to lift and position steel plates for fuel tank assembly. This traditional method was not only slow but also prone to causing surface damage and deformation to the workpieces, while posing consistent safety risks to the staff involved.

To address these bottlenecks, the company transitioned to a robotic handling system centered on a specialized automation gripper solution. The system features two custom-designed HEPMP-1814A-GW electro-permanent magnets integrated as a unified gripper, managed by an HEPC21-100A-4 controller. This specific configuration was engineered to handle a variety of workpieces required for fuel tank assembly, supporting a maximum lifting capacity of 200 kg.

The implementation of this magnetic automation gripper offered several technical advantages over traditional mechanical clamping. Because the gripper secures the steel plates from the surface using a powerful magnetic field, it eliminates the need for manual prying or clamping, which previously caused scratches and structural warping. Furthermore, the intelligent control system allows the gripper to adjust its magnetic output based on the plate's dimensions and thickness, ensuring that only a single sheet is picked up at a time with precision and speed.

The impact on production has been transformative, with the company reporting that capacity has increased by more than 3 times compared to the manual crane-based system. By replacing a 4-person crew with a fully unmanned automation gripper operation, the client has significantly reduced labor costs and almost entirely eliminated workplace injuries associated with material handling. The production environment is now more stable, with a lower defect rate and a significantly more efficient workflow for both the loading of raw materials and the unloading of finished fuel tanks.