Efficient Handling of Ferromagnetic Workpieces

In modern manual handling, magnetic grippers demonstrate their strengths: they accelerate work processes, reduce physical strain on employees and at the same time contribute to a high level of process safety.

Magnetic grippers are among the most important load lifting attachments for handling ferromagnetic workpieces. They enable steel and iron components to be picked up, moved and positioned safely without the need for mechanical clamping or slinging. Especially in combination with modern handling systems such as electronic rope balancers, magnetic grippers make a significant contribution to ergonomic and efficient workplaces.

Depending on the application, different magnetic technologies are used, including permanent magnets, electro-permanent magnets and electromagnetic grippers. The technology selected depends on the properties of the workpiece, the handling process and the relevant safety requirements. This article does not discuss the individual magnet types in detail; instead, it focuses on their use as load lifting attachments in manual handling.

Magnetic grippers are generally suitable for all ferromagnetic materials, for example:

• Steel sheets and steel plates

• Pipes

• Profiles

• Mechanical engineering components

• Laser-cut parts

• Cast components

– to name just a few examples.

Depending on the magnetic technology and design, workpieces of different sizes and weights can be handled safely.

Advantages of Magnetic Grippers in Manual Handling

Increased process speed

Cycle times are significantly reduced because operations such as attaching chains, clamping, hooking and time-consuming positioning are eliminated. Workpieces can be picked up and set down in a very short time.

Ergonomic working

The benefits of using a magnetic gripper for employees are obvious.

Instead of manually lifting and aligning heavy or awkward components, the magnet takes over the load handling. This significantly reduces physical strain, awkward postures and stress on the back, shoulders and arms.

Combined with an electronic rope balancer, workpieces can be moved almost weightlessly. This reduces operator fatigue while improving load control.

Precise workpiece positioning

Many handling processes require controlled and precise guidance of the workpiece.

Whether loading machines, during assembly or when changing tools, magnetic grippers enable precise positioning of workpieces. Combined with sensitive electronic rope balancers, accurate placement becomes even easier.

Safe handling

Safety is always the top priority when using a magnetic gripper. But what actually determines a magnet's holding force?

The rated load capacity of a magnetic gripper cannot simply be applied to every workpiece. The actual holding force depends on various factors, including:

• Material and magnetic properties

• Material thickness

• Surface condition (e.g. coatings, contamination or rust)

• Workpiece geometry: affects the size and shape of the contact area

• Centre of gravity and load distribution

• Temperature

• Dynamic loads, e.g. due to swinging movements or impacts

Safe handling therefore requires that the magnetic gripper is used only within its specified operating limits and that its rated load capacity is matched to the specific application.

More efficient workflows

The combination of the above advantages results in another key benefit: overall workflows become more efficient.

Shorter cycle times, higher machine availability and more ergonomic and safer processes help increase productivity while reducing the physical strain on employees.

Potential in Manual Handling

Modern companies aim to,

• Reduce physical strain on employees,

• Retain skilled workers over the long term,

• Reduce sickness-related absences,

• Improve workflow efficiency, and

• Ensure high precision and quality.

Magnetic grippers make an important contribution to these goals. Their full potential is realised particularly when combined with modern handling systems. Only the combination of a load lifting attachment and a sensitive lifting aid enables even heavy workpieces to be moved safely, precisely and ergonomically.

Electronic rope balancers provide weight compensation and support intuitive load guidance. The magnetic gripper ensures that the workpiece is gripped securely. Together, both systems help reduce physical strain and enable handling processes to be carried out in a controlled and repeatable manner.

Magnetic Grippers in Practice

The possible applications of magnetic grippers are as diverse as the requirements of manual handling. Depending on the workpiece, its weight and the process, different magnetic systems are used.

The photo collages below offer a glimpse into real-world industrial applications and demonstrate the versatility of magnetic grippers in manual handling.

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