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FullSharp · since 1991

FullSharp supplies a smart lift assist manipulator that combines a pneumatic balancing cylinder with a 24VDC electric control unit for parts from 5 to 300 kg. The part becomes almost weightless and moves with a light push, while sensors hold the load if air or power is lost and stop accidental release, with reach from 1.5 to 4 m.

Parts weighing tens to hundreds of kilograms require several people to lift manually, and the process is still slow. A standard hoist only moves up and down along a vertical line, so fitting a part into a mold or fixture still means wrestling it by hand. Doing this all shift long tends to cause spine, shoulder and neck injuries.

FullSharp supplies a smart lift assist manipulator using electric and pneumatic power. A pneumatic cylinder balances the load's exact weight so the part becomes almost weightless, moving with just a light push. The electric system handles load sensing, holds the load if air or power is lost, and prevents accidental release.

Smart Lift Assist Manipulator Using Electric and Pneumatic Power

Smart lift assist manipulator using electric and pneumatic power, mounted on a floor column at the workstation inside the plant.

Equipment Installed

  • Pneumatic balancing cylinder assembly: a pressure regulator keeps the push force equal to the load's weight, so the part stays put at any height.
  • Electric control unit: a 24VDC low-voltage circuit reads load and position sensors, and holds the load if power or pressure drops.
  • Product-specific end-of-arm tooling: clamp, vacuum pad or hook custom-built to match the shape of the part being lifted.
  • Column body and swing arm: floor-standing, wall-mounted, overhead-rail-mounted or mobile-cart column, with a body that rotates up to 360 degrees.
  • Control handle: clamp, rotate and tilt buttons right at hand, letting one worker complete the entire cycle.

Key Specifications

  • Lifting Capacity5 to 300 kg
  • Reach1.5 to 4 m
  • Body RotationUp to 360 degrees
  • Air PressureApprox. 5 to 7 bar
  • Power Supply220V or 380V, 50Hz
  • Control Circuit24VDC low voltage

Benefits for Your Plant

One Worker Replaces Two or Three

A task that once needed a whole crew can now be run by a single operator.

Millimeter-Level Positioning

The part stays suspended steadily, so aligning it into a mold or fixture is precise and avoids impact.

Multiple Safety Layers

Overload protection, automatic load-holding on air or power loss, and no accidental release.

Actual Installation Photos

Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 1 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 2 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 3 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 4 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 5 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 6 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 7 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 8 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 9 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 10 Smart Lift Assist Manipulator Using Electric and Pneumatic Power - photo 11

Click a photo to enlarge. Album of 11 photos taken on site.

Suitable Applications

  • Mechanical, automotive, motorcycle: loading/unloading CNC machines and plastic injection presses
  • Food, pharma, chemical: lifting and tilting drums and powder bags
  • Packaging, logistics: stacking boxes onto pallets
  • Electronics: assembling heavy component groups on the line

Related Products and Projects

Frequently asked questions

What is an electro-pneumatic lift assist?

Compressed air balances the part's exact weight, while a low-voltage electric unit reads load and position sensors. The electric side holds the load if air or power drops and prevents accidental release.

What are the typical specifications?

Lifting capacity is 5 to 300 kg, reach 1.5 to 4 m, body rotation up to 360 degrees, air pressure around 5 to 7 bar, and power 220V or 380V at 50Hz with a 24VDC control circuit.

How is a smart manipulator mounted?

The column can stand on the floor, mount on a wall, hang from an overhead rail or sit on a mobile cart. The end tooling is a clamp, vacuum pad or hook built to the part, chosen after FullSharp sees the actual workpiece.

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Get a Custom Plan for Your Plant

FullSharp measures the weight, shape and reach of the part along with the work cycle to select the manipulator configuration and end-of-arm tooling. Our engineers check the compressed air supply, power supply and mounting type to suit your floor plan. Contact FullSharp to schedule a site survey.

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