The truss structure power manipulator is an innovative material handling device that combines the linear motion advantages of the truss (gantry) with the manual assistance characteristics of the power manipulator (or balance crane). It is designed to provide operators with a large-scale, high-precision, easy and labor-saving solution for heavy object handling and positioning, especially for industrial scenarios that require flexible manual operation and a large working area
Core composition and working principle
Truss main structure (Gantry Structure):
Beams and columns: form a stable “door”-shaped frame that spans the entire working area.
Precision guide rails and drive systems: High-precision linear guide rails are laid on the beams, usually controlled by gear racks, synchronous belts or ball screws driven by servo motors, so that the trolley (or running mechanism) carrying the power manipulator can move accurately, smoothly and over a large range along the X-axis (horizontal direction). Some systems may also have the ability to move along the Y-axis to cover a larger plane area.
Power Manipulator / Balancer Arm: This is the core operating unit of the system, installed under the mobile trolley on the truss. It uses pneumatic balance, electric balance or mechanical balance principle to offset or balance most of the weight of the grasped workpiece, so that the operator can easily move heavy objects with only a small push and pull force. The power manipulator itself has the ability to lift and lower in the Z axis (vertical direction), as well as a certain range of rotation and tilt freedom. End-Effector / Gripper: Installed at the end of the power manipulator, it is the part that directly contacts the workpiece. It is customized according to the characteristics of the transported product (shape, size, weight, material, surface sensitivity, etc.). Common ones are: pneumatic grippers, vacuum suction cups, electromagnetic suction cups, clamps, hooks, etc. The operator controls the opening and closing of the gripper through the operating handle or button on the power manipulator. Control System: Compared with fully automatic robots, its control system is relatively simple. Mainly responsible for:
X/Y axis positioning and movement of the truss trolley (can be electric assisted or purely manual push-pull).
Balance force adjustment of the power manipulator.
Opening and closing control of the clamp.
Safety protection function.
Advantages
Ultimate labor-saving experience: Combined with the “zero gravity” effect of the power manipulator, operators can effortlessly carry hundreds of kilograms or even tons of heavy objects.
Large range of operation coverage: The truss structure provides a larger horizontal working range than an independent cantilever crane or a single power manipulator, which can cover the entire workstation or span multiple devices.
High-precision positioning and manual flexibility: Combines the precise positioning capability of the machine with the flexible judgment of the human. Operators can use tactile feedback and visual judgment to achieve positioning and assembly that is more precise, flexible, and more adaptable to complex situations than pure robots.
Improve production efficiency: Reduces physical labor and speeds up handling, thereby improving the overall efficiency of the production line.
Ensure work safety: Significantly reduce the risk of work-related injuries such as sprains, strains, and crushing injuries that may be caused by manual handling of heavy objects.
Adapt to complex workpieces: Truss-structured power manipulators have unique advantages for workpieces with irregular shapes, unstable centers of gravity, or that require manual fine adjustment of angles.
High space utilization: Usually installed above the production line, it does not occupy valuable ground space.
Relatively flexible investment: Compared with fully automated robot systems, its initial investment and programming complexity are usually lower, and it has a higher return on investment.
Post time: Jun-09-2025