Easy handling of batteries – Single Gripper for 8 different variants

HomeSuccess StoryEasy handling of batteries – Single Gripper for 8 different variants

Success Story

The battery giant from Italy was using Manipulators from a leading European brand. However, it was turning to be a relatively costly investment. With Fine Handling’s customised gripper, the company not just got an easier and efficient solution but at a much lesser investment and without any compromise on quality.
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Challenge & Innovations


The process required handling different types of batteries with a weight range of 10 to 105 Kg. The batteries are presented on a trolley and need to lifted and inserted into a battery bank placed on forklift or other such battery-operated equipment.



Vertical shaped batteries had to be lifted with the help of tapping bores of power supply. As the size and weight of the batteries were different so was the distance between the bores. Gripping with these tapping bores also involved the risk of draining the power supply of batteries during handling.

The batteries had a weight range of 10 to 105 kg. This meant the industrial manipulator and customised gripper was required to have a facility to adjust the weight capacity.

Adjustable gripper to handle eight different types of batteries

Clamping the batteries with the help of its tapping bores
Batteries had to be lifted with the help of bores. The smaller variants of the batteries had two bores, while the bigger variants had four bores. Even the distance between the bores varied for different types of batteries. A specialized gripper was designed with bolts similar to the tapping bolts, and a feature to automatically tighten the bolts for the gripping was provided.

Further, an additional float was provided to the gripper to adjust according to the distance between the tapping bores on the batteries.

Handling batteries with different size and weight
As the size of the batteries varied so did their weight. To match the requirement, a Column mounted manipulator was provided with a weight handling capacity of up to 110 kg. Easy to use accelerator type Gas grip was provided where the operator can adjust weight capacity. It was also provided with an indicator that would show the weight is now balanced.

Manipulator was supposed to handle eight different types of batteries. A manual adjuster was provided to adjust the distance between the bores.

Ensuring Safety
There was a slight chance that batteries might get drained or current may pass through the manipulator. This was risky. Fine Handling provided its gripping bolts with insulation so that current does not pass through and the risk of any shock or battery draining is nullified.

Even after ensuring all the aspects, couple of challenges were still half resolved. It was observed that the operator at time was finding it slightly inconvenient while adjusting to the tapping bores and further bolting them. Fine Handling solved this challenge by providing additional float to the tapping bolt itself so that operator can easily align the gripper.

While balancing the weight, especially in case of batteries that were heavy, an additional force was required to further lift the batteries. The option of additional force was provided for ease of operation.

Safety Features

  • The manipulator was equipped with a sensor to ensure proper clamping of the component
  • Specialized J type clamps were developed which to hold the component in case of air failure
  • Double hand clamping was included to ensure Operator alertness
  • De-clamping controls were provided on the backside of the control panel to eliminate any chance of accidental de-clamping

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