Robotics & Automation worked example

Robot Payload Utilization at 86% target payload utilization ceiling: a worked example

What does the result look like when target payload utilization ceiling reaches 86%? The full calculation is worked below with real intermediate numbers. Use it when sizing a robot for a new EOAT and part so the combined load stays inside the rated payload curve and your design margin target.

The inputs for this scenario

  • Combined load at the TCP (part + gripper/EOAT): 18 lb (unchanged)
  • Rated robot payload: 25 lb (unchanged)
  • Target payload utilization ceiling: 86 % (raised for this scenario; the documented default is 75)

Working through the calculation

  • Applying the documented formula (Robot payload utilization = combined load at TCP / rated robot payload) to the inputs above produces each figure below.
  • At this operating point the engine returns 72 % of rated payload for robot payload utilization, the number this scenario is built around.
  • At this operating point the engine returns 14 points for payload margin gap.
  • At this operating point the engine returns 18 value for combined load at tcp.
  • At this operating point the engine returns 25 value for rated robot payload.

How this compares with the baseline

  • Against the tool's baseline example, where target payload utilization ceiling sits at 75% and the headline result is 72 % of rated payload, this scenario lands almost exactly on the baseline at 72 % of rated payload.
  • A figure at this level is achievable when target payload utilization ceiling is genuinely sustained, not just peaked for a shift. It uses static weight only - it ignores inertia, center-of-gravity offset, and dynamic loads, which can exceed the arm's true limit even when static utilization looks safe.

Results at a glance

  • Robot payload utilization: 72 % of rated payload (headline result)
  • Payload margin gap: 14 points
  • Combined load at TCP: 18 value
  • Rated robot payload: 25 value

Run it with your numbers

  • Every input above is editable in the live Robot Payload Utilization calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.