SCHUNK OPS Anti-Collision and Overload Protection Sensor Review: Specs, Price and Applications
The SCHUNK OPS protects robots and handling units against collisions and overloads. When the tool hits an obstacle, the mounting flange deflects, a sensor detects the movement and the robot's emergency stop is triggered immediately.
Unlike the self-resetting OPR, the OPS is reset by hand after a collision. That deliberate manual step forces an inspection of the tool and the cause of the crash before production resumes, which many plants prefer for safety-critical or high-value processes.
Quick Verdict
A robust, adjustable collision sensor for cells where every crash should be inspected before restart. The VS variant with ±45° rotation limit is useful when the tool must not twist freely after triggering.
SCHUNK OPS Anti-Collision and Overload Protection Sensor at a Glance
Specification | Details |
Function | Collision and overload protection |
Trigger principle | Deflecting mounting flange actuates a sensor |
Reset | Manual reset to the original position |
Trigger force and torque | Adjustable via operating pressure |
Anti-rotation | Optional VS variant, rotational deflection limited to ±45° |
Signal | Integrated monitoring for immediate robot stop |
Mounting | Optional ISO adapter plates |
Lubrication | Food-grade lubricant as standard (NSF certificates available) |
Price | Request a quote |
Design and Operating Principle
Compressed air preloads the OPS so that the tool side stays rigid until an external force exceeds the set threshold. On overload, the flange deflects axially, tilts or rotates, and the integrated sensor switches the emergency stop. The mechanical compliance gives the robot time to brake without transmitting the full impact into the arm.
The manual reset is a design choice. After a crash the unit stays deflected until an operator returns it to the zero position, which confirms that someone has looked at the tool, the fingers and the part before restarting.
The VS variant limits rotational deflection to ±45°. This prevents a heavy or offset tool from swinging around the flange axis after triggering, protecting hoses and cables routed across the unit.
Integration and Selection
Adjust the operating pressure so normal accelerations and process forces do not trigger the unit, while real collisions do. Validate the setting with the actual tool mass and centre of gravity.
Connect the sensor output to the robot's protective or emergency-stop input, and include the manual reset in the recovery procedure and operator training. Choose the VS variant when cables or hoses cross the unit.
Industry Applications
Industry | Typical use |
Automotive | Protecting welding and handling tools in body shops |
Aerospace | Safeguarding high-value end effectors during drilling and handling |
Foundry and forging | Overload protection in harsh handling cells |
Food production | Food-grade lubricated collision protection |
Functional Uses
Immediate robot stop on collision
Overload protection during process forces
Controlled restart after manual inspection
Limiting tool rotation with the VS variant
Pros and Cons
Advantages
Adjustable trigger force and torque
Manual reset enforces inspection
Optional ±45° anti-rotation
Food-grade lubricant as standard
Limitations
Manual reset lengthens recovery time
Needs compressed air for preload
Adds length at the robot flange
Who Should Consider the SCHUNK OPS Anti-Collision and Overload Protection Sensor?
The OPS fits plants that want each collision investigated before restart, such as safety-critical, aerospace or high-value tooling applications.
Price and Availability
Price: Request a quote. SCHUNK prices the OPS 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 OPS Anti-Collision and Overload Protection Sensor FAQ
What is the SCHUNK OPS?
A pneumatic collision and overload protection unit that deflects on impact and triggers the robot's emergency stop through an integrated sensor.
How is the OPS reset?
It is reset manually after a collision and returned to its original position by the operator.
What is the OPS VS variant?
A version with anti-rotation protection that limits rotational deflection to ±45°.
Can the trigger threshold be adjusted?
Yes. Trigger force and torque are adjusted through the operating pressure.
Is the OPS suitable for food applications?
It uses food-grade lubricant as standard and NSF certificates are available, but it does not fully meet EN 1672-2:2020 hygienic design requirements.
OPS or OPR: which one to choose?
Choose the OPR for automatic reset and fast recovery; choose the OPS when a manual inspection after each collision is preferred.
