Protective Covers for Industrial Robots – A Guide to Selection, Design and Ordering
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Protective Covers for Industrial Robots – A Guide to Selection, Design and Ordering
A textile protective cover for robots – also known as a robot protective jacket or robot cover – reliably protects industrial robots from dust, paint overspray, welding spatter, heat, and other industrial influences. The aim is to protect the robot's mechanics, sensors, and electronics in the long term and extend the service life of the entire system. Each protective cover is custom- made – tailored to the robot type, working area, and environmental conditions .
Goals and benefits
- Protection of the mechanics: prevents contamination of joints, motors and seals.
- Longer lifespan: reduces maintenance costs and downtime.
- Reliable process quality: no dust particles or paint mist on workpieces.
- Clean appearance: important in cleanrooms or during customer visits.
- Integrated media routing: Cables, hoses and sensor lines can be routed inside the cover.
Materials and properties
The choice of material depends on the application. Typical high-performance fabrics offer the following properties:
| Characteristic | Description | Typical application |
|---|---|---|
| Antistatic / ESD-compatible | Dissipates electrostatic charge, prevents sparking. | Painting technology, explosion-proof zones, electronics manufacturing. |
| Dust and particle resistant | Prevents the ingress of dust, powder, and fibers. | Assembly, packaging, cleanroom-like areas. |
| Heat resistant | Resists sparks, welding spatter, and convection heat. | Welding, plasma cutting, thermal processes. |
| Solvent and chemical resistant | Resistant to paints, cleaners, and solvents. | Painting facilities, chemical production, cleaning lines. |
| Flexible & tear-resistant | High mobility despite repeated stress. | All-round use, handling, palletizing. |
| Multilayer composites | Combine multiple protective functions in one design. | Mixed applications (e.g., heat + dust + ESD). |
Depending on the intended use, the textiles are precisely cut, sewn, or welded . Upon request, the material selection includes, among other things, ESD fabrics, dustproof laminates, heat-resistant fiberglass or silicone coatings , as well as solvent-resistant options.
Measurements & girth measurements
Accurate measurements are crucial for an optimal fit. The following are primarily needed:
- Measurements (circumferences) of the robot axes: e.g., shoulder, elbow, wrist. Measure directly on the robot or in the CAD model using a flexible measuring tape.
- Consider the largest diameter: including cables, brackets, sensors – crucial for the width of the segments.
- Distances between axes: determine the segment lengths and prevent material compression during the process.
- End effector cover (optional): measure separately if required and design as a separate segment.
Tip: Document all dimensions in a simple sketch or CAD drawing with clear labels (A1, A2, A3 …) and note special features such as internal media routing or additional sensors .
"Bundles" – transitions between the segments
Cuffs are the transition areas between two robot axes (and at entry/exit points). They seal the joint while maintaining freedom of movement. Typical designs:
- Elastic/rubber cuffs: stretchable, quick to assemble, for light to medium requirements.
- Hook and loop or zipper closures: for frequent opening, cleaning and service access.
- Drawstrings/tension bands: finely adjustable tightness, easy to retrofit.
- Silicone or heat protection sleeves: for thermally stressed areas (welding/cutting area).
Design note: The transition should expand with the axis movement without chafing or pulling on the robot. Where possible, softly round inner edges and guide material folds precisely .
Ordering process & customization
- Identify robot: manufacturer, type, optional tool/end effector.
- Define the operating environment: welding, painting, assembly, food processing, cleanroom, etc.
- Select materials: e.g., ESD, dustproof, heat-resistant, solvent-resistant.
- Provide measurements or CAD data: girth measurements/distances + sketches.
- Manufacturing & Quality Assurance: segmented design, sewing/welding processes according to stress.
- Delivery & assembly instructions: ensure a precise fit, adjust the cuffs, and check the media routing.
Thanks to efficient processes, short delivery times are possible.
Care & Maintenance
- Dry cleaning: vacuuming/blowing away dust and loose particles.
- Wet cleaning: with soft cloths and mild cleaners (depending on the material).
- Segment replacement: heavily stressed areas are designed as replaceable segments .
Information regarding chemical compatibility and temperature ranges depends on the chosen fabric.
Conclusion
A custom-made protective cover for robots is more than just dust protection: it increases reliability , extends maintenance intervals , and ensures process quality – even in harsh environments. Designed for industrial performance.
