Robotics simulation for stiffer, lighter arms and grippers
Find out how far an arm or gripper deflects under payload and acceleration, where it is overstressed, how it vibrates and how hot its drives run, before the first links are machined.
A robot’s accuracy depends as much on its structure as on its control. Every link, joint housing and bracket bends a little under payload and acceleration, and those small deflections add up along the arm into a position error at the tool. Mass added to stiffen one link raises the load on every joint behind it, and a structure that is too flexible rings after each move, costing cycle time while the controller waits for it to settle.
More about robotics simulation
Robotics simulation puts numbers on those trade-offs. Structural models of the arm, gantry or gripper give deflection at the tool centre point, stress in links and fixings, and the natural frequencies and mode shapes of the assembly in its working poses. Thermal models show how hot motors, gearboxes and drive electronics run over a duty cycle, and whether an enclosure moves enough air to keep them within their limits.
Several poses, payloads and materials can be compared within one study. The outcome is a revised link section, rib pattern or material choice that can be taken straight into detailed design, drawings and production.
Typical systems: industrial and collaborative robot arms, gantry and Cartesian robots, pick-and-place heads, grippers and end-of-arm tooling, mobile robot chassis and robotic inspection equipment.
What a robotics study tells you
How far does the tool move under load?
Deflection at the tool centre point for your payload, reach and worst-case pose, with the share contributed by each link and joint.
Which parts are overstressed?
Stress in links, joint housings, flanges, fingers and fixings under payload, acceleration and emergency stop loads, set against the material limits you work to.
Why does the arm ring after a move?
Natural frequencies and mode shapes in different poses, so the lowest modes can be kept clear of the frequencies the motion and drives excite.
Where can mass come out?
Regions of low stress that contribute little to stiffness, where wall thickness or material can be reduced without losing accuracy.
Will the joints overheat on this cycle?
Motor, gearbox and drive temperatures over your duty cycle, including the effect of sealing the arm or adding covers.
Will the gripper hold without marking the part?
Finger deflection and contact pressure on the workpiece, including compliant pads and soft fingers that deform as they grip.
What we model
Link and frame stiffness
Static stiffness of arms, gantries, linear axes and bases, including the compliance of bolted joints and bearings where it matters.
Payload and inertial loads
Gravity, acceleration and braking loads at the poses you specify, including emergency stops and contact with end stops.
Vibration and modal analysis
Natural frequencies, mode shapes and harmonic response, used to keep structural modes away from motion and drive frequencies.
Grippers and end effectors
Fingers, vacuum cup mounts, tool changers and custom end-of-arm tooling, with contact and large deformation for compliant designs.
Fatigue
Life of links, welds and brackets that repeat the same load cycle every few seconds for years, using your cycle and load history.
Motor and drive heating
Heat from motors, gearboxes and brakes conducted through the joint housing, and the temperature rise over a duty cycle.
Enclosure and controller cooling
Airflow and temperatures in control cabinets and on-board electronics bays, with fans, vents and heat sinks represented.
Before you start
What to send us
- CAD of the arm, gantry or gripper assembly (STEP or native)
- Payload mass and centre of gravity, plus tool or end effector mass
- Working poses, accelerations and any emergency stop loads
- Accuracy or deflection targets at the tool, and any frequency targets
- Motor, gearbox and drive losses or ratings, with the duty cycle
- Materials, and any limits on mass, size or cost
Why does reach matter so much for stiffness?
For a simple cantilever, tip deflection is δ = FL³/(3EI), so doubling the reach multiplies deflection by eight for the same section. Long arms need their stiffness where the bending moment is highest, close to the base.
Can you include joint and bearing flexibility?
Yes. Bearings, gear stages and bolted joints can be represented by stiffness values from the manufacturer or your own test data, and they often lower the natural frequencies noticeably.
Do you simulate the robot’s motion control?
No. We model the structure and its thermal behaviour at the poses and loads you define. The stiffness and natural frequencies we provide are what your controls engineers tune against.
Can you work on an end effector on its own?
Grippers and tooling are often studied on their own, particularly where a lighter tool would allow a smaller robot or a faster cycle.
Send us your robot design
