Robotic manipulators

What is a robotic manipulator?

A robotic manipulator—often referred to as a robotic arm—is an electronically controlled mechanical system designed to execute precise movements across multiple axes.
Its architecture includes rigid links connected by articulated joints, allowing the arm to reach, lift, rotate, and position objects with high accuracy.

Interchangeable end-effectors—such as grippers, suction cups, magnetic tools or cutters—enable the manipulator to adapt to a wide range of tasks and environments.

Robotic manipulators are central in modern industrial automation, ensuring productivity, repeatability, and enhanced safety for human operators.

How robotic manipulators work

A robotic manipulator combines mechanical components, motors, sensors, and control software to generate controlled, coordinated movement with high precision and repeatability. Its operation is the result of several integrated subsystems working together in real time.

Mechanical structure

Links
These are the rigid structural segments that make up the arm. Their length, material composition and geometry define the manipulator’s reach, rigidity and payload capacity. High-performance manipulators often use lightweight alloys or composite materials to optimize strength-to-weight ratio.

Joints
Joints connect the links and enable motion.

• Rotary (revolute) joints allow rotation around a specific axis
• Linear (prismatic) joints provide extension or retraction along a straight line
  
  

The arrangement and number of joints determine the manipulator’s Degrees of Freedom (DoF) and overall workspace shape. Precision in joint construction—such as minimising backlash and integrating position sensors—is critical for accurate movement.

Control system

The control system coordinates motor commands, sensor feedback and trajectory generation.
Digital controllers continuously interpret inputs and adjust movement in real time, ensuring smooth and accurate performance even under dynamic load conditions.

Advanced algorithms, including inverse kinematics and motion planning, compute the optimal path to reach a target position and orientation (x, y, z + roll, pitch, yaw).
In more sophisticated systems, force sensors, torque feedback and vision systems can further enhance adaptability, allowing the manipulator to interact safely with varying objects or cooperate with human operators.

End-effector

The end-effector is the functional tool mounted at the tip of the manipulator and determines the nature of the task being executed.
It can take many forms:

• grippers for secure object handling
• vacuum or magnetic systems for smooth surfaces or metallic parts
• cutting or welding tools for fabrication tasks
• precision micro-tools for delicate or medical applications
  
  

Interchangeability is a key advantage: by adapting the end-effector, a single robotic manipulator can perform vastly different operations, enhancing flexibility and productivity across industries.

Custom tailor-made manipulation systems

Custom-made manipulation systems represent an evolution beyond standard robotic arms, as they are engineered to meet the specific operational requirements of each production environment. Instead of relying on predefined configurations, these systems are designed around the real workflow, the characteristics of the load, and the ergonomic needs of the operator.

A tailored manipulator is developed with a focus on:

Operator ergonomics

Custom systems reduce physical strain by adapting motion profiles, gripping solutions and control interfaces to the operator’s natural movements. This leads to safer, smoother and more intuitive handling.

Safety and risk reduction

By aligning the manipulator’s capabilities with process-specific hazards—such as repetitive lifting, awkward postures or hazardous materials—custom solutions significantly lower the risk of injury and ensure compliance with safety standards.

Process efficiency

Tailor-made manipulators optimize cycle times and material flow by matching the exact dimensions, weights and behaviors of the handled items. This results in higher throughput, reduced errors and improved repeatability.

Sustainability and energy efficiency

Designing a system around real operational needs minimizes unnecessary motion, reduces energy consumption and extends the lifecycle of key components. Lightweight structures, efficient actuators and reduced waste contribute to more sustainable production.

Human–machine synergy (Industry 5.0)

Custom manipulation systems are conceived to complement human skills, not replace them. Their design supports collaborative workflows where operators maintain control and oversight, while the manipulator takes on physically demanding or repetitive tasks. This balance reflects the core principles of Industry 5.0—technology enhancing human well-being and creativity.