Thema industrial manipulators
Thema originates from a long history and extensive experience of experts working in the industrial manipulator industry for nearly 30 years. At the heart of all Thema's activities is always the client and their needs – this philosophy is the key to success.
This approach is ingrained in the brand's DNA because delivering not just a product but a fully customized solution is only possible when the client and their requirements are the priority. Drawing from the tradition of Italian craftsmanship and the art of precise adaptation to individual needs, each Thema machine is tailor-made to meet the most diverse customer requirements and perfectly adapt to their specific applications.
Thema manipulators are the answer to the need for handling loads of various shapes and sizes. These solutions are used across many industries – from warehouse logistics, through various production sectors, to the packaging industry.
They enable ergonomic, safe, and efficient handling of nearly any type of product. Manipulators allow lifting loads of up to 1,850 kg using only compressed air. The perfect weight distribution makes load handling almost effortless, allowing the operator to work efficiently in the safest and most ergonomic conditions.
The complete range of THEMA manipulators consists of devices designed exclusively for manual operation, without any automation support. The manipulator can be powered by electricity, hydraulics, or pneumatics. These manipulators are designed to enable effortless lifting and handling of various loads. Their intuitive operation allows operators to move goods quickly, accurately, and safely within the working area. THEMA introduces a new standard in handling heavy and bulky loads, eliminating excessive strain on operators and reducing the risk of injuries. Thanks to an innovative approach and individually designed solutions, these manipulators adapt to even the most demanding working conditions, ensuring top-level ergonomics, efficiency, and safety.
For low to medium volume production and assembly lines, manually operated manipulators offer many advantages:
- Low cost – both for the manipulator and the workstation
- Minimal or no modifications to the workstation
- Operator safety
- Reduced labor demand
- Universal usability – any worker, regardless of physical strength or gender, can operate the manipulator
- Ergonomics – improved operator comfort
- Easy maintenance
- Reliability and durability – simple operating technology ensures long-lasting performance
THEMA manipulators – an overview of the models
When selecting the appropriate model of THEMA manipulator, several key factors should be considered, such as the maximum weight of the load to be lifted, the desired working area, the characteristics of the handled object, and the specific conditions in the workplace.
For light components and operations requiring easy and intuitive handling, industrial manipulators from the Perseo and Narciso lines are ideal. If greater reach and precise maneuverability across large workstations are needed, the Slite model, which operates on rail systems, is worth considering. Meanwhile, stable and safe handling of loads — even those with an uneven weight distribution — is ensured by manipulators with rigid arms, such as the Pegasus and Icon series. These models offer a wide load capacity range, reaching up to 1850 kg.
Perseo / Perseo Pro
Handles loads up to 60 kg / 120 kg.
Narciso
Suitable for loads up to 300 kg.
Slite
Reliable handling of loads up to 180 kg.
Pegasus / Pegasus Pro
Handles loads up to 375 / 625 kg.
Icon / Icon Pro
Ideal for loads up to 1000 kg / 1850 kg.
Each model is available in various mounting configurations and can be customized to meet the specific requirements of the user.
Gripping tools designed specifically for your products
The key element of each manipulator is a tailor-made gripping tool, designed to match the characteristics of the client’s product. Depending on the type of load and working conditions, the following technologies are available:
- Standard and custom-shaped hooks — ideal for simple, repetitive lifting tasks.
- Mechanical grippers — available in both manual and pneumatic versions, providing secure handling for various shapes and weights.
- Vacuum solutions — recommended for delicate or fragile surfaces that require a gentle yet firm grip.
- Magnetic grippers — perfect for safe and efficient handling of metal components.
All these solutions are selected individually based on a detailed analysis of the application, aiming to optimize workflows, enhance safety, and increase operator comfort.
Thema Manipulator Production Process
Each manipulator undergoes a carefully planned process – from analyzing customer needs, through design and production, to assembly and quality testing. This ensures that we provide solutions perfectly tailored to individual requirements.
1. On-Site Inspection
The process begins with customer contact and, if necessary, an on-site visit. The goal is to analyze the working conditions of the manipulator and determine the best solution.
2. Design
In the technical office, the manipulator system is created along with 3D simulations. At this stage, both the type of machine and the appropriate gripping tool, customized to the handled load, are defined.
3. Production
After consulting with the customer and selecting the optimal solution, the manipulator’s construction begins. Each component is precisely crafted by experienced specialists according to a well-established production process.
4. Pre-Assembly
Before final assembly, the machine is pre-assembled on a so-called “zero station.” This allows verification of the compliance of all components with ISO quality standards and ensures proper execution.
5. Painting
After initial mechanical tests, the machine is prepared for painting. Finish details are verified, and the color scheme is checked for compliance with order specifications.
6. System Installation
After painting, the manipulator moves to a dedicated department where the pneumatic system is installed. All connections are performed according to the order specification.
7. Inspection & Testing
The final stage is a comprehensive inspection of the device. The functionality of all components and the pneumatic system are verified to ensure full compliance with quality standards.
Safety is the highest priority
Each manipulator is designed and built in accordance with European safety standards and is CE certified. It is equipped with key safety systems, including:
- Built-in compressed air reserve tank with a check valve. In the event of sudden loss of the main pneumatic supply, this tank provides sufficient air to safely complete the work cycle, preventing uncontrolled load drop. Once the air reserve is depleted, the manipulator gently lowers the load to the ground.
- Special safety valve. It activates automatically if the operator mistakenly engages the balancing function without a load or prematurely commands the release of a load before it is properly positioned. This valve monitors the air flow in the balancing cylinder, damping the arm’s movement if the speed exceeds the set limit.
- Pneumatically operated brakes. All THEMA manipulators are equipped with these brakes, effectively locking the main structure and preventing lateral and vertical movements of the device when not in use. These brakes are user-friendly thanks to a pneumatic push button and, importantly, are spring-loaded to automatically engage in case of insufficient air pressure.
- Adjustable angle limiters. Both on the main and intermediate rotation axes of each manipulator, adjustable stops are installed to limit the arm’s movement range and prevent collisions with potential obstacles.
- Advanced load gripping and releasing systems, depending on the type of gripper (e.g., requiring an appropriate vacuum level or two-handed release operation).
- Power failure safety features. The manipulators are equipped with special electropneumatic and pneumatic anti-drop systems that, in the event of a power or compressed air failure, ensure the load is gently and safely lowered to the ground.
- Optional additional safety systems, such as an acoustic warning signal in case of pressure drop, an anti-jump device (a hydraulic cylinder with a flow control valve) that cushions upward arm movement if the load is suddenly released, and a load limiter that prevents lifting loads exceeding the manipulator’s maximum allowable capacity.
We provide manipulators tailored to your needs!
Customized Fixture Systems – Example Applications
