SCHUNK OPR Anti-Collision and Overload Protection Sensor Review: Specs, Price and Applications
The SCHUNK OPR is a collision and overload protection unit mounted between the robot flange and the gripper or tool. On impact the mounting flange deflects, a sensor detects the movement and the system's emergency stop is triggered before the robot, the tool or the workpiece is damaged.
Its defining feature is automatic reset. Once the tool is moved away from the obstacle, the OPR returns to its zero position by itself, so the cell can restart quickly without an operator re-seating the unit by hand.
Quick Verdict
A practical safeguard for expensive tooling and for cells where collisions occur during teaching, setup or part misalignment. Automatic reset makes it especially attractive for high-utilization cells that need short recovery times.
SCHUNK OPR Anti-Collision and Overload Protection Sensor at a Glance
Specification | Details |
Function | Collision and overload protection for robots and handling units |
Trigger principle | Mounting flange deflects and actuates the monitoring sensor |
Reset | Automatic return to zero position |
Trigger force and torque | Adjustable via operating pressure |
Signal | Integrated monitoring for immediate robot stop |
Mounting | Optional ISO adapter plates for most robot types |
Pressure-loss option | Integrated springs to hold position |
Lubrication | Food-compliant lubricants as standard |
Price | Request a quote |
Design and Operating Principle
The OPR is a pneumatically preloaded compliance element. Air pressure holds the tool side rigidly against the robot side during normal operation. When an external force or torque exceeds the preload, the flange tilts, rotates or compresses, and the integrated sensor switches. Because the preload depends on pressure, the trigger threshold can be tuned to the tool weight and the process forces.
The mechanical deflection gives the robot a short braking path. A robot cannot stop instantly, so a protection unit that yields while the controller decelerates prevents the peak forces that would otherwise bend fingers, break tool changers or damage the robot gearbox.
After the collision, the OPR resets itself as soon as the load is removed. Optional springs keep the tool in position if compressed air is lost, which avoids a drooping tool in a pressure failure.
Integration and Selection
Set the operating pressure so that the unit does not trigger during normal acceleration, braking and process forces, yet releases well below the damage threshold of the tool. Long tools create higher moments at the flange, so the torque setting matters as much as the axial force.
Wire the monitoring signal into the robot's emergency-stop or protective-stop circuit, and validate the response with test collisions at production speeds. Use the ISO adapter plates to fit the robot flange and the tool side.
Industry Applications
Industry | Typical use |
Automotive body and assembly | Protecting grippers and tool changers in high-speed handling |
Welding | Shielding torches and fixtures from crashes during teaching |
Machine tending | Preventing damage when parts sit incorrectly in fixtures |
Food handling | Collision protection with food-compliant lubricants |
Functional Uses
Detecting collisions and triggering an immediate robot stop
Absorbing impact energy while the robot brakes
Automatic reset for fast recovery
Adjustable sensitivity to match tool weight
Pros and Cons
Advantages
Automatic reset after a collision
Pressure-adjustable trigger threshold
Integrated monitoring signal
ISO adapter plates for most robots
Limitations
Requires a stable compressed-air supply
Trigger settings must be validated for each tool
Adds length and weight at the robot flange
Who Should Consider the SCHUNK OPR Anti-Collision and Overload Protection Sensor?
The OPR suits cells with valuable tooling, frequent setup changes or uncertain part positions, where quick unattended recovery after a collision matters.
Price and Availability
Price: Request a quote. SCHUNK prices the OPR by size, options and quantity, so the final figure depends on the exact configuration. Budget for the complete tooling package, including fingers or adapters, mounting, air or electrical connections and commissioning time, rather than the module alone.
Further Reading
SCHUNK OPR Anti-Collision and Overload Protection Sensor FAQ
What does the SCHUNK OPR do?
It protects robots, tools and workpieces by deflecting on impact and triggering the emergency stop through an integrated sensor.
Does the OPR need a manual reset?
No. It returns automatically to its zero position once the tool moves away from the obstacle.
How is the trigger force adjusted?
Trigger force and torque are adjusted through the operating pressure.
What happens if air pressure is lost?
Optional integrated springs hold the unit in position during a pressure loss.
How is the OPR mounted?
Optional ISO adapter plates allow mounting on most robot types between the flange and the tool.
What is the difference between the OPR and OPS?
The OPR resets automatically, while the OPS is reset manually after a collision.
