Robotic systems with gripping mechanisms

Abstract

This invention provides a robotic system with a gripping mechanism. The robotic system may include: an end effector configured to grasp an object; a sensor unit that monitors contact information received from a contact limit sensor; and a controller coupled to the sensor unit. The end effector may include: a suction cup assembly for engaging the object; and a contact limit sensor for detecting pressure associated with engagement between the suction cup assembly and the object, wherein the contact limit sensor sends contact information when it detects pressure exceeding a contact threshold. The controller may perform operations to control the end effector based on the received contact information to limit the end effector's movement toward the object to prevent damage to the object.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to Provisional U.S. Patent Application No. 62 / 979413, filed February 20, 2020, the contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates generally to robotic systems, and more specifically to systems having gripping mechanisms. Background Technology

[0004] Many robots (e.g., machines configured to perform physical actions automatically / autonomously) are now widely used in numerous fields as their performance continues to improve and costs decrease. For example, robots can be used in industries such as manufacturing and / or assembly, packaging and / or packing, and transportation and / or delivery to perform a variety of tasks (e.g., manipulating or transferring items through space). In performing tasks, robots can replicate human movements, thereby replacing or reducing human intervention required for performing dangerous or repetitive tasks.

[0005] However, despite technological advancements, robots often lack the complexity necessary to replicate the human interaction required to perform larger and / or more complex tasks. For example, existing systems cannot detect whether forces applied by grippers or manipulators are approaching or exceeding thresholds associated with safely gripping and / or picking up objects without damage. In such cases, the robot may damage fragile items without realizing that the gripping force has exceeded a safety threshold. Therefore, improved technologies and systems remain needed for managing the operation and / or interaction between robots and manipulated objects. Summary of the Invention

[0006] Various aspects of the present invention may include a robotic system. The robotic system may include: an end effector configured to grasp an object; a sensor unit monitoring contact information received from a contact limit sensor; and a controller coupled to the sensor unit. The end effector may include: a suction cup assembly configured to engage the object; and a contact limit sensor configured to detect pressure associated with engagement between the suction cup assembly and the object, wherein the contact limit sensor sends contact information when it detects pressure exceeding a contact threshold. The controller may be configured to perform operations to control the end effector based on the received contact information to limit movement of the end effector toward the object to prevent damage to the object.

[0007] Other aspects of the invention may include an article handling unit comprising: a robotic arm; and an end effector configured to grasp an article. The end effector may include: a suction cup assembly configured to engage the article; and a contact limit sensor configured to detect pressure associated with engagement between the suction cup assembly and the article, wherein when the contact limit sensor detects pressure exceeding a contact threshold, the contact limit sensor sends contact information, and wherein the sent contact information restricts movement of the end effector toward the article to prevent damage to the article.

[0008] Other aspects of the invention may include a clamp attachment for an article handling system, the clamp attachment including an end effector configured to grip an article. The end effector may include a suction cup assembly configured to engage the article and a contact limit sensor. The suction cup assembly may include: a housing; a first suction cup configured to be coupled to a vacuum pressure source, wherein the first suction cup is displaceable relative to the housing; and a second suction cup coupled to the vacuum pressure source, wherein the second suction cup is movable relative to the housing independently of the first suction cup. The contact limit sensor is configured to detect pressure associated with engagement between the suction cup assembly and the article based on the displacement of the first and second suction cups relative to the housing, wherein when the contact limit sensor detects pressure exceeding a contact threshold, the contact limit sensor sends contact information, and wherein the sent contact information restricts movement of the end effector toward the article to prevent damage to the article.

[0009] Some embodiments of the present invention have steps or components other than or replacing those described above. Those steps or components will become apparent to those skilled in the art by reading the following detailed description with reference to the accompanying drawings. Attached Figure Description

[0010] Exemplary embodiments of the present invention will be described in detail with reference to the following accompanying drawings, in which:

[0011] Figure 1 This is an illustration of an exemplary environment in which a robot system according to an exemplary embodiment of the present invention is situated;

[0012] Figure 2 This is a block diagram illustrating a robot system according to an exemplary embodiment of the present invention;

[0013] Figure 3A and 3B A robotic arm according to an exemplary embodiment of the present invention is shown;

[0014] Figures 4A-4E Various views of the end effector of a robot arm according to an exemplary embodiment of the present invention are shown;

[0015] Figure 5 It shows the intercept along line V-V' Figure 4A A cross-sectional view of the end effector;

[0016] Figures 6A-6F This is a perspective view of an end effector according to an exemplary embodiment of the present invention; and

[0017] Figure 7 A perspective view of a robotic arm according to an exemplary embodiment of the present invention is shown. Detailed Implementation

[0018] In the following description, numerous specific details are set forth to provide a thorough understanding of the currently disclosed technology. In other embodiments, the technology described herein may be practiced without these specific details. In other instances, well-known features such as particular functions or routines have not been described in detail to avoid unnecessarily obscuring this disclosure. References to “embodiment,” “an embodiment,” etc., in this specification mean that a particular feature, structure, material, or characteristic described is included in at least one embodiment of this disclosure. Therefore, the appearance of these phrases in this specification does not necessarily refer to the same embodiment. On the other hand, such references are not necessarily mutually exclusive. Furthermore, in one or more embodiments, particular features, structures, materials, or characteristics may be combined in any suitable manner.

[0019] It should be understood that the various embodiments shown in the accompanying drawings are merely illustrative representations. Furthermore, the drawings illustrating system embodiments are semi-schematic and not drawn to scale; in particular, some dimensions are exaggerated for clarity only. Similarly, although the views in the drawings generally show similar orientations for ease of description, such depictions in the drawings are arbitrary in most cases. Generally, the invention can operate in any orientation.

[0020] For clarity, some details describing structures or processes well-known and frequently associated with robotic systems and subsystems are not elaborated in the following description, but such details may unnecessarily obscure some important aspects of the disclosed technology. Furthermore, although several embodiments of different aspects of the technology are described below, several other embodiments may have configurations or components different from those described in this section. Therefore, the disclosed technology may have other embodiments that have additional components or do not have several of the components described below.

[0021] Many embodiments or aspects of this disclosure described below may take the form of computer-executable or controller-executable instructions, including routines executed by a programmable computer or controller. Those skilled in the art will understand that the disclosed techniques can be practiced on computer or controller systems other than those shown and described below. The techniques described herein can be implemented in a dedicated computer or data processor specifically programmed, configured, or constructed to execute one or more computer-executable instructions described below. Therefore, the terms “computer” and “controller” as commonly used herein refer to any data processor and may include internet devices and handheld devices, including handheld computers, wearable computers, cellular phones or mobile phones, multiprocessor systems, processor-based or programmable consumer electronics, network computers, minicomputers, etc. Information processed by these computers and controllers may be presented on any suitable display medium, including liquid crystal displays (LCDs). Instructions for performing computer or controller-executable tasks may be stored in or on any suitable computer-readable medium, including hardware, firmware, or a combination of hardware and firmware. Instructions may be contained in any suitable storage device, including, for example, flash drives, USB devices, and / or other suitable media.

[0022] The terms “link” and “connection” and their derivatives are used herein to describe structural relationships between components. It should be understood that these terms are not intended to be equivalent to each other. Rather, in certain embodiments, “connection” can be used to indicate that two or more components are in direct contact with each other. Unless otherwise apparent in the context, the term “link” can be used to indicate that two or more components are in direct or indirect contact with each other (with other intermediary components between them), or that two or more components cooperate or interact with each other (e.g., there is a causal relationship, such as for signal transmission / reception or for function invocation), or both.

[0023] The following embodiments are described in sufficient detail to enable those skilled in the art to make and use the invention. It should be understood that other embodiments will be apparent based on this disclosure, and system, process, or mechanical changes can be made without departing from the scope of the embodiments of the invention.

[0024] Now for reference Figure 1 An example environment is shown in which a robotic system 100 with an item handling mechanism can operate. The operating environment of the robotic system 100 may include one or more structures, such as robots or robotic devices, configured to perform one or more tasks. The aspects of the item handling mechanism shown herein can be practiced or implemented through various structures.

[0025] exist Figure 1In the example shown, the robotic system 100 may include an unloading unit 102, a transfer unit 104, a transport unit 106, a loading unit 108, or combinations thereof, located in a warehouse, distribution center, or delivery center. Each unit in the robotic system 100 may be configured to perform one or more tasks. Tasks may be combined sequentially to perform operations that achieve a goal, such as unloading items from a vehicle such as a truck, trailer, van, or train for storage in a warehouse, or removing items from a storage location and loading them onto a vehicle for delivery. In another example, a task may include moving items from one location (e.g., a container, cabinet, cage, basket, shelf, platform, pallet, or conveyor belt) to another location. Each unit may be configured to perform a series of actions, such as manipulating one or more of its components to perform a task.

[0026] In some embodiments, a task may include interaction with a target item 112, such as manipulating, moving, reorienting, or a combination thereof. The target item 112 is the item to be handled by the robotic system 100. More specifically, the target item 112 may be a specific item among a number of items that are the target of the operation or task of the robotic system 100. For example, the target item 112 may be an item that the robotic system 100 has selected to facilitate or is currently handling, manipulating, moving, reorienting, or a combination thereof. As an example, the target item 112 may include boxes, crates, tubes, parcels, bundles, various individual items, or any other item that can be handled by the robotic system 100.

[0027] As an example, a task may include transferring a target item 112 from an item source 114 to a task location 116. The item source 114 is a storage container for storing items. The item source 114 may include various configurations and forms. For example, the item source 114 may be a platform with or without walls on which items can be placed or stacked, such as a pallet, shelf, or conveyor belt. As another example, the item source 114 may be a partially or fully enclosed storage container with walls or a lid, such as a cabinet, cage, or basket, capable of holding items therein. In some embodiments, the walls of the item source 114 may be partially or fully enclosed, may be transparent, or may include openings or gaps of various sizes, such that portions of the items contained therein are visible or partially visible through the walls.

[0028] Figure 1Examples of possible functions and operations that can be performed by the various units of the robotic system 100 when handling the target item 112 are shown, and it should be understood that the environment and conditions may differ from those described below. For example, unloading unit 102 may be a vehicle unloading robot configured to transfer the target item 112 from a location in a carrier such as a truck to a location on a conveyor belt. Furthermore, transfer unit 104, such as a palletizing robot, may be configured to transfer the target item 112 from a location on a conveyor belt to a location on a transport unit 106, such as for loading the target item 112 onto a pallet located in the transport unit 106. In another example, transfer unit 104 may be a sorting robot configured to transfer the target item 112 from one container to another. Upon completion of the operation, transport unit 106 may transfer the target item 112 from the area associated with transfer unit 104 to the area associated with loading unit 108, and loading unit 108 may transfer the target item 112 from transfer unit 104 to a storage location, such as a location on a shelf, for example, by means of a pallet carrying the target item 112. The following provides detailed information about the task and its associated actions.

[0029] For illustrative purposes, the robot system 100 is described in the context of a delivery center. However, it should be understood that the robot system 100 can be configured to perform tasks in other environments or for other purposes (e.g., for manufacturing, assembly, packaging, healthcare, or other types of automation). It should also be understood that the robot system 100 may include other units, such as manipulators, service robots, or modular robots, which... Figure 1 Not shown. For example, in some embodiments, the robot system 100 may include: a depalletizing unit for transferring items from a cage, trolley, or pallet to a conveyor or other pallet; a container exchange unit for transferring items from one container to another; a packaging unit for packaging items; a sorting unit for grouping items according to one or more characteristics of the items; and a sorting unit for manipulating items differently (e.g., sorting, grouping, and / or transferring) according to one or more characteristics or combinations thereof.

[0030] Now for reference Figure 2 The diagram illustrates a block diagram of a robot system 100 according to one or more embodiments of the present invention. In some embodiments, for example, the robot system 100 may include electronic devices, electrical devices, or combinations thereof, such as a control unit 202, a storage unit 204, a communication unit 206, a system interface, one or more actuation devices 212, one or more transport vehicles 214, one or more sensor units 216, or combinations thereof, which are interconnected and connected to the above-mentioned... Figure 1The integration or connection of one or more units or robots or combinations thereof as described herein.

[0031] The control unit 202 can be implemented in a variety of different ways. For example, the control unit 202 can be a processor, an application-specific integrated circuit (ASIC), an embedded processor, a microprocessor, hardware control logic, a hardware finite state machine (FSM), a digital signal processor (DSP), or a combination thereof. The control unit 202 can execute software to provide intelligence to the robot system 100.

[0032] Control unit 202 may include control interface 240. Control interface 240 can be used for communication between control unit 202 and other functional units in robot system 100. Control interface 240 can also be used for communication with the outside of robot system 100. Control interface 240 can receive information from other functional units or external sources, or can send information to other functional units or external destinations. External sources and external destinations refer to sources and destinations outside of robot system 100.

[0033] The control interface 240 can be implemented in different ways, and may include different implementations depending on which functional unit or external unit interfaces with the control interface 240. For example, the control interface 240 may be implemented using pressure sensors, inertial sensors, microelectromechanical systems (MEMS), optical circuits, waveguides, wireless circuits, wired circuits, application programming interfaces, or combinations thereof.

[0034] Storage cell 204 can store software, master data 246, or a combination thereof. For illustrative purposes, storage cell 204 is shown as a single element; however, it should be understood that storage cell 204 can be a distribution of storage elements. Also for illustrative purposes, robot system 100 is shown having storage cell 204 as a single hierarchical storage system, although it will be understood that robot system 100 can have storage cells 204 with different configurations. For example, storage cell 204 can be formed using different storage technologies to form a memory hierarchical system including different levels of cache, main memory, spinning media, or offline memory.

[0035] Storage unit 204 can be volatile memory, non-volatile memory, internal memory, external memory, or a combination thereof. For example, storage unit 204 can be non-volatile memory such as non-volatile random access memory (NVRAM), flash memory, disk storage, or volatile memory such as static random access memory (SRAM). As another example, storage unit 204 can be a non-transitory computer medium including non-volatile memory, such as a hard disk drive, NVRAM, solid-state storage device (SSD), optical disc (CD), digital video disc (DVD), or universal serial bus (USB) flash memory device. Software can be stored on a non-transitory computer-readable medium for execution by control unit 202.

[0036] Storage unit 204 may include control interface 240. Control interface 240 can be used for communication between storage unit 204 and other functional units within robot system 100. Control interface 240 can also be used for communication with the outside of robot system 100. Control interface 240 can receive information from other functional units or external sources, or can send information to other functional units or external destinations. External sources and external destinations refer to sources and destinations outside of robot system 100.

[0037] The control interface 240 may include different implementations depending on which functional units or external units are interfacing with the storage unit 204. The control interface 240 may be implemented using techniques similar to those used in the implementation of the control interface 240.

[0038] In one embodiment, storage unit 204 can be used to further store and provide access to processing results, predetermined data, thresholds, or combinations thereof. For example, storage unit 204 can store master data 246, which includes descriptions of one or more target items 112, such as boxes, box classes, crates, product types, or combinations thereof. In one embodiment, master data 246 can include the size, shape (e.g., templates of potential poses or computer-generated models for recognizing one or more target items 112 in different poses), color scheme, images, identification information (e.g., barcodes), quick-response (QR) codes, logos, expected location, expected weight, or combinations thereof for one or more target items 112 expected to be manipulated by robotic system 100.

[0039] In one embodiment, master data 246 may also include manipulation-related information about one or more objects that the robotic system 100 may encounter or handle. For example, the manipulation-related information may include: the center of gravity position on each object, expected sensor measurements (e.g., force, torque, pressure, or contact measurements corresponding to one or more actions, operations, or combinations thereof).

[0040] The communication unit 206 enables the robot system 100 to communicate with external devices. For example, the communication unit 206 enables the robot system 100 to communicate with other robot systems or units, external devices (such as external computers, external databases, external machines, external peripherals, or combinations thereof) via a communication path 218 such as a wired or wireless network.

[0041] Communication path 218 can traverse and represent various networks and network topologies. For example, communication path 218 can include wireless communication, wired communication, optical communication, ultrasonic communication, or combinations thereof. Examples of wireless communication that can be included in communication path 218 include satellite communication, cellular communication, Bluetooth, Infrared Data Association (IRDA) standards, Wi-Fi, and WiMAX. Examples of wired communication that can be included in communication path 218 include cable, Ethernet, Digital Subscriber Line (DSL), fiber optic lines, Fiber to the Home (FTTH), and Politecnico di Tolerancing (POTS). Furthermore, communication path 218 can traverse many network topologies and distances. For example, communication path 218 can include direct connections, Personal Area Networks (PANs), Local Area Networks (LANs), Metropolitan Area Networks (MANs), Wide Area Networks (WANs), or combinations thereof. Robot system 100 can transmit information between its various units via communication path 218. For example, information can be transmitted between control unit 202, storage unit 204, communication unit 206, system interface, actuation device 212, transport vehicle 214, sensor unit 216, or combinations thereof.

[0042] The communication unit 206 can also be used as a communication hub to allow the robot system 100 to act as part of the communication path 218, and is not limited to being an endpoint or terminal unit of the communication path 218. The communication unit 206 may include active and passive components for interacting with the communication path 218, such as microelectronic devices or antennas.

[0043] Communication unit 206 may include communication interface 248. Communication interface 248 can be used for communication between communication unit 206 and other functional units in robot system 100. Communication interface 248 can receive information from other functional units or external sources, and can also send information to other functional units or external destinations. External sources and external destinations refer to sources and destinations outside of robot system 100.

[0044] The communication interface 248 may include different implementations depending on which functional units are interfaced with the communication unit 206. The communication interface 248 may be implemented using techniques similar to those used in the control interface 240.

[0045] I / O device 208 may include input devices and output devices. Examples of input devices for I / O device 208 may include a keypad, touchpad, soft keys, keyboard, microphone, sensor for receiving remote signals, camera for receiving movement commands, or any combination thereof to provide data and communication input. Examples of output devices may include display interface 210. Display interface 210 may be any graphical user interface, such as a monitor, projector, video screen, or any combination thereof.

[0046] Control unit 202 can operate I / O device 208 to present or receive information generated by robot system 100. Control unit 202 can operate user interface to present information generated by robot system 100. 202 can also execute software for other functions of robot system 100. Control unit 202 can also execute software to interact with communication path 218 via communication unit 206.

[0047] Robot system 100 may include physical or structural components, such as robotic manipulator arms, which are jointed for movement, such as rotational displacement, translational displacement, or a combination thereof. The structural components and joints may form a kinetic chain configured to manipulate an end effector, such as a gripper, to perform one or more tasks, such as clamping, rotation, or welding, depending on the use or operation of the robot system. Robot system 100 may include actuation devices 212 configured to drive, manipulate, displace, reorient, or combine thereof on or around structural components at or around corresponding joints, such as motors, actuators, wires, artificial muscles, electroactive polymers, or combinations thereof. In some embodiments, robot system 100 may include a transport vehicle 214 configured to transport corresponding units from one location to another.

[0048] The robot system 100 may include a sensor unit 216 configured to acquire information for performing tasks and operations, such as manipulating structural members or transporting robot units. The sensor unit 216 may include devices configured to detect or measure one or more physical properties of the robot system 100, such as the state, condition, or position of one or more structural members or joints, information about objects or the surrounding environment, or combinations thereof. As an example, the sensor unit 216 may include an imaging device 222, a system sensor 224, a contact sensor 226, or combinations thereof.

[0049] In some embodiments, sensor unit 216 may include one or more imaging devices 222. Imaging devices 222 are devices configured to detect the surrounding environment. For example, imaging devices 222 may include 2D cameras, 3D cameras, both of which may include combinations of visual and infrared capabilities, LIDARS, RADARS, other ranging devices, and other imaging devices. Imaging devices 222 may generate a representation of the detected environment, such as digital images or point clouds, for use in machine / computer vision for automated inspection, robot guidance, or other robotic applications. As described further below, robot system 100 may process digital images, point clouds, or combinations thereof via control unit 202 for identification. Figure 1 The target item 112, the pose of the target item 112, or a combination thereof. To manipulate the target item 112, the robotic system 100 can capture and analyze images of a designated area (e.g., inside a truck, inside a container, or at the pick-up location of an item on a conveyor belt) to identify the target item 112 and its position within the designated area. Figure 1 The source of the items is 114. Similarly, the robot system 100 can capture and analyze images of another designated area (e.g., a placement location for placing items on a conveyor belt, a location for placing items inside a container, or a location on a pallet for stacking purposes) to identify... Figure 1 The task location is 116.

[0050] In some embodiments, sensor unit 216 may include system sensor 224. System sensor 224 is a device for monitoring the robot unit. For example, system sensor 224 may include a unit or device for detecting and monitoring the position of structural members such as robot arms and end effectors, corresponding joints of the robot unit, or combinations thereof. As another example, robot system 100 may use system sensor 224 to track the position, orientation, or combinations thereof of structural members and joints during task execution. Examples of system sensor 224 may include accelerometers, gyroscopes, or position encoders.

[0051] In some embodiments, sensor unit 216 may include contact sensor 226, such as a pressure sensor, force sensor, strain gauge, piezoresistive / piezoelectric sensor, capacitive sensor, elastic sensor, torque sensor, linear force sensor, or other tactile sensor, configured to measure characteristics associated with direct contact between multiple physical structures or surfaces. For example, contact sensor 226 may measure characteristics corresponding to the clamping of the end effector on target article 112, or it may measure the weight of target article 112. Accordingly, contact sensor 226 may output contact measurements representing quantified measures, such as the measured force or torque corresponding to the degree of contact or adhesion between the clamp and target article 112. For example, contact measurements may include one or more force or torque readings associated with the force applied to target article 112 by the end effector.

[0052] Figure 3A and 3B A robotic arm 330 with a gripper attachment 328 including an end effector 332 is shown according to an exemplary embodiment of the invention. In the example embodiment, the robotic arm 330 may be configured to manipulate items, such as picking items from a container or placing items at a destination such as a conveyor belt or another container. Figure 1 and Figure 2 The robotic system 100 includes a robotic arm 330 having a gripper attachment 328 including an end effector 332. The end effector 332 is part of the robotic arm 330 and includes components configured to contact, manipulate, hold, or grasp an article or any combination thereof. The portion of the end effector 332 that contacts the article may be referred to as a gripper head.

[0053] The gripper attachment 328 includes an offset bracket 338 that engages the gripper attachment 328 with the robot arm 330. The offset bracket 338 provides a mechanical connection between the gripper attachment 328 and the robot arm 330. In some example embodiments, the offset bracket 338 may also provide an electrical connection to allow the exchange of electrical signals between the robot arm 330 and the gripper attachment 328. For example, electrical signals may be exchanged between the robot arm 330 and sensors and other components located on the gripper attachment 328.

[0054] The robotic arm 330 can use one or more actuation devices (e.g., Figure 2 The actuating device 212 shown rotates and actuates the offset bracket 338. The actuating device 212 can provide rotary actuation, torsional actuation, linear actuation, or any other type of actuation that is obvious to a person skilled in the art.

[0055] An offset bracket 338 can be connected to an offset plate 334, which provides lateral offset between the robotic arm 330 and the end effector 332. In other words, the offset plate 334 provides lateral offset between the axis 3 of the robotic arm 330 and the axis 4 of the end effector 332 mounted on the offset plate 334. The offset plate 334 can be formed of a material selected to provide structural support for the end effector 332. In some exemplary embodiments, the offset plate 334 can be formed of a metal such as a steel alloy, an aluminum alloy, or any other alloy that may be apparent to those skilled in the art. In other exemplary embodiments, depending on the intended application or intended use of the end effector 332, the offset plate 334 can be formed of a polymeric material, a composite material, or a ceramic material.

[0056] The end effector 332 is connected to the offset plate 334 via a torque bracket 340, which may include a torque sensor 336. The torque sensor 336 measures the force on the end effector 332 to sense the weight of the object currently held or manipulated, and senses any forces caused by resistance or obstacles encountered by the end effector 332 during operation. The offset plate 334, the offset bracket 338, and the torque bracket 340 provide internal connections to provide tubing / airways and wiring paths for wires, allowing for electrical connections between the robotic arm 330 and the end effector 332.

[0057] In some exemplary embodiments, such as Figure 2 The actuating device 212 shown, the torque bracket 340 can also be used to rotate and actuate the end effector 332 relative to the offset bracket 338. The actuating device 212 can provide rotary actuation, torsional actuation, linear actuation, or any other type of actuation that is obvious to those skilled in the art.

[0058] The torque bracket 340 can be connected to the head connector 342, which in turn connects to the head extension 344 of the suction cup assembly 346 supporting the end effector 332. The head extension 344 can be a structural member extending from the torque bracket 340 to increase the length between the robotic arm 330 and the suction cup assembly 346. The head extension 344 allows the end effector 332 to position the suction cup assembly 346 to access items in a container, while providing clearance for the robotic arm 330 to manipulate it without colliding with the container or items adjacent to it.

[0059] The head connector 342 and head extender 344 can be formed of a material selected to provide structural support for the end effector 332. In some example embodiments, the head connector 342 and head extender 344 can be made of a metal (e.g., a steel alloy, an aluminum alloy, or any other alloy readily apparent to those skilled in the art). In other example embodiments, depending on the intended application or intended use of the end effector 332, the head connector 342 and head extender 344 can be formed of a polymeric material, a composite material, or a ceramic material.

[0060] The offset plate 334 also includes a tube holder 348 connected to air supplied from the robotic arm 330 and provides a tube connector 350 to distribute air to the suction cup block assembly 346. The tube connector 350 can be connected to an air supply tube 356 coupled to the suction shaft interface 354, which extends through a contact limit sensor device 352 associated with the suction cup block assembly 346 of the end effector component. More specifically, as an example, the suction cup block assembly 346 may include a contact limit sensor device 352. The tube holder 348 can constrain and position the air supply tube 356 during operation of the robotic arm 330 to prevent the air supply tube 356 from coiling or breaking. The contact limit sensor device 352 can be a sensor capable of preventing the end effector 332 from applying contact pressure that could potentially damage an item through contact. Details regarding the contact limit sensor device 352 will be discussed below.

[0061] In some exemplary embodiments, the tube connector 350 may be connected to one or more vacuum sources (not shown) to provide suction to the suction shaft interface 354 of the suction block assembly 346 of the end effector 332. For example, the tube connector 350 may be connected to one or more vacuum ejectors that use compressed air to generate vacuum pressure. For example, the vacuum ejector may allow compressed air to pass through a nozzle shaped to create a low-pressure area, which provides vacuum pressure to the suction block assembly 346.

[0062] The generated vacuum pressure can be supplied from the tube connector 350 to the suction shaft interface 354 via the air supply pipe 356. The vacuum pressure supplied to the suction shaft interface 354 can be supplied to the suction cup block assembly 346 to provide suction for gripping and releasing items, or to securing items to or releasing items from the end effector 332. The operation of the suction cup block assembly 346 will be discussed in more detail below.

[0063] The end effector 332 can be operated by means of, for example Figure 2The actuators 212 connected to the structural members of the robotic arm 330, the joints of the robotic arm 330, and the brackets (e.g., offset bracket 338, torque bracket 340) or combinations thereof are actuated. The end effector 332 can be operated to grip or release articles by operating one or more actuators 212 associated with or attached to one or more portions of the end effector 332. The end effector 332 can use the vacuum pressure provided to the suction cup block assembly 346 to grip and release articles, thereby securing articles to or releasing articles from the end effector 332.

[0064] Figures 4A-4E Various views of the end effector 332 of a robotic arm 330 according to an exemplary embodiment of the present invention are shown. In the various views, Figure 4A A front view of the end effector 332 is shown, while Figure 4B A top view of the end effector 332 is shown. Furthermore, Figure 4C A bottom view of the end effector 332 is shown, while Figure 4D A side view of the end effector 332 is shown. Figure 4E This shows the section intercepted along the IVE-IVE' line. Figure 4A A cross-sectional view of the end effector 332.

[0065] As shown in the figure, the tube bracket 348 can be located on the side of the offset plate 334 opposite to the torque bracket 340 and the torque sensor 336. Figure 3A and 3B Air supply pipe 356 in Figures 4A-4E The details are omitted to better visualize the tube connector 350 and the suction port 354. As shown, the tube connector 350 extends forward from the tube bracket 348.

[0066] The torque bracket 340 can be mechanically coupled to the head connector 342 to transfer any force or torque from the head extender 344 to the torque sensor 336. In some example embodiments, the torque sensor 336 can be a type similar to... Figure 2 The contact sensor 226 is a contact sensor.

[0067] As shown in the figure, the head extender 344 can be coupled to the head connector 342 via a clamping assembly. However, in other example embodiments, the head extender 344 can be coupled to the head connector 342 via a crimp assembly, screw assembly, welding, adhesive, or any other mechanical coupling mechanism that is obvious to those skilled in the art.

[0068] The head extender 344 can be mechanically coupled to the end effector 332 to transfer any force or torque from the suction cup block assembly 346 of the end effector 332 to the torque sensor 336. As shown, the head extender 344 can be coupled to the suction cup block assembly 346 via an attachment screw 3701. However, in other exemplary embodiments, the head extender 344 can be coupled to the suction cup block assembly 346 via a press-fit assembly, clamp-fit ​​assembly, welding, adhesive, or any other mechanical coupling mechanism that will be obvious to those skilled in the art. Thus, any force or torque experienced by the suction cup block assembly 346 is transferred to the torque sensor 336 via the torque bracket 340, the head connector 342, and the head extender 344.

[0069] The configuration that may include a torque sensor 336 near the torque bracket 340, head connector 342, and / or head extender 344 allows impacts or collisions to the suction cup assembly 346 to be transferred to the torque sensor 336 to provide feedback to the robotic arm 330. The torque sensor 336 can also measure the size of objects grasped or held by the suction cup assembly 346 (e.g., [item name missing]). Figure 1 The weight of the target item 112) and the weight variation of the item as the suction cup block assembly 346 is being moved or positioned.

[0070] Furthermore, in some example embodiments, the end effector 332 may also include one or more additional sensor units. For example, Figure 2 One or more contact sensors 226 may be attached to or integrated within the end effector 332. In some example embodiments, in addition to a torque sensor 336 attached to the end of the offset plate 334 opposite the offset bracket 338, the contact sensor 226 may be a force, pressure, torque, and / or other tactile sensor attached to or integrated with the end effector 332. In another example embodiment, the contact sensor 226 may include an item (e.g., an object held or supported by the suction cup block assembly 346) configured to measure the force, pressure, torque, and / or other tactile sensation. Figure 1 A separate linear force sensor for the weight of the target item (112). Other examples of sensor units (such as the contact limit sensor 366 in Figure 6) will be discussed below.

[0071] The suction cup block assembly 346 may include a plurality of suction shaft interfaces 354 extending upward from the contact limit sensor device 352. Each suction shaft interface 354 is communicatively coupled to either suction cup 358 or suction cup 360. In some embodiments, suction cup 358 may have a larger relative diameter than suction cup 360. Having two different sizes of suction cups 358 and 360 allows for greater flexibility in gripping or holding objects through the suction cup block assembly 346. For example, the smaller relative-sized suction cup 360 can better grip smaller or irregularly shaped objects (because of its smaller size). Furthermore, since the gripping force is the product of vacuum pressure and suction cup surface area, the larger relative-sized suction cup 358 can achieve higher gripping strength for gripping and manipulating larger objects.

[0072] In the illustrated embodiment, the suction cup block assembly 346 is shown having four total suction cups (358 and 360) with two different relative sizes. However, exemplary embodiments of the invention may include more than four total suction cups or fewer than four total suction cups. Similarly, in some exemplary embodiments, suction cups with more than two different relative sizes may be provided. Alternatively, a single-size suction cup may be provided.

[0073] Figure 5 It shows the intercept along line V-V' Figure 4A A cross-sectional view of the end effector 332. As shown, the end effector 332 includes a head extension 344 that connects the suction cup block assembly 346 to the offset plate 334. As described above, the suction cup block assembly 346 includes a plurality of suction shaft interfaces 354 extending upward from the contact limit sensor device 352, each suction shaft interface 354 being communicatively connected to a suction cup 358 or a suction cup 360. In some example embodiments, the suction cup 358 may have a larger relative diameter than the suction cup 360.

[0074] like Figure 5 As shown, the suction cup block assembly 346 also includes a suction shaft 362, which is connected in communication with a suction shaft interface 354 to one of the suction cups 358 and 360. When the suction shaft interface 354 is connected to a vacuum pressure source via an air supply pipe 356, the vacuum pressure from the air supply pipe 356 is transmitted through the suction shaft 362 to the suction cups 358 and 360, thereby generating sufficient suction to pick up objects. In some exemplary embodiments, the suction shaft 362, the suction cups 358 / 360, and the suction shaft interface 354 may be movable relative to the contact limit sensor device 352. For example, the contact limit sensor device 352 may include a housing 368 through which the suction shaft 362 may slide vertically to allow the suction cups (358 / 360) below the housing 368 and the suction shaft interface 354 above the housing 368 to move relative to the housing 368, as indicated by arrow 370.

[0075] Furthermore, the suction cup block assembly 346 may also include a displacement recovery mechanism 364 that provides biasing force to restore the suction cups 358 and 360, the suction shaft 362, and the suction shaft interface 354 to their default positions after displacement relative to the housing 368 of the suction cup block assembly 346. In some example implementations, the displacement recovery mechanism 364 may be a spring, such as a compression spring, a conical spring, a gas spring, or other biasing mechanisms that may be apparent to those skilled in the art. The displacement recovery mechanism 364 may be positioned or housed inside the housing 372 (e.g., an outer tube) of the suction shaft 362. Thus, the displacement recovery mechanism 364 allows the suction cups 358 / 360 to return to their default positions after displacement due to contact with an object or obstacle during operation.

[0076] Each of the suction shaft 362 and / or displacement recovery mechanism 364 can be guided through the contact limit sensor device 352. In some embodiments, the path of the suction shaft 362 through the contact limit sensor device 352 can fix the horizontal position of the suction shaft 362 and the suction cups 385 / 360 relative to each other.

[0077] Figures 6A-6F This is a perspective view of the end effector 332, showing the displacement of the suction cups 358 / 360 of the end effector 332 according to an exemplary embodiment of the present invention. Figure 6A One of the suction cups (suction cup 360A) is depicted moving upward from its default position. Figure 6B The two suction cups (suction cups 360A and 360B) are depicted being displaced from their default positions. Figure 6C All four suction cups (suction cups 360A, 360B, 358A, and 358B) are depicted displacing from their default positions. Figure 6D The displacement of the contact limit sensor device 352 is depicted. Figure 6E yes Figure 6B A view of the rear of the end effector 332, which depicts two suction cups (suction cups 360A and 360B) displaced from their default position. Figure 6F yes Figure 6E The end effector 332, but the contact limit sensor device 352 is shown as transparent.

[0078] As shown in the figure, the end effector 332 may include suction cups 358 / 360 in a default position. The default position of each suction cup 358 / 360 may share a common horizontal plane. As described above, the end effector 332 may be configured to allow each suction cup 358 / 360 to displace independently of each other relative to the contact limit sensor device 352 from its default position. For example, when one or more suction cups 358 / 360 contact an object, each suction cup 358 / 360 may displace due to pressure or force on the suction cup 358 / 360. Each suction cup 358 / 360 may displace independently of the other suction cups 358 / 360. Figure 6A The suction cup 360A is shown to be displaced independently relative to the other suction cups 358 / 360. Figure 6B The suction cups 360A and 360B are shown to be displaced independently relative to the suction cup 358. Figure 6C All four suction cups (360A, 360B, 358A, and 358C) are shown in their full displacement. The displacement direction can be along the axis 374 of the suction shaft 362 (e.g., perpendicular to the ends of suction cups 358 / 360 / the base of the shaft cylinder). Figure 6E Shown from the back Figure 6B The displacement of the two suction cups (suction cups 360A and 360B), and Figure 6F It shows Figure 6B The same displacement of the two suction cups (suction cups 360A and 360B), wherein the contact limit sensor device 352 is shown as transparent.

[0079] In other words, each suction cup (i.e. Figure 6C The independent displacement of suction cups 360A, 360B, 358A, and 358C allows each suction cup 358 / 360 to be in a different relative position to the others. The independent displacement allows the end effector 332 to accommodate or conform to items with varying surface profiles (i.e., non-uniform / irregular surfaces), such as bags and other flexible containers.

[0080] In some example implementations, the contact limit sensor device 352 can also be displaced. For example, the contact limit sensor device 352 can be displaced from... Figures 6A-6C The initial position shown is shifted to Figure 6D The contact limit position is shown. In some embodiments, the contact limit sensor device 352 is located from... Figures 6A-6C initial or default position to Figure 6D The displacement of the contact limit position can be caused by the displacement of one or more suction cups 358 / 360. In some example embodiments, the displacement of the contact limit sensor device 352 to the contact-limited position caused by the displacement of one or more suction cups 358 / 360 can correspond to the suction cups 358 / 360 applying pressure to the article exceeding a contact threshold (also known as the contact limit) that may potentially damage the article.

[0081] The displacement of the contact limit sensor device 352 can be recorded by the contact limit sensor 366, which sends a signal (e.g., contact information) to... Figure 2 The control unit 202 prevents the end effector 332 from applying further pressure to the article when a contact threshold is reached. This prevents the end effector 332 from moving further toward the article when the contact limit sensor 366 detects that a contact threshold (e.g., a contact limit) has been reached. By providing an end effector 332 with a contact limit sensor device 352, the advantage is that only a single sensor can determine whether the end effector 332 has exceeded the contact limit on the article due to displacement of the contact limit sensor device 352 to the contact limit position caused by either of the suction cups 358 / 360.

[0082] In some exemplary embodiments, as shown in Figures 6a-6f, suction cups 360 with smaller relative sizes (e.g., the first pair of suction cups) can be used to hold smaller or fragile items (e.g., easily broken items), while suction cups 358 with larger relative sizes (e.g., the second pair of suction cups) can be used to hold larger items or items that are unlikely to be damaged.

[0083] Furthermore, in some exemplary embodiments, the housing 368 of the contact limit sensor device 352 may include an offset step 376 that provides a greater displacement distance for the larger relative-sized suction cup 358 (also referred to as the larger suction cup) than for the smaller relative-sized suction cup 360 (also referred to as the smaller suction cup). For example, since the smaller suction cup may be used for fragile items, less force or pressure should be applied before reaching the contact limit to prevent damage. Therefore, the smaller suction cup may reach the contact limit position before the larger suction cup, which can be achieved by the offset step 376 in the contact limit sensor device 352.

[0084] Figure 7 A perspective view of a robotic arm 330 according to an exemplary embodiment of the present invention is shown. As shown, the robotic arm 330 includes a compressed air supply source 705 coupled to an end effector 332 of a gripper attachment 328. Specifically, the compressed air supply source 705 is coupled to a tube holder 348 via a fluid supply conduit 710. The compressed air supply source 705 can be used to provide vacuum pressure to the tube holder 348, which in turn provides vacuum pressure to the suction cups 358 / 360 of the suction cup block assembly 346.

[0085] As shown in the figure, the offset bracket 338 of the gripper attachment 328 can be attached to the robotic arm 330 via an actuator 715, which allows the gripper attachment 328 to be actuated by rotation in the horizontal plane. The actuator 715 can be coupled to a second actuator 720, which allows the gripper attachment 328 to be actuated by rotation in the vertical plane. A third actuator 725 can be coupled to the second actuator 720 to allow further actuation of the gripper attachment 328. In general, actuators 715, 720, and 725 allow the robotic arm 330 to manipulate the end effector 332 of the gripper attachment 328 to grasp an item 730, enabling the item 730 to be picked up, repositioned, or moved.

[0086] The methods, processes, apparatuses, devices, products, and / or systems obtained by this invention are cost-effective, highly versatile, precise, sensitive, and efficient, and can be implemented by adapting known components to readily available, efficient, and economical manufacturing, application, and utilization methods. Another important aspect of an embodiment of this invention is that it effectively supports and serves historical trends of cost reduction, system simplification, and performance improvement.

[0087] Therefore, these and other valuable aspects of one embodiment of the present invention further elevate the state of the technology to at least the next level.

[0088] Although some exemplary embodiments have been shown and described, these exemplary embodiments are provided to convey the subject matter described herein to those skilled in the art. It should be understood that the subject matter described herein can be implemented in various forms and is not limited to the exemplary embodiments described. The subject matter described herein can be practiced without those specifically defined or described subjects, or without other or different components or subjects described. Those skilled in the art will understand that changes can be made to these exemplary embodiments without departing from the subject matter described herein as defined in the appended claims and their equivalents.

Claims

1. A robot system, comprising: An end effector configured to grasp an object, the end effector comprising: Suction cup assembly, configured to engage articles; and A contact limit sensor is configured to detect pressure associated with engagement between the suction cup assembly and the article, wherein the contact limit sensor sends contact information when it detects that the pressure exceeds a contact threshold; A sensor unit that monitors contact information received from the contact limit sensor; and A controller, coupled to the sensor unit and configured to perform an operation, which controls the end effector based on received contact information to limit the movement of the end effector toward the article to prevent damage to the article; The suction cup assembly includes: case; A first suction cup, connected to a vacuum pressure source, wherein the first suction cup is displaceable relative to the housing; and A second suction cup is connected to a vacuum pressure source, wherein the second suction cup is displaceable relative to the housing independently of the first suction cup; The housing includes an offset step configured to allow the displacement of the second suction cup relative to the housing to be greater than the permissible displacement of the first suction cup; and the contact limit sensor is configured to detect pressure associated with engagement between the suction cup assembly and the article based on at least one of the displacement of the first suction cup relative to the housing, the displacement of the second suction cup relative to the housing, the permissible displacement of the first suction cup, and the permissible displacement of the second suction cup.

2. The robot system of claim 1, wherein the first suction cup has a smaller size relative to the size of the second suction cup.

3. The robot system according to claim 1, wherein the suction cup assembly further comprises: A suction shaft extends through the housing, wherein the first suction cup is communicatively connected to the suction shaft and a vacuum pressure source, and The suction shaft is movable relative to the housing.

4. The robot system according to claim 3, wherein the suction cup assembly further comprises: A displacement recovery mechanism is configured to bias the suction shaft to a default position relative to the housing, and The contact limit sensor is configured to detect the pressure associated with the engagement between the suction cup assembly and the article based on the pressure used to overcome the bias provided by the displacement recovery mechanism.

5. The robot system according to any one of claims 1 to 4 further includes a torque sensor configured to measure the force applied by the end effector.

6. An item handling unit, comprising: Robotic arm; as well as An end effector configured to grasp an object, the end effector comprising: Suction cup assembly, which is configured to engage articles; and A contact limit sensor is configured to detect the pressure associated with the engagement between the suction cup assembly and the article. When the contact limit sensor detects that the pressure exceeds the contact threshold, the contact limit sensor sends contact information. The contact information sent restricts the movement of the end effector toward the article to prevent damage to the article. The suction cup assembly includes: case; A first suction cup, connected to a vacuum pressure source, wherein the first suction cup is displaceable relative to the housing; and A second suction cup is connected to a vacuum pressure source, wherein the second suction cup is displaceable relative to the housing independently of the first suction cup; The housing includes an offset step configured to allow the displacement of the second suction cup relative to the housing to be greater than the allowable displacement of the first suction cup. The contact limit sensor is configured to detect the pressure associated with the engagement between the suction cup assembly and the article based on at least one of the displacement of the first suction cup relative to the housing, the displacement of the second suction cup relative to the housing, the permissible displacement of the first suction cup, and the permissible displacement of the second suction cup.

7. The article handling unit according to claim 6, wherein the first suction cup has a smaller size relative to the size of the second suction cup.

8. The article handling unit according to claim 6, wherein the suction cup assembly further comprises: A suction shaft extends through the housing, wherein the first suction cup is communicatively connected to the suction shaft and a vacuum pressure source. The suction shaft is movable relative to the housing.

9. The article handling unit according to claim 8, wherein the suction cup assembly further comprises: A displacement recovery mechanism is configured to bias the suction shaft to a default position relative to the housing. The contact limit sensor is configured to detect the pressure associated with the engagement between the suction cup assembly and the article based on the pressure used to overcome the bias provided by the displacement recovery mechanism.

10. The article handling unit according to any one of claims 6 to 9, further comprising a torque sensor configured to measure the force of the end effector.

11. A clamping attachment for a goods handling system, comprising: An end effector configured to grasp an object, the end effector comprising: A suction cup assembly configured to engage an article, the suction cup assembly comprising: case; A first suction cup, configured to be coupled to a vacuum pressure source, wherein the first suction cup is displaceable relative to the housing; and A second suction cup, connected to a vacuum pressure source, wherein the second suction cup is displaceable relative to the housing independently of the first suction cup; and A contact limit sensor is configured to detect the pressure associated with the engagement between the suction cup assembly and the article. When the contact limit sensor detects that the pressure exceeds the contact threshold, the contact limit sensor sends contact information. The contact information sent restricts the movement of the end effector toward the article to prevent damage to the article. The housing includes an offset step configured to allow the displacement of the second suction cup relative to the housing to be greater than the allowable displacement of the first suction cup. The contact sensor is configured to detect pressure associated with engagement between the suction cup assembly and the article based on at least one of the displacement of the first suction cup relative to the housing, the displacement of the second suction cup relative to the housing, the permissible displacement of the first suction cup, and the permissible displacement of the second suction cup.

12. The clamp accessory of claim 11, wherein the first suction cup has a smaller size relative to the size of the second suction cup.

13. The clamp accessory according to claim 11 or 12, wherein the suction cup assembly further comprises: A suction shaft extends through the housing, wherein the first suction cup is communicatively connected to the suction shaft and a vacuum pressure source, and wherein the suction shaft is movable relative to the housing; as well as A displacement recovery mechanism is configured to bias the suction shaft to a default position relative to the housing. The contact sensor is configured to detect the pressure associated with the engagement between the suction cup assembly and the article based on the pressure used to overcome the bias provided by the displacement recovery mechanism.

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