How much clearance does a robot protective case need?

Answer: 30 mm per side on the stowed envelope, which is also the foam thickness.

What load rating suits a 165 kg robot?

Answer: 500 kg static, a 2.5 dynamic factor, and 840 kg for the bottom case in a three-tier stack.

Answer: For sea freight and outdoor staging, yes; a clean indoor cell can drop to IP54. The difference is 30 percent gasket compression at 350 mm latch centres.

Is thicker foam always safer?

Answer: No. At 800 mm, 30 mm of EPDM already holds the peak under 40G; 60 mm buys little and costs cavity volume.

What latch force is right?

Answer: About 180 N, openable in gloves. Under 120 N it shakes open in transit.

How to Choose a Robot Protective Case: Five Decision Points

Quick answer: Size the cavity from the stowed arm posture, the base from the loaded weight, the foam from the drop test. A 165 kg six-axis unit with 2650 mm reach folds to about 1450 by 900 by 1200 mm and must stay under 40G on an 800 mm drop.

Sizing the Robot Protective Case to the Stowed Arm Posture
Load Rating and Stacking Decide the Base
Foam Density and Drop G-Values
Sealing Class and the Wet Environment
Lifting and Unpacking Flow
FAQ

1. Sizing the Robot Protective Case to the Stowed Arm Posture

Measure the machine folded, not the floor drawing. With axis two at 30 degrees, axis four folded back and the tool flange pointing down, a 165 kg arm with 2650 mm reach occupies about 1450 by 900 by 1200 mm.

Add 30 mm per side for foam, and take positioning from the base: four M16 bolts through locating blocks on a 200 mm circle, heads sunk 5 mm below the foam.

Decision point	Number to lock	How to check
Cavity	Envelope plus 30 mm per side	Cardboard template at the real posture
Positioning	4 x M16 on flange pitch	Feeler gauge at the block face
Wall	6 mm rotomoulded, double lip	Ultrasonic gauge, six points

2. Load Rating and Stacking Decide the Base

For a robot protective case the bare arm is 165 kg, the tool and cables add 40 kg, so the working load is 205 kg. A 2.5 dynamic factor puts 510 kg on the base: 18 mm plywood over steel cross members at 300 mm centres, with a 4 mm plate at each caster mount.

Robot protective case: dark navy case on a wooden cabin floor, two reinforcing ribs and side latches

Stacking is usually left out. Three tiers means the bottom case carries 560 kg, and a 1.5 safety factor lifts that to 840 kg; a robot protective case with a 6 mm wall holds lid deflection under 3 mm, while 4.5 mm without ribs sags at two tiers. Casters are 150 mm polyurethane, 300 kg dynamic each, two swivel with brakes.

3. Foam Density and Drop G-Values

Inside a robot protective case, damage comes from deceleration. At 800 mm with 30 mm of foam the peak should stay under 40G; at 20 mm it passes 70G, where the gearbox output shaft is most exposed.

EPDM at 45 kg per cubic metre carries about 90 kPa at 25 percent compression and returns with under 10 percent set. Use 50 mm at the base, 30 mm on the sides, 25 mm in the lid, at densities of 55, 45 and 35.

Zone	Thickness	Density	Job
Base	50 mm	55 kg/m3	Absorb the drop
Sides	30 mm	45 kg/m3	Stop lateral travel
Lid	25 mm	35 kg/m3	Hold the top down

Cutouts run 2 mm interference, CNC routed to plus or minus 1 mm. Add 500 g of desiccant so humidity stays below 40 percent.

4. Sealing Class and the Wet Environment

A robot protective case meets both a machine shop and a sea freight box. A Shore 55A silicone gasket of 8 mm section, compressed 30 percent against a double lip, gives IP67: 30 minutes at one metre, dry inside. Salt spray is verified at 480 hours, so hinges and latches are 304 stainless.

Robot protective case: black foam insert close-up, square cutout holding a metal part

A 1200 mm case needs four cam latches at 350 mm centres; stretch to 500 mm and the gasket lifts midway. Ten cycles from minus 25 to 60 degrees Celsius leave silicone under 0.5 mm of set, while nitrile measures 1.5 mm and leaks by the second cycle.

5. Lifting and Unpacking Flow

Loaded, the robot protective case weighs 273 kg, so lifting points belong on the drawing: four corner eye bolts rated 1.2 t, sling angles at or below 60 degrees, fork pockets at 120 mm high and 60 mm deep.

Hinges on the long side open to 105 degrees on two 300 N gas struts, and stainless pins in self-lubricating bushes add under 0.3 mm of play after 5000 cycles.

Handling	Interface	Limit	Watch out
Crane	4 eye bolts	1.2 t per point	Guards at 60 degrees
Forklift	Pockets 120 x 60 mm	Forks 1.2 m or longer	Seat fully, lift level

Conclusion

The order is fixed: cavity from the posture, base from the dynamic factor, foam from the G-value, seal from the shipping route, lifting from the loaded weight. Written into the drawing and the acceptance clause, those five numbers make quotations comparable. Settle the structure first, and the robot protective case closes, carries and stays dry.

This article discusses only the container (case body) side of specifications and design intent, and does not cover any handling, loading or use of the contents.