What is a Vacuum Gripper? Structure, Applications, and Operating Principle

Have you ever wondered how modern factory robots can lift everything from heavy boxes to fragile glass sheets without breaking or dropping them? The secret often lies in a powerful and flexible tool called the Vacuum Gripper.

If you are curious about how this technology works, its advantages and disadvantages, and why it has become the top choice for industrial automation, this comprehensive guide will help you understand it in the simplest way possible.

Table of Contents

What is a Vacuum Gripper?

Definition of a Vacuum Gripper

In the world of robotics, the “hand” at the end of the robotic arm is called the End-of-Arm Tooling (EOAT). A Vacuum Gripper is a common type of EOAT that uses suction force to lift, hold, and move objects.

Imagine it as an extremely advanced and powerful suction cup system for robots. Instead of clamping around an object like a mechanical claw, it adheres tightly to the surface, typically from above.

The Role of Vacuum Grippers in Automation & Industrial Robotics

This simple yet effective method makes vacuum grippers extremely useful for a multitude of tasks, especially:

Robotic Palletizing: The process of neatly stacking products onto pallets for shipping.
High-Speed Pick & Place: Moving light, flat objects between points on a production line.
Assembly and Packaging: Handling sensitive, fragile surface products like glass and electronic components.

They are core to the automation of material handling, packaging, assembly, and quality control across all industries.

How Does a Vacuum Gripper Work? (Detailed Explanation)

The “magic” of a vacuum gripper stems from a fundamental physical principle: creating a Differential Pressure.

Creating Low Pressure: The vacuum generation system (a vacuum pump or Venturi unit) actively draws air out of the sealed space inside the suction cup after it has made contact with the object’s surface. This process creates a low-pressure area (a vacuum).
Atmospheric Push: The Earth’s surface is constantly subjected to Atmospheric Pressure at about 101.3 kPa (or 14.7 psi) at sea level. When the gripper creates a vacuum, the Atmospheric Pressure outside the suction cup becomes much higher than the low pressure inside.
Forming the Holding Force: This pressure differential creates a strong pushing force. The Atmospheric Pressure pushes the object tightly against the surface of the suction cup. This holding force is proportional to the magnitude of the pressure differential and the contact area of the suction cup. This is the secure holding force that allows the robot to lift and move the object without dropping it.

Operating Principle of Vacuum Grippers

Creating Suction Force through Pressure Differential

The holding force is directly proportional to the pressure differential and the contact area.

The formula for calculating the holding force (F) can be simply understood as: F = (Pressure Differential) x (Contact Area)

The pressure differential is the difference between the Atmospheric Pressure (outside) and the Vacuum Pressure (inside the suction cup). By removing the air inside the cup, the internal pressure drops to a vacuum level, creating an external pushing force that secures the object to the gripper. The safest suction force is achieved with absolute sealing.

Types of Vacuum Generation Sources

To create the necessary vacuum, the system uses one of the following sources:

Suction Source	Technology	Advantages	Disadvantages
Vacuum Pump	Uses electrical energy to create and maintain the vacuum.	High vacuum level, stable, no compressed air required.	High initial cost, larger size.
Venturi Vacuum Gripper	Uses compressed air passing through a Venturi tube to create a vacuum effect.	Compact, lightweight, no electricity needed (if compressed air is available).	Consumes compressed air, less energy-efficient, often noisy.
Electric Vacuum Gripper	Integrates an electric pump, valves, and sensors into a single module.	Energy efficient, quiet, reduced operating costs.	May be heavier than the Venturi type.

Step-by-Step Operation Process

The gripping/releasing process is automatic and rapid:

Approach: The robotic arm moves the gripper so that the suction cups or foam pads press against the object, creating a sealed cushion.
Activation: The vacuum generator activates, extracting air from inside the suction cups, creating a vacuum.
Fixation: The higher air pressure outside pushes the object against the gripper, securing it firmly.
Movement: The robotic arm moves the object to its destination.
Release: A valve opens, or a blow-off valve injects compressed air into the suction cups, equalizing the pressure and breaking the seal, gently setting the object down.

Factors Affecting Suction Force

To achieve a stable holding force, the following factors must be considered:

Contact Area: The larger the direct contact surface area, the stronger the holding force.
Leakage: A perfect seal (minimal leakage) is the most critical factor. Porous material or uneven surfaces will reduce the seal.
Surface Material: Smooth surfaces (glass, metal) provide optimal suction. Porous surfaces (cardboard, wood) require a stronger vacuum or a larger contact area.
Movement Speed: Sudden acceleration or changes in direction create inertial forces, reducing the effective holding force. The suction force must be optimized to withstand high acceleration.

Advantages and Disadvantages of Vacuum Grippers

Advantages	Disadvantages
Low Initial Cost	High Operating Cost (for Venturi systems consuming compressed air).
Versatility (grips diverse products, shapes, materials).	Noise (especially pneumatic systems).
Fast Replacement Time (suction cups).	Inconsistency (with porous, wet, or dirty products).
Safety (fewer moving parts, gentle object handling).	Risk of Denting fragile materials if not properly designed.
Seamless Automation (easy integration).	Clogging and Contamination (debris can block vacuum ports).

Vacuum Gripper Components

A complete vacuum gripper system typically includes the following basic components:

Vacuum Suction Cup / Pad

This is the direct contact interface with the object. It comes in various shapes (flat, oval, bellows cup) and materials (Nitrile Rubber NBR, Silicone) to suit different surfaces and temperatures.

Gripper Frame / Module

The main mechanical structure, which functions to:

Connect the suction cups, valves, and pump (if electric) together.
Serve as the attachment point to the robotic arm (Robot Flange) via standard interfaces (e.g., ISO standard) or a Quick Changer.

Vacuum Control Valve

Controls the airflow. It includes the vacuum supply valve (opening/closing suction) and often a blow-off valve to inject compressed air into the cups for instant release.

Filter and Vacuum Sensor

Filter: Prevents dust and debris from the environment or object from entering, protecting the vacuum pump.
Vacuum Sensor: Monitors pressure to confirm successful object grasping (Part Present Sensing), providing feedback to the robot.

Vacuum Pump or Venturi Generator

This is the “heart” of the system, the source that creates the necessary pressure differential.

Hoses & Manifolds

The system of hoses that routes vacuum air from the generation source to each suction cup. A manifold allows for zone-based vacuum control (multi-zone control) so the robot only activates suction in necessary areas.

Foam Vacuum Gripper – for Large/Uneven Surfaces

Instead of individual suction cups, this gripper uses a large foam pad to create a seal over a wide area. They are ideal for gripping multiple items simultaneously or objects with inconsistent shapes or rough surfaces (e.g., cement bags, pallets).

Popular Types of Vacuum Grippers

By Suction Structure

Vacuum cup gripper: The most common, using 1 or more independent suction cups.
Area/foam vacuum gripper: Suitable for gripping multiple items of various sizes simultaneously, or large, rough surface objects.
Bernoulli vacuum gripper (non-contact): Creates lift by blowing high-speed air (Bernoulli effect). Used for extremely fragile materials where physical contact is undesirable (e.g., wafers, plastic film).
Needle vacuum gripper (for porous materials): Uses small needles that pierce the surface of porous material to create a holding force.

By Vacuum Generation Technology

Pneumatic / venturi vacuum gripper: Uses compressed air.
Electric vacuum gripper: Uses an integrated electric pump (the modern trend).
Battery vacuum gripper (for mobile lines): Electric type with an integrated battery, allowing for mobile robots or operation in areas without power/compressed air sources.

By Application

Bag gripper: Often uses a large foam pad with strong suction.
Box gripper: Uses suction cups with rubber lips or foam pads.
Glass gripper: Uses silicone suction cups with high friction and a soft surface.
Bottle gripper: Typically uses bellows cups to grip the neck or cap of the bottle.

Comparison of Type Advantages and Disadvantages

Gripper Type	Key Advantage	Main Disadvantage
Venturi	Lightweight, easy to install.	Consumes compressed air, noisy, unstable vacuum if air supply is weak.
Electric	Energy efficient, quiet, stable vacuum.	Higher initial cost, heavier.
Foam/Area	Grips various sizes/shapes, handles uneven objects well.	Prone to leakage on very porous objects, hard to clean.

Applications of Vacuum Grippers in Industry

Vacuum grippers have revolutionized many stages of manufacturing:

Production – Assembly Lines

Ensuring the precise gripping and positioning of small or large components and parts during high-speed automotive and electronics assembly with perfect repeatability.

Palletizing – Packaging (Palletizing Vacuum Gripper)

Automatically and neatly stacking boxes, bags, or product layers onto pallets, reducing manual labor and the risk of injury.

High-Speed Pick & Place

Used in light industries (food, pharmaceuticals) where cycle times are very fast, requiring instantaneous gripping and releasing speed.

Handling Large / Uneven Surface Materials

Gripping large metal sheets, wood panels, plywood, or complex-shaped objects using foam pads or multi-zone suction systems.

Application in Collaborative Robots (Cobots)

Due to their easy integration (plug-and-play) and light weight (especially the electric type), vacuum grippers are the standard EOAT for cobots performing simple tasks.

Application for Hollow, Porous, or Holed Materials

Uses grippers capable of generating very high-flow vacuum to compensate for air leakage, e.g., gripping unsealed cardboard packaging or insulation material.

Vacuum Grippers in Industrial Robotics

Mounting Vacuum Grippers on 6-Axis, SCARA, and Cobots

The gripper is mounted to the flange at the end of the robotic arm. Leading EOAT manufacturers like OnRobot provide Quick Changer interfaces and ready-to-use control applications (Urcaps for Universal Robots), allowing robots to automatically swap EOATs and program quickly.

How to Optimize Suction Force for Fast, Stable Robot Operation

Calculate Safety Force: The minimum holding force must be 2 times the inertial force (caused by acceleration/deceleration) of the object when the robot moves at its highest speed.
Use a Blow-Off Valve: Reducing the object release time is key to optimizing the cycle time.
Use Sensors: Continuously monitor vacuum pressure so the robot can stop or slow down if leakage is detected, protecting the product.

Criteria for Selecting a Vacuum Gripper for Robots

Payload: The gripper must be light to maximize the actual payload the robot can lift.
Compatibility: Must have compatible hardware and software interfaces (drivers/Urcaps) for the robot (e.g., Universal Robots, Fanuc, Kuka).
Ease of Programming: Prioritize plug-and-play solutions to reduce setup and operating time.

Popular Vacuum Gripper Brands

To see how modern grippers address many of the discussed challenges, let’s consider a specific example from OnRobot.

OnRobot Vacuum Gripper

VG10 & VGC10: These are electric, plug-and-play vacuum grippers that require no compressed air. The VGC10 is compact, lightweight, ideal for cobots, and offers a payload of up to 15 kg. They stand out for their infinite customization options for suction cups.
VGP20: OnRobot’s heavy payload electric vacuum gripper line, specifically designed for heavy Palletizing applications, handling loads up to 20kg.

Robotiq EPick

EPick is a compact, lightweight electric vacuum gripper, optimized for Pick & Place tasks and light load gripping. It stands out for its flexible and easy-to-program design.

Schmalz

Schmalz is a world-leading manufacturer of vacuum technology. Their product lines are highly diverse, including:

FXP/FMP: Flexible Area Grippers that can grip multiple items simultaneously over a wide surface area.
Custom Solutions: Provides specialized vacuum solutions for almost any particular application.

How to Choose the Right Vacuum Gripper

Selecting the correct vacuum gripper is a decisive factor for the performance and stability of the robotic system.

Choose by Product Material

Smooth, Sealed: Use standard suction cups (NBR, Silicone).
Porous (cardboard, wood): Use suction cups with large rubber lips or foam pads, requiring a high-flow vacuum pump.
Soft, Thin (bags, pouches): Use bellows cups or foam pads.

Choose by Weight & Size

Determine the total required contact area. For heavy objects, ensure the minimum holding force is double the object’s lifting load.

Choose by Cycle Time Speed

If the speed is high, an electric or Venturi type with a powerful blow-off valve is needed to ensure minimum release time.

Choose by Surface Sealing Level (Leakage)

If the surface has significant leakage (due to porosity or unevenness), choose a vacuum generator with the capacity for a high flow rate to compensate for the air loss.

Choose by Robot Type

Ensure the gripper is compatible in terms of payload, mounting interface, and software ecosystem (plug-and-play).

Common Mistakes When Choosing Equipment

Gripper is too heavy: Reduces the actual payload the robot can lift.
Weak suction force: Causes objects to drop or be damaged when the robot accelerates.
No blow-off valve: Object sticks to the cup, slowing down the cycle time.
Choosing a Venturi type in an environment without compressed air: Requires the cost of installing a compressor, increasing operating expenses.

A Case Study in Innovation: The OnRobot VGC10 Electric Vacuum Gripper

To see how modern grippers solve many of the challenges we’ve discussed, let’s look at a specific example from OnRobot, a global leader in robotic end-of-arm tooling. Their VGC10 compact electric vacuum gripper is a perfect illustration of modern innovation.

Based on the award-winning design of its larger cousin (the VG10), the VGC10 was developed to be smaller and lighter, making it ideal for smaller robot arms and applications in constrained spaces. Despite its compact size, it offers an impressive payload of 15 kg (35 lb).

One of its standout features is its unlimited customization. The VGC10 allows for easily changeable suction cup options and the ability to add or replace arms. This configurability means it can grip a wide array of small, multi-dimensional, and even heavy objects with precision.

Furthermore, the VGC10 features two independently controlled air channels. This allows it to act as a dual gripper, enabling it to pick up and release objects in the same action, which significantly reduces cycle time and boosts efficiency.

Crucially, as a fully electric gripper, it requires no compressor or external air supply.12 This directly addresses the major disadvantages of traditional systems by eliminating the cost, noise, space requirements, and maintenance associated with producing compressed air.

As Enrico Krog Iversen, CEO of OnRobot, noted, “We heard from customers that they loved the features of the VG10 gripper but sometimes needed a more configurable, compact version, so we delivered.”

Key Features of the OnRobot VGC10:

Compact, lightweight, and powerful design
Replaceable and customizable arms
Configurable suction cups for various applications
15 kg (35 lb) payload with a gripper weight of just .814 kg (1.79 lb)
Small footprint of 100mm x 100mm
2 independent air channels for dual gripping functionality
Built-in electric vacuum (no external air supply needed)
Integrated software for easy deployment
IP54 rated for durability in harsh conditions

Servo Dynamics Engineering: Authorized Distributor of OnRobot in Vietnam

To ensure your robotic solutions are equipped with the highest quality and most suitable End-of-Arm Tooling, choosing a reputable supplier is critical.

Servo Dynamics Engineering (SDE) is the official authorized distributor of OnRobot in Vietnam.

As an official partner, SDE provides the full range of OnRobot’s advanced electric vacuum grippers, such as the VG10, VGC10, and VGP20, along with other EOAT solutions. Partnering with the official distributor helps businesses to:

Ensure the quality and genuine origin of products, fully warranted.
Receive in-depth technical support and reliable maintenance services.
Consult on optimal, precise solutions for each specific application in the factory.