Most people in the manufacturing industry are already familiar with gantry systems, but often, gantry systems are associated with other automation technologies on the factory floor.

Let’s explore gantry systems—specifically, what they are, how they differ from other automation technologies, such as conveyor systems and robotic arms, and where they fit in today’s manufacturing industry.

What Are Gantry Systems?

Gantry systems are categorized as a type of industrial automation that falls into the category of robotic systems. That said, the technology of a gantry system is quite different from the typical robotic arm.

A gantry system is an overhead, fixed-axis system, particularly suited for applications with limited floor space and those that require vertical integration. In factory automation, it’s usually referred to as a gantry robot, or a linear motion robotic system. These gantry systems work on the same mechanical principle as an overhead crane, but are designed for automated parts handling and high-speed precision tasks.

Unlike other automation technologies often anchored at a base with multiple pivot points (such as a traditional 6-axis robot), a gantry system runs on a fixed linear axis, typically X, Y, and Z. Gantry systems resemble overhead cranes. They feature a bridge or beam running across an area with a tool head or carriage along the bridge to assist with moving products and components through the manufacturing process.

Gantry system movement is typically:

• Lateral (X-axis)
• Longitudinal (Y-axis)
• Vertical (Z-axis)

Some systems may also include a rotational or gripper axis. Whatever movement the gantry system is designed for, it uses vertical space. Manufacturers can optimize limited square footage, adapt to tight indoor spaces, and work around obstructions in the line path.

Gantry vs. Conveyor vs. Robotic Arms

Robotic arms are prevalent in many automation applications because they offer significant flexibility, featuring multiple joints (typically 6-7 axes). They can handle several essential tasks like welding, assembly, and part placement. In many applications, a robotic arm is the best solution for moving materials.

Conveyor systems also move materials, but horizontally, and follow a fixed path. Conveyors are typically used in assembly lines. They’re suited for continuously moving bulk components throughout the floor, and by that design, require a significant amount of floor space.

Gantry systems, on the other hand, offer repeatable, high-speed motion from the top down. The gantry robots are usually suspended overhead or designed into structural supports. Gantry systems are most effective for top-down machine tending and heavy loads. Linear robots make efficient use of vertical space on the manufacturing floor and offer a high level of precision, even when spanning long distances and high speeds.

While robotic arms are one of the most flexible automation solutions, they can have a higher upfront cost and require a more complex integration process to align with other machinery.

Common Applications for Gantry Systems

One of the most common uses for gantry systems is machine tool tending. A series of machines, such as CNC mills or lathes, need service in a linear arrangement.

Most typical gantry system setups run along an overhead structure above a row of tools. The typically single axis system picks up the workpiece from a fixed load station and moves it along into the appropriate machine from above. Once the cycle is complete, the gantry retrieves the part and moves it to the next step (or returns it to inspection or packaging).

The advantages of a gantry design set up include:

• Reducing cycle time for increased productivity.
• Keeping aisles and pathways clear of obstruction.
• Handling heavy materials and parts with precision, consistency, and excellent load capacity.
• Reducing the burden and safety concerns on the human operator.
• Minimizing errors and product loss due to operator fatigue.

A gantry automation system can also be used for packaging and palletizing (especially when there’s a need to maximize overhead space). In warehousing, a gantry is used in automated storage and retrieval systems (AS/RS). Gantry systems are also used for high-precision pick-and-place work in electronic and component assembly, as well as other industrial applications.

The Pros and Cons of Using Gantry Systems in Manufacturing

Gantry systems have several benefits that make them the ideal solution for certain manufacturing applications.

The benefits of gantry systems include:

• Optimized Space: Overhead mounting leaves more floor space for team members, tools, and machines, making gantry systems a good solution for high-density operations and instances where scaling is needed within a set footprint.
• Precision: Gantries work on fixed axes and rails, following the same path and repeating precise movements over distances, with minimal deviation or variance.
• Long-Range: Robotic arms are limited by their size and reach, but gantry systems can cover an entire production line. The systems are scalable and can cover a range of tasks.
• Cleanliness: In cleanroom environments and other situations where cross-contamination is a concern, gantries offer a clean solution. They create minimal dust and contaminants from the floor because the machines operate from overhead.
• Safety: The overhead design of a gantry system reduces the risk of machines colliding with other machines or presenting a hazard to human workers. With the right guidance and controls, gantries provide a safer workplace.

Although gantry systems are an excellent solution in many cases, the benefits do come with a few challenges.

The limitations of gantry systems include:

• Less Flexibility: Unlike robotic arms, gantries are limited to linear axes (X, Y, Z) and some gripper motions. While multi-axis gantries exist, they still don’t match the full articulation of a 6-axis robotic arm.
• Linear Alignment Requirements: Because a gantry works on a beam system, everything beneath the system must be perfectly aligned. Offsetting and rearranging can be challenging with a gantry system.
• Limited to Vertical Load Paths: Gantry systems are typically made for vertical pick-and-place applications. If a job requires angular adjustments, side loading, or complex component orientations, you may need additional actuators or need to integrate with other robotic systems.
• Costly Workarounds: Because flexibility is limited, many workarounds like grippers, multi-axis extensions, and vision systems increase the system cost. This can offset some of the initial efficiency and installation cost savings.

Choosing a Gantry System

When is a gantry system the right fit for an operation? You should choose a gantry motion control system for situations where you have machines and tools in a fixed layout or a straight line. Gantry systems are ideal for vertical part handling, especially when floor space is limited (but ceiling clearance is plentiful). They can also move components throughout a large area and offer high precision linear motion for material handling.

Gantry systems offer high throughput and consistency. If your system layout is relatively static and you don’t require flexibility, then gantry systems are a good answer.

By contrast, you may prefer a robot or hybrid system if you need to handle components from multiple angles or if your pieces widely vary in size, shape, or orientation. You may also want a robotic system if your line layout is flexible or often changes.

In many cases, a gantry solution can be paired with robotic arms to give manufacturers the best of both worlds. A gantry might transport the component between machines, while a robotic arm at each machine or station performs the more intricate tasks. This type of hybrid approach helps you get the most use out of your gantry situations to meet specific needs.

At Wes-Tech, we are well-versed in designing and integrating custom automation systems for unique situations. These systems may include gantries, robots, conveyors, or a mix of the three.

If you’re looking for an effective solution to help move components in your space and meet process goals and throughput, Wes-Tech can help. Reach out today to learn how a gantry system can offer you the high-precision and high-speed part movement you need, especially if floor space is limited.