VACUUM-BASED END EFFECTOR WITH EXTENDABLE SUCTION CUP.
Patent Information
- Authority / Receiving Office
- MX · MX
- Patent Type
- Patents
- Current Assignee / Owner
- FORTNA SYSTEMS INC
- Filing Date
- 2022-07-15
- Publication Date
- 2026-05-19
Smart Images
Figure MX433808B0
Abstract
Description
EXTREME VACUUM-BASED EFFECT WITH EXTENDABLE VACUUM CUP Cross-Reference with Related Applications This application claims priority to U.S. Patent Application Serial No. 62 / 962,608 filed on January 17, 2020, the entire disclosure of which is incorporated herein by reference. Background of the Invention The present invention relates to vacuum-based end effectors or end-effectors that are useful for handling packages within a sortation facility or the like. In particular, the present invention relates to a vacuum-based end effector or end-effector that includes an extendable vacuum cup or suction cup for selectively gripping packages. In a package sorting facility, various packages are unloaded from trucks or other vehicles at unloading locations, sorted, and then loaded onto trucks or other vehicles at loading locations for delivery to the intended recipients. Therefore, within the sorting facility, there is usually a complex system of conveyors and equipment that facilitates the transportation and sorting of the various packages within the facility. One such piece of equipment useful for sorting the various packages is a robotic arm with an end effector mounted at its distal end that grips the IVIA / t'ZUZZ / UZ / 0 10 > Π Ñ CNN C2a packages that are placed on the conveyors of the systems and transfers the packages to a target location. In this regard, there are several different end effectors or end effectors in the art, some of which are vacuum-based end effectors that use one or more vacuum cups in fluid communication with a vacuum source, which provides sufficient suction for the cups to engage and transfer packages. However, in prior art constructions of vacuum-based end effectors, the vacuum cups of the end effector are generally arranged to move in unison. Furthermore, in prior art constructions, the flange of each vacuum cup (i.e., the lowest portion of the cup that engages a package during operation) is typically in the same plane.Therefore, during operation, when a particular suction cup (or cups) engages a target package, other suction cups on the end effector may engage a non-target package, which may be undesirable. This is particularly problematic in cases where packages, such as flat envelopes or sachets, are stacked vertically on top of each other. Consequently, there remains a need for improvements in vacuum-based end effectors to efficiently couple packages in a sorting facility or similar. Brief Description of the Invention The present invention is a vacuum-based end effector that includes an extendable suction cup for selectively engaging packages. A vacuum-based end effector for selectively engaging packages includes a base plate on which a plurality of suction cups are mounted. Each suction cup is configured to be positioned in fluid communication with a vacuum source and includes a bellows having a distal end connected to a flange for gripping packages. The vacuum-based end effector further includes a linear actuator that is mounted to the base plate and includes an extendable arm to which at least one of the plurality of suction cups is operatively connected. The linear actuator is selectively actuatable to extend or retract the extendable arm to adjust the distance between the suction cup or suction cups operatively connected to the extendable arm and the base plate.In this regard, the linear actuator may be selectively actuated to vertically extend and direct the suction cup or cups operatively connected to the extendable arm toward the target packages for engagement therewith. End effector suction cups that are not operatively connected to the extendable arm are generally held in a fixed position relative to the base plate during end effector operation (i.e., they are not vertically extendable), and as such, the flanges thereof may be oriented to define a common plane. As the extendable arm extends, the edge of the suction cup or cups operatively connected to the extendable arm moves below the common plane to individually target a target package, thereby reducing the risk of other end effector suction cups inadvertently engaging a non-target package. In this way, the vertically extendable suction cup is particularly beneficial in cases where the presence of two separate packages is identified, but it cannot be determined which package is positioned at a higher level (i.e., closer to the end effector). In some embodiments, suction cups that are not operatively connected to the extendable arm are mounted directly to the base plate, while the linear actuator is indirectly connected to the base plate. In some embodiments, the base plate defines a plurality of ports, each port having a connector configured to be connected to a vacuum source in fluid communication with a suction cup. To address different build packages, in some embodiments, the plurality of suction cups includes a first set of one or more suction cups with ridges consisting of a first material and a second set of one or more suction cups with ridges consisting of a second material. In such an embodiment, the first set of one or more suction cups includes ridges consisting of silicone rubber to provide a particular surface. IVIA / t'ZUZZ / U / / 0 10 suitable for holding packages that include opaque or glossy-based materials, while the second set of one or more suction cups includes flanges consisting of polyurethane very suitable for coupling packages with flexible packaging materials, such as plastic bags (poly). The vacuum-based end effector of the present invention is configured to be mounted on a robot and, therefore, can be combined with a robot to provide an improved system for gripping packages. In this regard, the base plate of the end effector provides a mounting surface to which the robot or portion thereof can be connected. In some embodiments, the movement of the robot and, therefore, the vacuum-based end effector, can be regulated by a vision and control subsystem (e.g., by communicating instructions to the robot) using data acquired by a sensor and / or one or more cameras. The one or more cameras of the vision and control subsystem are configured to acquire image data corresponding to the positioning of packages within a sortation facility (e.g., packages traveling along a conveyor).The vision and control subsystem sensor is configured to acquire data corresponding to the positioning of a package, pneumatic engagement of one or more suction cups with the package, and / or the amount of compression experienced by one or more of the suction cups. In some embodiments, the sensor may consist of multiple sensors, which may include a photoelectric sensor, an ultrasonic sensor, a vacuum sensor, or combinations thereof. Description of the Drawings Figure 1 is a partial perspective view of a package coupling system including an exemplary vacuum-based end effector manufactured in accordance with the present invention; Figure 2 is a perspective view of the exemplary vacuum-based end effector of the package coupling system of Figure 1; Figure 3 is a bottom view of the exemplary vacuum-based end effector of the package coupling system of Figure 1; Figure 4 is a bottom view of a base plate of the vacuum-based end effector example of the package coupling system of Figure 1; Figure 5A is a side view of the package holding system of Figure 1, implemented within a sorting facility that includes a conveyor for transporting packages; Figure 5B is another side view of the package holding system of Figure 5A; Figure 5C is another side view of the package coupling system of Figure 5A; IVIA / t'ZUZZ / UZ / 0 10 Figure 5D is another side view of the package holding system of Figure 5A; Figure 5E is another side view of the package holding system of Figure 5A; Figure 6 is a front view of the package holding system of Figure 5A and Figure 7 is a schematic diagram of a vision and control subsystem for use with the package gripping system of Figure 1. Detailed Description of the Invention The present invention consists of a vacuum-based end effector that includes an extendable suction cup for selectively engaging packages. 1 is a partial perspective view of a package engaging system 10 (or system 10), including an exemplary vacuum-based end effector 20 (or end effector 20) fabricated in accordance with the present invention mounted to a robot portion 12. It should be appreciated that the robot portion 12 shown in FIG. 1 may be a component, such as a robotic arm, of a larger robot or robotic system that is configured to move the end effector 20 to selectively grasp packages. For example, the robot portion 12 may be a component of a Delta P6 robot manufactured by Schneider Electric and available, for example, from Advantage Industrial Automation of Duluth, IVIA / t'ZUZZ / U / / 0 10 Georgia. As discussed below with reference to Figure 7, the movement of such a robot may, in some embodiments, be controlled based on instructions received from a vision and control subsystem 70. Figures 2 and 3 are, respectively, a perspective view and a bottom view of the exemplary end effector 20. Figure 4 is a bottom view of a base plate 30 of the exemplary end effector 20. Figures 5A, 5B, 5C, 5D and 5E are multiple side views of system 10 implemented within an area of a sortation facility having a conveyor 80 with packages 60a, 60b loaded thereon, as discussed below. Figure 6 is a front view of system 10 deployed in the same area of the sorting facility shown in Figures 5A, 5B, 5C, 5D and 5E. Referring now to Figures 1-4, 5A-E and 6, the end effector 20 includes a plurality of vacuum cups 40a, 40b, 40c, 40d, 40e, which can be connected and, therefore, placed in fluid communication with a vacuum source 90 (Figure 7) via a vacuum hose (not shown) to provide sufficient suction to grip and lift packages 60a, 60b moving through a sortation facility, for example, by means of conveyor 80. The end effector 10 further includes a base plate 30 to which the plurality of vacuum cups 40a, 40b, 40c, 40d, 40e are mounted, either directly or indirectly. Still referring to Figures 1-4, 5A-E and 6, in this exemplary embodiment, the end effector 20 includes five suction cups 40a, 40b, 40c, 40d, 40e: a first suction cup 40a; a second suction cup 40b; a third suction cup 40c; a fourth suction cup 40d; and a fifth suction cup 40e. The first suction cup 40a is operatively connected to a linear actuator 50, which is selectively actuatable to vertically reposition the first suction cup 40a relative to the base plate 30, as described below. In this exemplary embodiment, the linear actuator 50 is mounted to a bracket 35 which, in turn, is connected to the base plate 30. Thus, in this exemplary embodiment, the first suction cup 40a is indirectly mounted to the base plate 30. Conversely, in this exemplary embodiment, each of the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d, and the fifth suction cup 40e are directly mounted to the base plate 30.An upper surface 32 of the base plate 30 provides the mounting surface to which the robot 12 is connected. In this exemplary embodiment, both the robot 12 and the bracket 35 carrying the linear actuator 50 to which the first suction cup 40a is operatively connected are mounted to the base plate 30 via a plurality of bolts 31, although, of course, alternative fasteners may be used without altering the operation of the end effector 20 or the system 10 as a whole. Referring now to Figures 1-3, 5A-E and 6, each suction cup 40a, 40b, 40c, 40d, 40e includes a bellows 42a, 42b, 42c, 42d, 42e having a proximal end and a distal end to which a flange 44a, 44b, 44c, 44d, 44e of the suction cup 40a, 40b, 40c, 40d, 40e is attached. Each of the bellows 42a, 42b, 42c, 42d, 42e effectively defines a path for air flow through the respective suction cups 40a, 40b, 40c, 40d, 40e. As best shown in Figure 3, each flange 44a, 44b, 44c, 44d, 44e consists of an elastomeric material that extends around the distal portion of the bellows 42a, 42b, 42c, 42d, 42e of the respective suction cups 40a, 40b, 40c, 40d, 40e. In this exemplary embodiment, the flanges 44a, 44b, 44c of the first suction cup 40a, the second suction cup 40b and the third suction cup 40c consist generally of a silicone rubber and each of the flanges 44d, 44e of the fourth suction cup 40d and fifth suction cup 40e consist generally of polyurethane. In this regard, the end effector 20 thus includes a first set of suction cups 40a, 40b, 40c with ridges 44a, 44b, 44c consisting of a first material and a second set of suction cups 40d, 40e with ridges 44d, 44e consisting of a second material, to better handle the packages 60a, 60b of IVIA / t'ZUZZ / UZ / 0 10 different materials or construction. The rubber or silicone rubber material of the flanges 44a, 44b, 44c of the first suction cup 40a, the second suction cup 40b and the third suction cup 40c are generally less flexible than the polyurethane material of the flanges 44d, 44e of the fourth suction cup 40d and the fifth suction cup 40e. Without wishing to be bound by any particular theory, it is believed that the silicone rubber ridges 44a, 44b, 44c of the first suction cup 40a, the second suction cup 40b and the third suction cup 40c are particularly useful for holding packages made of or glossy paper-based materials, such as stiff cardboard and taut plastic (e.g., taut surfaces of polyester bags), since such ridges are able to adhere to and form a seal with those surfaces.Furthermore, and again without wishing to be bound by any particular theory, it is believed that the polyurethane ridges 44d, 44e of the fourth suction cup 40d and the fifth suction cup 40e are particularly useful for holding packages in flexible packaging materials, such as plastic bags (polybags), which may include a wrinkled or non-uniform surface. Still referring to Figure 3, in this exemplary embodiment, the polyurethane used for the ridges 44d, 44e of the fourth suction cup 40d and the fifth suction cup 40e is such that a first portion of each ridge 44d, 44e proximal to the bellows 42d, 42e exhibits a first durometer and a second portion of each ridge 44d, 44e distal to the bellows 42d, 42e exhibits a first durometer. IVIA / t'ZUZZ / UZ / 0 10 exhibits a second durometer, which is softer than the first durometer. More specifically, in this exemplary embodiment, the first portion of the ridges 44d, 44e of the fourth suction cup 40d and the fifth suction cup 40e exhibit a hardness of approximately 50 while the second portion of the ridges 44d, 44e exhibit a hardness of approximately 30. Of course, one of skill in the art will readily appreciate that the hardness of the ridges 44d, 44e of the fourth suction cup 40d and the fifth suction cup 40e can be adjusted to better suit different types of packages or applications. In fact, in some embodiments, the durometer may be uniform across all of the ridges 44d, 44e of the fourth suction cup 40d and the fifth suction cup 40e. One of skill in the art will further appreciate that the type or construction of any particular flange 44a, 44b, 44c, 44d, 44e of the respective suction cups 40a, 40b, 40c, 40d, 40e of the end effector 20 may be modified to better suit different sorting applications. For example, to better suit sorting applications requiring the processing of a high volume of flexible plastic bags, the end effector 20 may be modified so that each flange 44a, 44b, 44c, 44d, 44e consists of polyurethane. Conversely, in other sorting applications requiring the processing of a high volume of matte or glossy paper-based materials, the end effector 20 may be modified so that each flange 44a, 44b, 44c, 44d, 44e consists of silicone rubber.Furthermore, in alternative embodiments, the rim 44a, 44b, 44c, 44d, 44e of each suction cup 40a, 40b, 40c, 40d, 40e may consist, at least partially, of silicone rubber, with one or more of the suction cups 40a, 40b, 40c, 40d, 40e being further defined by a foam material (e.g., foam rubber) that is centrally positioned on a bottom surface of the silicone rubber portion of such suction cups. In this regard, the end effector 20 may, in some embodiments, include one or more dual-material suction cups, such as those described in U.S. patent application Serial No. 16 / 793,058 , which is also incorporated herein by reference. 1-3, 5A-E, and 6, the end effector 20 further includes a plurality of connectors 36a, 36b, 36c, 36d, 36e, with each connector 36a, 36b, 36c, 36d, 36e corresponding to a vacuum cup 40a, 40b, 40c, 40d, 40e. In this exemplary embodiment, the end effector 20 includes five connectors 36a, 36b, 36c, 36d, 36e: a first connector 36a corresponding to the first suction cup 40a; a second connector 36b corresponding to the second suction cup 40b; a third connector 36c corresponding to the third suction cup 40c; a fourth connector 36d corresponding to the fourth suction cup 40d and a fifth connector 36e corresponding to the fifth suction cup 40e. Of course, depending on the intended application, the number of suction cups 40a, 40b, 40c, 40d, 40e and corresponding connectors 36a, 36b, 36c, 36d, 36e may vary.Each connector 36a, 36b, 36c, 36d, 36e is in fluid communication with the bellows 42a, 42b, 42c, 42d, 42e of the respective vacuum cup 40a, 40b, 40c, 40d, 40e to which it corresponds and is configured to be connected to the vacuum source 90 (figure 7) via a vacuum hose (not shown) to provide suction (i.e., draw air past the flange 44a, 44b, 44c, 44d, 44e and into the bellows 42a, 42b, 42c, 42d, 42e) through the respective vacuum cup 40a, 40b, 40c, 40d, 40e. In this manner, the connectors 36a, 36b, 36c, 36d, 36e can be selectively connected or disconnected from the vacuum source 90 to independently turn on or off and thus individually address the suction cups 40a, 40b, 40c, 40d, 40e. Referring now to Figures 1-4, 5A-E and 6, the second connector 36b, the third connector 36c, the fourth connector 36d and the fifth connector 36e are each in fluid communication with the bellows 42b, 42c, 42d, 42e of the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d and the fifth suction cup 40e, respectively, via the base plate 30. In this regard, the base plate 30 defines: a first port 30a, which is configured to place the second connector 36b in fluid communication with the bellows 42b of the second suction cup 40b; a second port 30b, which is configured to place the IVIA / t'ZUZZ / U / / 0 10 third connector 36c in fluid communication with the bellows 42c of the third suction cup 40c; a third port 30c, which is configured to place the fourth connector 36d in fluid communication with the bellows 42d of the fourth suction cup 40d and a fourth port 30d, which is configured to place the fifth connector 36e in fluid communication with the bellows 42e of the fifth suction cup 40e, as best shown in Figure 4. Thus, in this exemplary embodiment, the second connector 36b, the third connector 36c, the fourth connector 36d and the fifth connector 36e are each connected to the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d and the fifth suction cup 40e via the base plate 30. Conversely and perhaps as best shown in Figures 1 and 2, in this exemplary embodiment, the first connector 36a is connected to the bellows 42a of the first suction cup 40a via an adapter 37 connected to an extendable arm 52 (Figure 5C) of the linear actuator 50. As is evident from looking at Figures 5B and 5C in sequence, the first suction cup 40a may extend vertically relative to the base plate 30 such that the distance between the flange 44a of the first suction cup 40a and the base plate 30 may increase or decrease. The proximal ends of the respective bellows 42b, 42c, 42d, 42e of the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d and the fifth suction cup 40e, on the other hand, are mounted directly to the base plate 30, as perhaps best shown in Figures 1 and 2. In this regard, each of the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d and the fifth suction cup 40e maintains a fixed position with respect to the base plate 30 during operation of the end effector 20.Of course, although only the first vacuum cup 40a is operatively connected to the linear actuator 50 and is therefore vertically extendable relative to the base plate 30, it is appreciated that in alternative embodiments, more than one vacuum cup could be operatively connected to the linear actuator 50 and configured for such vertical extensibility relative to the base plate 30 without departing from the spirit or scope of the present invention. 1 , 2, 5A-E, and 6, the linear actuator 50 is connected and configured to vertically reposition the first suction cup 40a relative to the base plate 30. As indicated above, in this exemplary embodiment, the linear actuator 50 is mounted to the bracket 35 which, in turn, is mounted to the base plate 30. Thus, in this exemplary embodiment, the linear actuator 50 is indirectly mounted to the base plate 30. As best shown in FIG. 5C, the linear actuator 50 includes an extendable arm 52 to which the first suction cup 40a is operatively connected, either directly or indirectly, such that the extendable arm 52 may be extended to increase the distance between the shoulder 44a of the first suction cup 40a and the base plate or retracted to decrease the distance between the shoulder 44a of the first suction cup 40a and the base plate. 40a and motherboard 30.Thus, when connector 36a of first suction cup 40a is connected to vacuum source 90 (FIG. 7), first suction cup 40a may be lowered to provide suction in a plane below a common plane defined by shoulders 44b, 44c, 44d, 44e of second suction cup 40b, third suction cup 40c, fourth suction cup 40d, and fifth suction cup 40e. In this manner, first suction cup 40a may be extended to grip a target package 60a, without risk of second suction cup 40b, third suction cup 40c, fourth suction cup 40d, or fifth suction cup 40e also inadvertently gripping a non-target package 60b located near target package 60a. Figure 7 is a schematic diagram of a vision and control subsystem 70 for use with the package gripping system 10. Referring now to Figure 7, to detect the location of packages 60a, 60b (as shown in Figures 5A-E and 6) within a facility and regulate movement of robot 12 and thus end effector 20 mounted thereon, in this exemplary embodiment, package gripping system 10 includes a vision and control subsystem 70. Vision and control subsystem 70 includes one or more cameras 72, wherein each camera 72 is configured to acquire two-dimensional and / or three-dimensional image data either on command (e.g., in response to an electronic signal or similar trigger) or substantially continuously. Suitable cameras for use in the present invention include three-dimensional image sensors manufactured and distributed by ifm Efector Inc. of Malvern, Pennsylvania.Each camera 72 is positioned such that the field of view of each camera 72 includes an area along which a package 60a, 60b (as shown in Figures 5AE) may travel while being transported through the sorting facility. Still referring to Figure 7, the vision and control subsystem 70 further includes a controller 74 to which each camera 72 is operatively connected, such that image data collected by the one or more cameras 72 is transmitted to the controller 74 for further processing. The controller 74 includes a processor 76 for executing instructions (routines) stored in a memory component 78 or other computer-readable medium. With respect to processing the image data from the one or more cameras 72, the controller 74 analyzes the data received by the camera 72 (or cameras) to identify the position of a target package within the sorting facility. For example, Figures 5A-E and 6 illustrate a target package 60a traveling along a conveyor 80 within the sorting facility.In this exemplary embodiment, to provide feedback to the controller 74 regarding the position of the target package 60a within the installation and / or coupling of the suction cup with the target package 60a, the vision and control subsystem 70 further includes one or more sensors 73 (such as that described below) operatively connected to the controller 74. 5A, 5B, and 7, upon identifying the target package 60a, the controller 74 communicates instructions to the robot 12 (or various motors and / or actuators associated therewith) to move toward the target package 60a such that the first extendable suction cup 40a is positioned over the target package 60a. In this regard, the controller 74 is thereby operatively connected to the robot 12. The controller 74 may be operatively connected to the robot 12 directly or indirectly, such as for example through a motor control subsystem (not shown) associated with the robot 12 such as that described in U.S. Pat. No. 10,646,898, which is also incorporated herein by reference.To assist the controller 74 in identifying when the first suction cup 40a is positioned over the target package 60a, in some embodiments, the one or more sensors 73 may include a photoelectric sensor, which is attached to the end effector 20 and provides feedback to the controller 74 to alert the controller 74 when the target package 60a is in close proximity to the first suction cup 40a. Alternatively, the. IVIA / t'ZUZZ / UZ / 0 10 controller 74 may rely exclusively on image data collected by the one or more cameras 72. Referring now to Figures 5C and 7, after determining that the first suction cup 40a is positioned on the target package 60a, the controller 74 communicates instructions to the linear actuator 50 to extend the extendable arm 52, thereby directing the first suction cup 40a toward the target package 60a, causing the flange 44a of the first suction cup 40a to engage the target package 60a. In this regard, the controller 74 is also operatively connected to the linear actuator 50. At this point, the vertical separation that exists between the first extendable suction cup 40a and the remaining stationary suction cups 40b, 40c, 40d, 40e prevents the non-target package 60b from being inadvertently grasped by the stationary suction cups 40b, 40c, 40d, 40e (i.e., those suction cups that maintain a fixed position with respect to the base plate 30).Thus, the first extendable suction cup 40a is particularly beneficial in cases where the vision and control subsystem 70 can identify the presence of two separate packages 60a, 60b, but cannot determine which package 60a, 60b is positioned at a higher level (i.e., closer to the end effector 20). Referring still to Figures 5C and 7, in this exemplary embodiment, compressed air is used to extend the extendable arm 52. Accordingly, in some embodiments, the IVIA / t'ZUZZ / U / / 0 10 linear actuator 50 may include a vacuum ejector (not shown) that is configured to be positioned in fluid communication with a source of compressed air (not shown) and may be used to provide the first suction cup 40a with a dedicated vacuum source that is separate from one or more vacuum sources that provide suction to the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d, and the fifth suction cup 40e. However, in alternative embodiments, the first suction cup 40a, the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d, and the fifth suction cup 40e may share a single vacuum source. In this regard, the vacuum source 90 illustrated in Figure 7 may consist of a single vacuum source or multiple vacuum sources. Still referring to Figures 5C and 7, to assist the controller 74 in determining whether the flange 44a of the first vacuum cup 40a is sufficiently engaged with the target package 60a, in some embodiments, the one or more sensors 73 include a vacuum sensor. The vacuum sensor is attached to the end effector 20 and provides feedback to the controller 74 that can be used to determine whether the first vacuum cup 40a is pneumatically engaged with the target package 60a. In some embodiments, the end effector 20 may use a vacuum sensor corresponding to each of the suction cups 40a, 40b, 40c, 40d, 40e.To this end and now referring to Figures IO and 5A-E , the end effector 20 includes a first sensor port 38a corresponding to the first suction cup 40a, a second sensor port 38b corresponding to a second suction cup 40b, a third sensor port 38c corresponding to the third suction cup 40c, a fourth sensor port 38d corresponding to the fourth suction cup 40d and a fifth sensor port 38e corresponding to the fifth suction cup 40e. Each sensor port 38a, 38b, 38c, 38d, 38e is in fluid communication with the vacuum cup 40a, 40b, 40c, 40d, 40e to which it corresponds and is configured to be operatively connected to a vacuum sensor (not shown in Figures 1-3 and 5A-E.). Referring again to Figure 7, in some embodiments, the sensor 73 (or sensors) additionally or alternatively include an ultrasonic sensor. The ultrasonic sensor is connected to the end effector 20 and provides feedback to the controller 74 regarding the amount of compression experienced by the bellows 42a of the first suction cup 40a that can be used to determine whether the first suction cup 40a pneumatically engages the target package 60a. In some embodiments, multiple ultrasonic sensors can be connected to the end effector 20 to provide feedback to the controller 74 regarding the amount of compression experienced by the bellows 42a, 42b, 42c, 42d, 42e of each suction cup 40a, 40b, 40c, 40d, 40e. Still referring to Figure 7, in this exemplary embodiment, the vacuum source(s) 90 are operatively connected to the controller 74 such that the controller 74 can communicate instructions that activate, deactivate, or otherwise adjust the vacuum source(s) 90 to regulate the suction applied to the suction cups 40a, 40b, 40c, 40d, 40e in fluid communication therewith. Accordingly, in cases where the vacuum source 90 consists of multiple vacuum sources corresponding to different suction cups 40a, 40b, 40c, 40d, 40e, the controller 74 can selectively regulate which suction cups 40a, 40b, 40c, 40d, 40e of the end effector 20 are activated at a given time. In this regard, the activation and deactivation of the vacuum source or sources 90 may be based on feedback provided to the controller 74 from the one or more chambers 72 and / or sensor or sensors 73. Referring now to Figures 5D-5E, 6 and 7, after determining that the first vacuum cup 40a is pneumatically coupled to the target package 60a, the controller 74 communicates instructions to the linear actuator 50 to retract the extendable arm 52, thereby lifting the target package 60a and / or to the robot 12 (or various motors and / or actuators associated therewith) to move the end effector 20 to the intended destination of the target package 60a. In some instances, the instructions communicated to the linear actuator 50 may cause the extendable arm 52 to retract the first suction cup 40a into the common plane defined by the shoulders 44b, 44c, 44d, 44e of the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d, and the fifth suction cup 40e.Depending on the positioning of the target package 60a in such instances, the suction provided by the second suction cup 40b, the third suction cup 40c, the fourth suction cup 40d, and the fifth suction cup 40e may assist the first suction cup 40a in lifting the target package 60a. As shown in FIGS. 5D-E, in instances where a non-target package 60b is stacked on top of a target package 60a, retracting the extendable arm 52 and lifting the target package 60a upward may cause the non-target package 60b to fall off the target package 60a. As shown in FIG. 6, the controller 74 may further communicate instructions to the robot 12 (or various motors and / or actuators associated therewith) to tilt the end effector 20 from a vertical position to cause the non-target package 60b to slide off the target package 60a. The above process may be repeated by the package coupling system 10 to selectively couple and process the remaining packages located on the conveyor 80. One of skill in the art will recognize that additional embodiments and implementations are also possible without departing from the teachings of the present invention. This detailed description, and in particular the specific details of exemplary embodiments and implementations disclosed herein, are provided primarily for ease of understanding and should not be construed as unnecessarily limiting the same, since modifications will be apparent to those skilled in the art upon reading this description and may be made without departing from the spirit or scope of the invention.
Claims
1. A vacuum-based end effector, characterized in that it comprises: a base plate; a plurality of suction cups mounted on the base plate and configured to be in fluid communication with a vacuum source, each suction cup of the plurality of suction cups including a bellows having a distal end connected to a flange for holding a package; and a linear actuator mounted to the base plate and including an extendable arm operatively connected to at least one suction cup of the plurality of suction cups and configured to extend and retract to adjust the distance between the at least one suction cup operatively connected to the extendable arm and the base plate.
2. The vacuum-based end effector according to claim 1, characterized in that the plurality of suction cups includes one or more suction cups that maintain a fixed position with respect to the base plate during operation of the vacuum-based end effector.
3. The vacuum-based end effector according to claim 2, characterized in that the respective flanges of the one or more suction cups that maintain the fixed position with respect to the base plate define a common plane and wherein the flange of the at least one operable suction cup 27 connected to the extendable arm moves below the common plane as the extendable arm is extended.
4. The vacuum-based end effector according to claim 1 and characterized in that it further comprises: a plurality of connectors, each connector of the plurality of connectors being in fluid communication with a suction cup of the plurality of suction cups and configured to connect to the vacuum source.
5. The vacuum-based end effector according to claim 4, characterized in that the base plate defines a plurality of ports, each port of the plurality of ports places a connector of the plurality of connectors in fluid communication with a suction cup of the plurality of suction cups.
6. The vacuum-based end effector according to claim 1, characterized in that the plurality of suction cups includes a first set of one or more flanged suction cups consisting of a first material and a second set of one or more flanged suction cups consisting of a second material.
7. The vacuum-based end effector according to claim 6, characterized in that the respective flanges of the first set of one or more suction cups consist of silicone rubber and the respective flanges of the second set of one or more suction cups consist of polyurethane. IVIA / t'ZUZZ / U / / 0 10 8. The vacuum-based end effector according to claim 1 and characterized in that it further comprises: one or more sensor ports, each one or more sensor ports being in fluid communication with a suction cup of the plurality of suction cups and configured to be operatively connected to a vacuum sensor.
9. A system for holding packages, characterized in that it comprises: a robot and an end effector mounted to the robot, the end effector including: a base plate, a plurality of suction cups mounted to the base plate and configured to be in fluid communication with a vacuum source, each suction cup of the plurality of suction cups including a bellows having a distal end connected to a flange for holding a package, and a linear actuator mounted to the base plate and including an extendable arm operatively connected to at least one suction cup of the plurality of suction cups, the extendable arm being configured to extend and retract to adjust the distance between the at least one suction cup operatively connected to the extendable arm and the base plate.
10. The system according to claim 9 and characterized in that it further comprises: a vision and control subsystem operatively connected to the robot and the end effector, the vision and control subsystem including a camera for acquiring image data corresponding to the positioning of the package and a controller operatively connected to the camera and including a processor for executing instructions stored in a memory component for (i) receiving and analyzing image data received from the camera to identify the position of the package and (ii) communicating instructions to the robot and the linear actuator causing the robot to move the end effector towards the package and the linear actuator to extend the extendable arm to cause the at least one suction cup operatively connected to the extendable arm to grasp the package.
11. The system according to claim 10 and characterized in that it further comprises: a sensor operatively connected to the controller, the sensor being configured to acquire data corresponding to at least one of the package positioning, pneumatic coupling of one or more suction cups of the plurality of suction cups with the package, and the amount of compression experienced by one or more suction cups of the plurality of suction cups.
12. The system according to claim 10, characterized in that the processor is further configured to execute instructions stored in memory component 30 to tilt the end effector.
13. The system according to claim 11, characterized in that the sensor includes at least one of a photoelectric sensor, an ultrasonic sensor, and a vacuum sensor.
14. The system according to claim 9, characterized in that the plurality of suction cups includes one or more suction cups that maintain a fixed position with respect to the base plate during the operation of the end effector.
15. The system according to claim 14, characterized in that the one or more suction cups that maintain the fixed position with respect to the base plate define a common plane and wherein the rim of the at least one suction cup operatively connected to the extendable arm moves below the common plane as the extendable arm is extended.
16. The system according to claim 9, characterized in that the plurality of suction cups includes a first set of one or more flanged suction cups consisting of a first material and a second set of one or more flanged suction cups consisting of a second material.
17. The system according to claim 16, characterized in that the respective flanges of the first set of one or more suction cups consist of silicone rubber and the respective flanges of the second set of one or more suction cups 31 consist of polyurethane.
18. The system according to claim 9 and characterized in that it further comprises: a plurality of connectors, each connector of the plurality of connectors being in fluid communication with a suction cup of the plurality of suction cups and configured to connect to the vacuum source, wherein the base plate defines a plurality of ports, each port of the plurality of ports placing a connector of the plurality of connectors in fluid communication with a suction cup of the plurality of suction cups.