Sawyer Hardware

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This page provides detailed information about the hardware of the Sawyer robot.

Sawyer Hardware Overview

This section provides a basic overview of the hardware that makes up the Sawyer robot. For more technical specifications, see our Sawyer Arm Specifications section of this page.

Sawyer Overview

Sawyer Hardware Overview.PNG

Training Cuff

Use the training cuffs to move the arm, manipulate the state of the gripper, and secondarily, to select on-screen options.

Sawyer Training Cuff.png

  1. Zero-G Mode - Squeeze this switch at the indentation in the cuff to move the robot’s arm. When this switch is squeezed, the blue indicator on the arm’s navigator button lights up.
  2. Grasp Button - Press to toggle a parallel gripper open or closed, or a vacuum gripper on or off.
  3. Action Button - Press to select items on the display screen. Create waypoints, Hold actions; select, copy, or move actions on the task map, as well as outline a visual search area.
  4. Traning Cuff Light - Indicator light to provide feedback when actions are performed and display the current state (ie: running in zero-g mode) of the arm.


Use the navigator on the arm or base to scroll to and interact with options on the screen.

Sawyer Navigator Basic.png

  1. Back Button - Press to exit the current screen and return to the previous screen. Will also cancel the last action.
  2. Rethink Button - Access the Robot Screen Menu
  3. Selector Knob - Scroll the knob to move between on-screen options. Press the knob (OK) to select an option.
  4. Zero-G Mode - Press and hold this button to move the robot's arm with motor assist. This button has the same functionality as the Zero-G button on the training cuff.
  5. Square- Quick access to options currently available. Long press will re-position the robot screen towards end of arm.
  6. X Button - Toggles the active tool center point

Sawyer Head LED Status

Head LED Status Table
Sawyer Condition Head LED Color
Working/Running Solid Green
Error In Task Flashing Yellow
Connected to Intera Studio Solid Yellow
Not Connected to Intera Studio Solid White
E-Stop Engaged Flashing Red, SOS Pattern
Hardware Issue Flashing Red, SOS Pattern
Boot Up No Color

Sawyer Cuff LED Status

Cuff LED Status Table
Sawyer Condition Cuff LED Color
Arm Power On Amber
Zero G Active White
Jogging Arm White
Insert Node/Update Pose Flashing White
Joint Limit Red
Collision Detected Flashing Red
Wait/Wait Until Node Active Flashing Green
E-Stop Engaged No Color

Sawyer Electrical Specifications

Description Spec
Interface Standard 120VAC power. Robot power bus and internal PC both have “universal” power supplies and support  90 - 264V AC (47 - 63Hz)
Max Consumption 4A at 120V AC, 480W max per unit
Supply Voltage Available 24V at 1A via Terminal Block
Electrical Efficiency 87% to 92%
Power Supply Uses industrial-grade DC switching power supply for robot power bus
Tolerance to sags Sags tolerated to 90V. Sustained interruption will require manual power-up
Voltage Flicker Holdup time 20mS
Voltage Unbalance Single phase operation only

Sawyer Environmental Specifications

Description Spec
Environment Indoor Use
Altitude Up to 2000 meters
Operating Temperature 5°C to 40°C
Relative Humidity 80% for temperatures up to 31°C, decreasing linearly to 50% relative humidity at 40°C
Storage Temperature -30°C to 65°C. Relative humidity (maximum): 5% to 95% (non-condensing)
Pollution Degree 2

Sawyer Arm Specifications

The arm of the Sawyer Robot is the most important component of the robot and having a solid understanding of the different specifications of the arm is crucial when it comes to understanding how the robot operates. The information in the sections below will provide you with the knowledge necessary to gain a better understanding of how the Sawyer works.

Joint and Link Names

Sawyer joint and link names are referenced many times in technical documentation and will be referenced by Rethink Robotics support representatives regularly. The diagram below labels the joints and link of the Sawyer arm.

Sawyer Joints and Links Named.PNG

The joint and link naming for the Sawyer arm starts at the base and increases incrementally up to the wrist. The joints are named J0 - J6 and the links are named L0 - L6.

The joints in the Sawyer are also classified into two categories (roll or pitch) by their movement. The small table below lists each joint in one of these two categories.

Joint Classification
Roll Pitch
J0, J2, J4, J6 J1, J3, J5

Link Lengths

Link lengths for Sawyer's joints are measured in mm, from the center of one joint to the center of the next. They can be found in the image and table below.

Sawyer Link Lengths.PNG

Link Lengths
Link Name Length
L0 81mm
L1 192.5mm
L2 400mm
L3 168.5mm
L4 400mm
L5 136.3mm
L6 133.75mm

Range of Motion - Roll Joints

The range of motion of each roll joint is presented below. The overall joint range is specified.

Sawyer Even Numbered Joints.png

Roll Joints
Joint Name Range (Degrees)
J0 350
J2 350
J4 341
J6 540

Range of Motion - Pitch Joints

The range of motion of each pitch joint is presented below. The overall joint range is specified.

Sawyer Odd Numbered Joints.PNG

Pitch Joints
Joint Name Range (Degrees)
J1 350
J3 350
J5 341

Embedded Camera Specifications

Arm Vision System

Description Spec
Camera Resolution 752 x 480
Lens Size 3.7 mm
Lens Type Wide Angle
Chromo Grayscale
Other Features Global Shutter, Synchronized Embedded Lighting

Head Camera

Description Spec
Camera Resolution 1280 x 800
Lens Type Wide Angle
Chromo RGB

Control Box

Useful Links

General Dimensions

Note: All dimensions are in millimeters.

Sawyer Control Box General Dimensions.PNG

Ports and Devices

Side View

Sawyer Control Box Ports Side View.PNG

Bottom View

800px-Sawyer Control Box Ports Bottom View.PNG

  • Inputs:
    • Power
    • Air
  • Outputs
    • Air (4x)
    • Power and Data
    • Video

Inside View

Sawyer Control Box Inside View.PNG

  • Terminal Unit (8 Digital Inputs, 8 Digital Outputs) Link
  • Safety Rated Controller Link
  • Terminal Block Voltage Supply (24V at 1A max)
24V Terminal Block.png
  • Solenoid Valve (2x) Link
  • Ethernet Port
  • USB Port (2x)

Low Power Mode

Click Here for More Information on the Banner Safety Controller

Sawyer is designed as a power and force limited robot by inherent design, but customers can choose to further limit the capabilities of the robot by further limiting the power available to the robot in such a way that limits the maximum speed at which it can run. This is done by operating Sawyer in Low Power Mode.

The Banner Safety Controller found inside the Controller has been customized to monitor the voltage of the power going to Sawyer's arm. To place Sawyer in Low Power mode, jumper the Low Voltage Enable signal before powering up the robot (see the schematic below for the wiring diagram). The robot’s maximum speed will be limited to approximately half that of normal operation.

Banner Wiring.png

If, at some point, the Banner Safety Controller senses the robot operating at normal power mode when the wiring is configured for low power mode, the motor power relay will be opened, cutting power to the motors in the arm, and a safety violation error will be reported.

Low Power Mode in the Intera UI

When the Banner Safety Controller has been set up properly for low power mode, you will see the highlighted feedback in the UI in both the Robot Screen and Intera Studio.

Low Power Mode Studio.png

Robot Screen LPM.png


General Dimensions

Note: All dimensions are in centimeters.

800px-Sawyer Pedestal Basic Dimensions.PNG


Sawyer Pedestal Overview.PNG

Sawyer Workspace Dimensions

Sawyer Workspace Drawing (PDF)

For access to 3D models and the above drawing in DWG format, please Contact Rethink Robotics Support

Basic Overview

Sawyer Reach Dimensions.png

Top Down View

Sawyer Top Down View Workspace.PNG

Side View

Sawyer Side View Workspace.PNG