Systems and methods for robotic suction grippers

Abstract

To provide a suction gripper mechanism capable of operating in environments, such as recycling and consumer waste handling facilities, where the atmosphere contains a lot of dust or other particulates, and where the target object to be captured is not clean and may have random and irregular surfaces.SOLUTION: A robotic vacuum sorting system comprises: a vacuum system coupled to a suction gripper mechanism mounted to a sorting robot; and an imaging device coupled to robot control logic and electronics coupled to the sorting robot and the vacuum system. In response to an image signal from the imaging device, the robot control logic and electronics outputs robot control signals to control the sorting robot, and outputs one or more airflow control signals to the vacuum system to execute a capture action on a target object using the suction gripper. During the capture action, the robot control logic and electronics outputs control signals such that the vacuum system pulls a vacuum at a gripping port of the suction gripper mechanism as the suction gripper mechanism is applied to capture and hold the target object.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Cross - Reference to Related Applications

[0001] This application claims the priority and benefit of U.S. Provisional Patent Application No. 62 / 561,400, filed on September 21, 2017, titled "SYSTEMS AND METHODS FOR ROBOTIC SUCTION GRIPPERS", which is hereby incorporated by reference in its entirety.

Background Art

[0002]

[0002] A suction gripper is a mechanism used to pick up and move an object by applying a vacuum concentrated on a part of the surface of the object with a vacuumed strength sufficient to hold the object against the gripper.

Summary of the Invention

Problems to be Solved by the Invention

[0003] Thus, suction grippers have several distinct advantages over mechanical grippers. For example, a suction gripper mechanism can be implemented with fewer mechanical parts that wear out, fail, or require maintenance. However, such grippers face challenges when operating in environments such as recycling facilities and consumer waste handling facilities where the atmosphere contains a lot of dust or other particles and the target objects to be captured may have dirty, uneven, and non - uniform surfaces. Additionally, elements such as vacuum piping and other hardware elements can become larger and less easy to maneuver and / or position when used in combination with moving robotic equipment.

[0004]

[0003] For the reasons described above and other reasons that will become apparent to those skilled in the art upon reading and understanding this specification, there is a need in the art for systems and methods for robotic suction grippers.

Means for Solving the Problems

[0005]

[0004] Embodiments of the present disclosure provide methods and systems for robotic suction gripping machines, and will be understood by reading and learning the following specifications.

[0006]

[0005] In one exemplary embodiment, the robot vacuum sorting system comprises a suction gripping mechanism pivotably mounted on one or more robot arms of a sorting robot; a vacuum system coupled to the suction gripping mechanism; robot control logic and electronics coupled to the sorting robot and the vacuum system; and an imaging device coupled to the robot control logic and electronics, wherein the robot control logic and electronics, in response to an image signal from the imaging device, outputs one or more robot control signals for controlling one or more robot arms of the sorting robot, and outputs one or more airflow control signals to the vacuum system to perform a capture operation on an object using the suction gripping mechanism, and during the capture operation, the robot control logic and electronics outputs control signals such that the vacuum system pulls a vacuum at the gripping port of the suction gripping mechanism when the suction gripping mechanism is applied to capture and hold an object.

[0007]

[0006] Embodiments of the present disclosure can be more readily understood when considered in view of the description of preferred embodiments and the following drawings, and their further advantages and uses will also become more readily apparent. [Brief explanation of the drawing]

[0008] [Figure 1] This figure shows an exemplary robotic vacuum sorting system of one embodiment of the present disclosure. [Figure 1A] This figure shows a robot control logic electronic device according to one embodiment of the present disclosure. [Figure 2] This figure shows an exemplary suction gripping device of one embodiment of the present disclosure. [Figure 2A] This figure shows an exemplary suction gripping device of one embodiment of the present disclosure. [Figure 2B] This figure shows an exemplary interchangeable suction cup assembly of one embodiment of the present disclosure. [Figure 2C] This figure shows an exemplary mounting assembly of one embodiment of the present disclosure. [Figure 3] This figure shows an example of a sorting robot in combination with a suction gripping machine according to one embodiment of the present disclosure. [Figure 3A] This figure shows an example of a sorting robot in combination with a suction gripper according to one embodiment of the present disclosure. [Figure 3B] This figure shows an example of a sorting robot in combination with a suction gripper and vacuum system according to one embodiment of the present disclosure. [Figure 4] This figure shows an exemplary vacuum generator according to one embodiment of the present disclosure. [Figure 4A] This figure shows an exemplary vacuum generator according to one embodiment of the present disclosure. [Figure 5] Figure 5 shows an alternative illustrative suction gripping device of one embodiment of the present disclosure. [Figure 5A] Figure 5A shows an alternative illustrative suction gripping device of one embodiment of the present disclosure. [Figure 6] This figure shows another alternative illustrative suction gripping device of one embodiment of the present disclosure. [Figure 7] This figure shows another alternative illustrative suction gripping device of one embodiment of the present disclosure. [Figure 8] This figure shows another alternative illustrative suction gripping device of one embodiment of the present disclosure. [Modes for carrying out the invention]

[0009]

[0017] Following common practice, the various features described are not depicted to a fixed scale, but rather to highlight the features relevant to this disclosure. Reference letters indicate similar elements throughout the figures and text.

[0010]

[0018] The following detailed description refers to the accompanying drawings, which form part of this specification, and the drawings are shown as specific embodiments that may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice them, and it should be understood that other embodiments may be available, and that logical, mechanical, and electrical modifications may be made without departing from the scope of this disclosure. Therefore, the following detailed description should not be taken as limiting.

[0011]

[0019] In many industrial facilities, such as recycling facilities and / or other waste sorting facilities, materials are often transported via conveyor belts when various sorting machines separate waste based on various criteria, such as the type of material. For example, an initial material intake conveyor belt may transport a group of mixed waste, including, for example, glass, plastic, and cardboard objects. As the waste is being transported, sorting machines may be used to selectively separate various objects and transport them to different parts of the facility based on the type of material. For example, glass bottles may be separated and transported to a different part of the facility from plastic milk cartons. In the exemplary embodiments described herein, waste moving along a conveyor belt is used as the exemplary object of study, but it should be understood that in alternative implementations of these embodiments, the object of study does not have to be waste and may include any type of material that sorting and / or separation is desired. Furthermore, while a conveyor belt is used as the exemplary transport mechanism for transporting the object of study within the range of a suction gripper, it should be understood that other transport mechanisms may be used in alternative implementations of these embodiments.

[0012]

[0020] According to embodiments of the present disclosure, a computerized robotic system equipped with a suction gripper is utilized to pick a selected object, referred to herein as the "target object," from a conveyor belt (or other transport mechanism) for the purpose of collecting and separating a selected substance or removing unwanted substances (i.e., objects that may be regarded as material contaminants) from the conveyor belt. As will be appreciated, particularly in waste and recycling facilities, the target objects that need to be removed from the conveyor belt are dirty, crushed, and / or folded, which may make it difficult for the suction gripper to create a good seal on the object to secure the target object and lift it from the conveyor belt. Further, the conveyor belt, the target object, and the surrounding atmosphere are generally expected to contain fine particles, dust, or other contaminants (all of which are generically referred to herein as "dust") that are drawn into the suction gripper when the suction gripper attempts to pick up the target object.

[0013]

[0021] The inventors of this disclosure have found that one reason why suction grippers available today in the art are hindered from operating in such facilities is that the gripping elements used by suction grippers to attempt to draw a vacuum on the surface of an object are physically too small (e.g., diameter and / or area) to obtain sufficient suction force to hold the object, given that a complete seal cannot be achieved due to the surface condition of the object. In other words, the degree of dust contamination and disordered, irregular surface shapes make it difficult or impossible to establish and maintain a vacuum seal for many objects. To address this problem, embodiments of this disclosure provide a suction gripper including a gripping port that is enlarged compared to suction grippers available today in the art. Increasing the diameter of the gripping port increases the number of surface irregularities, defects, and contaminants that the gripping port must interact with. However, the total amount of air that can be drawn into the suction gripper by the gripping port of the suction gripper (and therefore the maximum vacuum force that the suction gripper can apply to the object) is proportionally increased by a larger factor. As a result, a mechanism is obtained that can achieve sufficient retention of the object (even if imperfectly sealed) so that the object can be lifted from the conveyor belt and moved to the desired location.

[0014]

[0022] For example, in some embodiments disclosed herein, the suction gripper may include a gripping port having a diameter of at least 1 / 4 inch (0.635 cm) (or, in the case of a non-circular gripping port, an equivalent area). In some embodiments, the vacuum can be drawn through such a gripping port by a vacuum source that can draw at least 5 SCFM (5 standard cubic feet per minute; approximately 141.6 liters) per minute through the port at the point where the suction gripper contacts the surface of the target object. Applying such a vacuum through the gripping port has the undesirable side effect of drawing additional dust and other potential substances such as plastic bags and wraps into the internal components of the suction gripper mechanism. Further contamination within the suction gripper mechanism is also exacerbated by the fact that gaps in the imperfect seal between the suction gripper and the target object continue to draw in dust and contaminants even after the suction gripper has achieved sufficient retention to lift the object. For these reasons, the embodiments presented herein may also use a reversal of the air flow, as discussed in more detail below.

[0015]

[0023] Figure 1 shows a robotic vacuum sorting system 10 of one embodiment of the present disclosure. As shown in Figure 1, a suction gripping mechanism 100 is pivotably mounted on one or more arms of a sorting robot 150. The system 10 supplies airflow to the suction gripping mechanism 100 via a vacuum system 140. In some embodiments, the vacuum system 140 may be further pneumatically coupled to an air source 145, which may include a blower, an air compressor, a compressed air reservoir, or some combination thereof. The present disclosure may refer to “airflow,” “air compressor,” and “air” with respect to other elements, but it should be understood that the term “air” is used in an inclusive sense to refer to any compressible gas or mixture of gases. The sorting robot 150 and the vacuum system 140 are coupled to and controlled by a robotic control logic electronics unit 160. In some embodiments, the robot control logic electronics unit 160 may be implemented having a logic circuit or, otherwise, one or more processing units 161 coupled to a memory device 164 and programmed to execute code 163 to perform functions attributed to the robot control logic electronics unit 160 as described herein (as shown in Figure 1A). Thus, to transmit control signals, the robot control logic electronics unit 160 may further include elements for generating electrical signals and / or control air signals to the sorting robot 150 and the vacuum system 140. In some embodiments, the robot vacuum sorting system 10 further includes at least one imaging device 162 (e.g., an infrared camera, a visible spectrum camera, or some combination thereof) directed towards the conveyor belt 50 that transports objects of interest (indicated as 55) within the operating range of the robot vacuum sorting system 10. The imaging device generates an image signal that is sent to the robot control logic electronics unit 160, which can be used by the robot control logic electronics unit 160 to send control signals to the sorting robot 150 to position the suction gripping mechanism 100, and to send airflow control signals to the vacuum system 140 to initiate the capture operation, as will be further described below.In some embodiments, the robotic vacuum sorting system 10 may also include a pressure sensor 143 that provides a signal to the robotic control logic electronics unit 160 so that a vacuum can be successfully obtained, as will be discussed further below.

[0016]

[0024] Figures 2 and 2A show a side view and an inclined side view, respectively, of a suction gripping mechanism 100 (also referred to herein as the “suction gripping mechanism 100”) of one embodiment of the present disclosure as described with respect to Figure 1. As shown in Figure 2, the suction gripping mechanism 100 comprises a body assembly 202 housing a linear bearing component 209 and a mounting assembly 203 that is firmly mounted around the body assembly 202 housing the linear bearing component 209. In one embodiment, the mounting assembly 203 includes a ring-shaped assembly having a through hole through which the linear bearing component 209 is positioned and firmly mounted. In some embodiments, the mounting assembly 203 and the body assembly 202 may be firmly joined to each other by welding or mechanical fasteners, etc. In some embodiments, the mounting assembly 203 and the body assembly 202 may include a single integrated part. The mounting assembly 203 further comprises one or more mounting points 204, and the mounting assembly 203 is pivotably coupled to the sorting robot 150 via these mounting points 204.

[0017]

[0025] As shown in Figures 2 and 2A, the suction gripping mechanism 100 further comprises a linear shaft element 201 fixed within a linear bearing component 209 and having the freedom to move axially up and down with respect to the axis of the linear bearing component 209. The linear shaft element 201 includes an internal airflow passage 220 configured to transmit airflow (having positive or negative air pressure) between an airflow application port 207 located at a first end of the linear shaft element 201 and a gripping port 206 located at a second end on the opposite side of the linear shaft element 201. As shown in Figure 2B, a suction cup assembly 215 comprising a flexible cup element 216 (which may be made of rubber, latex, or other flexible material) and a removable coupler 210 may be attached to the gripping port 206. As described above, the linear shaft element 201 is free to move axially up and down within the linear bearing component 209. The spring mechanism 205 is positioned between the mounting assembly 203 and a retaining device 212 located near the distal second end of the straight shaft adjacent to the gripping port 206, to hold the straight shaft element 201 in a fully extended position when the suction gripper 100 is not holding the target object 55. A top view of the mounting assembly 203 as seen from the airflow application port 207 is provided in Figure 2C.

[0018]

[0026] Figures 3, 3A, and 3B show the robot actuator 352 and robot arm 354 of the sorting robot 150, with the suction gripping mechanism 100 coupled to the distal end of the robot arm 354. The robot actuator 352 controls the position of the robot arm 354 based on robot control signals from the robot control logic electronics unit 160 to position the suction gripping mechanism 100. As described above, the distal end of the robot arm 354 may be configured to engage with the mounting point 204 of the mounting assembly 203 to secure the suction gripping mechanism 100 to the robot arm 354. In one such embodiment, the mounting assembly 203 may be configured to fit a delta-style robot, as shown in Figures 3, 3A, and 3B. In other embodiments, other types of robots may be available. Although the sorting robot 150 in Figures 3, 3A, and 3B is shown to have three robotic arms 354, it should be understood that in other embodiments the sorting robot 150 may have more or fewer robotic arms 354.

[0019]

[0027] In operation, the robot control logic electronic device 160 is programmed to move both the robot arm 354 and the vacuum system 140 to perform what is considered in this specification to be a “capture operation” or “pick” of the target object 55. In some embodiments, the capture operation includes at least positioning the suction gripper 100 over the target object 55, activating the vacuum system 140, and controlling the sorting robot 150 to lower the suction gripper 100 toward the target object 55 and make contact with the surface of the target object 55 while applying a vacuum. The system can know to some extent how tall the target object 55 is before it attempts to pick it (for example, by processing data such as an image acquired by the imaging device 162 or data from another sensor), but the sorting robot 150 cannot be certain of the exact height of the target object 55. Therefore, the suction gripping mechanism 100 may be configured such that when contact is made with the target object 55, the contact force causes the lower end of the linear shaft element 201 to slide upward into the linear bearing component 209 (which in turn causes the opposite upper end of the linear shaft element 201 to slide out of the linear bearing component 209), thereby compressing the spring mechanism 205. In this way, target objects of various dimensions can be accepted without causing damage to the components of the robot 150 due to impact forces. Once the capture operation is complete and the vacuum is deactivated by the robot control logic electronics unit 160, the spring mechanism 205 extends the linear shaft element 201 back to its fully extended position. In some embodiments, upon completion of each capture operation, the robot control logic electronics unit 160 controls the vacuum system 140 to arbitrarily reverse the airflow through the suction gripping machine 100 so that positive air flows out of the gripping port 206. The reversal of the airflow not only frees the object 55 from the suction cup assembly 215 and / or propels it, but also purges dust from the vacuum system 140, and also removes other (plastic) drawn into the internal airflow passage 220 of the suction gripper 100. It can also be used to discharge substances (such as plastic bags or plastic wrap).

[0020]

[0028] In some embodiments, the mounting assembly 203 may be configured in a central mounting configuration, that is, the mounting assembly 203 positions the suction gripper 100 at a central position between multiple robot arms 354, as shown by the examples in Figures 3, 3A, and 3B. As shown in Figure 2C, in some embodiments, the mounting assembly 203 may comprise a plurality of spherical mounting points 204 positioned to surround the mounting assembly 203, each fitted to pair with a complementary socket element at the distal end of a robot arm 354, thereby defining a ball-and-socket coupling that secures the mounting assembly 203 to the robot arm 354. The ball-and-socket coupling provides sufficient freedom for the robot arm 354 to pivot in multiple directions around the suction gripper 100 with sufficient clearance to avoid interference while positioning and manipulating the suction gripper 100 during the gripping operation. The central mounting configuration also allows the linear shaft element 201 to move freely so as to extend its range upward through the linear bearing component 209 and beyond the mounting assembly 203, without interfering with the free movement of the robot arms 354, as would be the case if the suction gripper 100 were mounted at a position offset with respect to a central axis defined at the center point between the robot arms 354. In one embodiment, each robot arm 354 is fixed to the mounting assembly 203 by a set or pair of ball-and-socket connection points (shown as 204-1, 204-2, and 204-3), each positioned in a plane oriented perpendicular to the orientation of the linear shaft element 201 within the linear bearing component 209.

[0021]

[0029] As described above, the flexible cup element 216 shown in Figure 2B can be attached to the gripping port 206 by an interchangeable coupler 210. As shown in Figures 2 and 2A, the coupler may include a barbed lip or recess (shown in 211) over which the flexible cup element 216 is extended or held by friction fitting in order to secure the flexible cup element 216 to the coupler 210. The coupler 210 may be secured around the gripping port 206 by, for example, a set screw that is tightened to secure the coupler to the straight shaft element 201. In other embodiments, a different fastening technique may be used. For example, in some embodiments, the coupler 210 may be fastened to the straight shaft element 201 by a screw connection. In this way, the facility can keep pre-assembled combinations of flexible cup elements 216 attached to the interchangeable coupler 210 as spare parts. The flexible cup element 216 is bound to deteriorate during operation, and the replaceable coupler 210 can be quickly removed from the gripping port 206, and a new assembly including a new flexible cup element 216 pre-installed on the new replaceable coupler 210 can be quickly attached to the gripping port.

[0022]

[0030] As shown in Figure 3B, in some embodiments, the vacuum system 140 includes a vacuum generator 342 coupled to the airflow application port 207 of the suction gripper 100 by an air supply pipe 344. The air supply pipe 344 may be routed along one of the robot arms 354 and fixed to it. In one embodiment, the vacuum generator 342 includes a compressed air-driven Venturi vacuum system and / or Coanda vacuum system. That is, the driving force for drawing a vacuum through the supply pipe 344 is the flow of compressed air flowing through the vacuum generator 342 (supplied, for example, by an air source 145). The use of a Venturi and / or Coanda vacuum generator avoids the problem of drawing contaminated air into the intake of the vacuum motor. That is, if the vacuum motor is used in a dusty environment rich in particulate matter, an in-line filter would be needed to prevent the accumulation of contaminants that would eventually contaminate the inside of the vacuum motor. However, in dusty environments rich in particulate matter, the in-line filter would also frequently clog, limiting the vacuum force available to the suction gripper 100 for securing the object 55. Thus, such an in-line filter would require frequent maintenance, resulting in significant downtime for the system 10. Utilizing a Venturi and / or Coanda vacuum generator in combination with the suction gripper 100 reduces the need for filtration, as such a vacuum system can first separate dust particles from the airflow received from the suction gripper. Dust not separated by the vacuum system can be conveniently discharged, for example, into an optional holding container, as opposed to being drawn into a vacuum motor.

[0023]

[0031] Figures 4 and 4A show an exemplary vacuum generator 342 that may be used to implement a vacuum system 140 for some embodiments of the present disclosure. The vacuum generator 342 comprises a chamber 414 having a pressurized air inlet port 410, a control airflow port 412, and an exhaust port 416. In this particular exemplary embodiment, the chamber 414 is a venturi chamber having one or more venturi structural features (such as a venturi nozzle). It should be understood that in other exemplary embodiments, the chamber 414 of the vacuum generator 342 may instead operate on the Coanda principle and have corresponding Coanda structural features. In one embodiment, the pressurized air inlet port 410 receives a supply of pressurized air from a pressurized air source 145. The supply of pressurized air from the pressurized air source 145 to the pressurized air inlet port 410 may be selectively controlled by a valve 422 that responds to an airflow control output from a robotic control logic electronics unit 160. In this way, the robot control logic electronic device 160 can control the activation and deactivation of the gripping force applied by the suction gripper 100. During operation, a positive pressure airflow applied at the pressurized air injection port 410 flows into the venturi chamber 414 and exits through the exhaust port 416. The airflow traversing one or more venturi features within the chamber 414 creates a negative air pressure at the control airflow port 412, which draws air into the chamber 414 through the piping 344 connected to the suction gripper 100, thus creating a suction force at the gripping port 206 of the suction gripper 100. One example of a device featuring such a venturi chamber 414 is the "Adjustable Inducer / Venture System" by Airtrim Pneumatic Conveyance Systems, described in U.S. Patent No. 6,732,897, the entirety of which is incorporated herein by reference. See also U.S. Patent No. 3,716307 and U.S. Patent Application Publication No. 2004 / 0055250, both of which are incorporated herein by reference in their entirety.

[0024]

[0032] In some embodiments, the vacuum generator 342 may include a reversible airflow generator, meaning that the direction of the airflow at the control airflow port 412 can be reversed. As described above, in some embodiments, upon completion of each capture operation (or at other times), the robot control logic electronics unit 160 may control the vacuum system 140 to reverse the airflow through the suction gripper 100 so that positive-pressure air flows out of the gripping port 206. This reversal may be used to release and / or propel the target object 55 from the suction cup assembly 215, to purge dust from the vacuum system 140, and / or to expel other material (such as a plastic bag or wrap) drawn into the internal airflow passage 220 of the suction gripper 100. To implement reversible airflow, the vacuum generator 342 shown in Figures 4 and 4A may further comprise an airflow direction control piston 420, which is operated by an airflow control signal output from the robot control logic electronics unit 160. The airflow direction control piston 420 includes an extendable shaft 419 and a stopper 418 positioned and aligned with the exhaust port 416 of the venturi chamber 414 (shown in 424). During the capture operation, as vacuum is drawn from the suction gripper 100, the extendable shaft 419 retracts into the piston 420 and the stopper 418 is pulled away from the exhaust port 416 (as shown in Figure 4), allowing air to exit the exhaust port 416 of the venturi chamber 414. To reverse the airflow so that a positive pressure airflow is pushed out of the suction gripper 100, the robot control logic electronics unit 160 acts on the airflow direction control piston 420 to extend the shaft 419 and insert the stopper 418 into the exhaust port 416 (as shown in Figure 4A). Closing the exhaust port 416 disrupts the normal airflow within the venturi chamber 414 so that the pressurized air applied to the input port 410 flows out instead through the control airflow port 412 and into the air supply piping 344, and as a result, a positive pressure airflow exits through the gripping port 206. It should be understood that the reversible airflow from the vacuum system 140 may be obtained by other means.For example, in one embodiment, the vacuum generator 342 may include a switchable bypass valve or other similar mechanism that can be controlled by a robotic control logic electronic device 160 to selectively switch between applying the supply of pressurized air to the input port 410 and applying it directly to the air supply piping 344. In other words, the vacuum chamber 414 filled with compressed air reverses the airflow to "push" contaminants into the vacuum hose 344. In this way, the system 10 can self-clean.

[0025]

[0033] In yet another embodiment, the robot vacuum sorting system 10 may include a pressure sensor 143 (which may be, for example, coupled to or otherwise placed within the vacuum piping 344) so ​​that the system 10 can detect whether or not a vacuum has been achieved or to what extent a vacuum has been achieved. If a vacuum pressure exceeding a predetermined threshold is detected during the capture operation, this measurement may indicate a successful capture of the target object 55. The absence of such detection may indicate that the robot 150 should attempt to capture again, or the robot control logic electronics unit 160 may store this data in its memory for later use. Furthermore, the robot control logic electronics unit 160 may optionally detect an obstruction in the vacuum system 140 by activating the vacuum system when the vacuum system is not attempting to pick up the target object 55. In this case, a vacuum should not be achieved, as air should be able to flow freely through the suction gripper system 100. If a vacuum is detected, it may mean that an undesirable object is obstructing the free flow of air. The pressure sensor 143 may include any form of vacuum detection mechanism, which is an analog or digital pressure sensor, and may also be connected to a programmable logic control device (PLC), which is part of a robot control logic electronic device 160, for example.

[0026]

[0034] In yet another alternative embodiment, as shown in Figures 5 and 5A, a single suction gripper 100 may comprise a plurality of linear shaft elements 201, each of which is contained within its own body assembly and linear bearing components 209 in the same manner as described in any of the above embodiments, all of which are held within a single mounting assembly 203 for securing this alternative suction gripper 100 to the robot arm 354. Figures 5 and 5A provide an example showing a suction gripper 100 having three independently operating linear shaft elements 201, but other embodiments may have two or more independently operating linear shaft elements 201. Each of the plurality of linear shaft elements 201 comprises its own gripping port 206, including an associated suction cup assembly 215, so that each linear shaft element 201 can operate essentially independently during the gripping operation to attempt to secure the object 55. In some embodiments, each linear shaft element may be coupled to a vacuum system 140 by dedicated piping 344. In other embodiments, each airflow application port 207 of the linear shaft elements 201 may be coupled to a common manifold, which is coupled to a vacuum system 140. During the capture operation, each linear shaft element 201 can be individually repositioned, and their associated suction cups are required to synchronously adapt to the local surface contour of the object to be captured. A suction gripper 100 having multiple linear shaft elements 201 increases the opportunity for the system 10 to capture the object 55.

[0027]

[0035] In yet another alternative embodiment, as shown in Figures 6, 7, and 8, the vacuum generator 342 (operating under the Venturi or Coanda principle) may be incorporated into the linear shaft element 201 or otherwise integrated with the linear shaft element 201. Thus, the air source 145 (which in this case may again include, for example, a blower, an air compressor, a compressed air reservoir, or a combination thereof) is directly coupled to the airflow application port 207 of the suction gripper 100, as shown in Figures 6 and 7.

[0028]

[0036] In this case, the linear shaft element 201 is also the vacuum generator 342, and therefore its exterior should be a smooth shaft so that the vacuum generating device can still slide within the linear bearing component 209 as described in any of the embodiments above. In this alternative suction gripper 100, the airflow application port 207 includes a port to which compressed air is applied. The vacuum-generating structural feature 810 is located within the body of the linear shaft element 201 (this may be a Venturi or Coanda structural feature), and as compressed air flows into the airflow application port 207 and out through the exhaust port 812, the structural feature 810 draws a vacuum through the internal airflow passage 220, as shown in Figure 8. The spring mechanism 205 surrounds the body of the linear shaft element 201 as described above. In some embodiments, the airflow through the internal airflow passage 220 can be reversed by blocking the exhaust port 812 using a controlled stopper, as described above. One potential benefit of this specific embodiment is the absence of hoses that could become clogged with the aspirated object. Furthermore, because the system generates the vacuum near where it is used, strength and flow can be maintained with limited loss by avoiding the addition of connectors and piping.

[0029]

[0037] Exemplary Embodiments Example 1 includes a robotic vacuum sorting system comprising: a suction gripping mechanism pivotably mounted on one or more robotic arms of a sorting robot; a vacuum system coupled to the suction gripping mechanism; a robotic control logic electronics unit coupled to the sorting robot and the vacuum system; and an imaging device coupled to the robotic control logic electronics unit, wherein the robotic control logic electronics unit outputs one or more robotic control signals for controlling one or more robotic arms of the sorting robot in response to an image signal from the imaging device, and outputs one or more airflow control signals to the vacuum system to perform a capture operation on an object using the suction gripping mechanism, and during the capture operation, the robotic control logic electronics unit outputs control signals such that the vacuum system draws a vacuum at the gripping port of the suction gripping mechanism when the suction gripping mechanism is applied to capture and hold an object.

[0030]

[0038] Example 2 includes the system of Example 1, wherein during the capture operation, the robot control logic electronics unit outputs a control signal to cause the vacuum system to first create a vacuum at the gripping port of the suction gripping mechanism and then reverse the air pressure to purge the air from the gripping port of the suction gripping mechanism when the suction gripping mechanism is applied to capture and hold the target object.

[0031]

[0039] Example 3 includes one of the systems from Examples 1 or 2, wherein the vacuum system is coupled to an air source, where the vacuum system is configured to selectively convert a positive-pressure airflow supplied from the air source into vacuum suction in a suction gripping mechanism.

[0032]

[0040] Example 4 includes any of the systems in Examples 1 to 3, wherein the vacuum system comprises a vacuum generator, and the vacuum generator includes a compressed air-driven Venturi vacuum system or a compressed air-driven Coanda vacuum system.

[0033]

[0041] Example 5 includes the system of Example 4, where the vacuum generator is incorporated into the suction gripping mechanism.

[0034]

[0042] Example 6 includes a system from any of Examples 1 to 5, wherein the suction gripping mechanism comprises a body assembly housing linear bearing components; a linear shaft element fixed within a linear bearing and having freedom to move axially up and down with respect to the axis of the linear bearing; an internal airflow passage within the linear shaft element configured to transmit airflow between an airflow application port located at a first end of the linear shaft element and a gripping port located at a second end on the opposite side of the linear shaft element; a suction cup assembly including a flexible cup element coupled to the gripping port by a removable coupler; and a mounting assembly rigidly fixed around the body assembly, further including one or more mounting points pivotably coupled to one or more robot arms of a sorting robot.

[0035]

[0043] Example 7 includes the system of Example 6, wherein the suction gripping mechanism further comprises a spring mechanism positioned around the outer circumference of a linear shaft element between a mounting assembly and a locking device, the spring mechanism being configured to extend the linear shaft element to a fully extended position when the suction gripping mechanism is not holding an object.

[0036]

[0044] Example 8 includes any system from Examples 6-7, wherein the linear shaft element has the freedom to move through the linear bearing so as to extend at least partially above the mounting assembly in response to the force applied to the suction cup assembly by contact with the object during the performance of the capture operation.

[0037]

[0045] Example 9 includes the system of Example 8, wherein the vacuum system includes a vacuum generator coupled to the airflow application port of the suction gripping mechanism.

[0038]

[0046] Example 10 includes the system of Example 9, wherein the vacuum generator comprises a chamber having a pressurized air inlet port, a control airflow port, and an exhaust port, the pressurized air inlet port being coupled to an air source, and the control airflow port being coupled to an airflow application port of a suction gripping mechanism.

[0039]

[0047] Example 11 includes the system of Example 10, wherein one or more structural features within the chamber are configured to create negative air pressure at a control airflow port that draws air from the suction gripping mechanism into the chamber, thereby generating a suction force at the gripping port.

[0040]

[0048] Example 12 includes any system from Examples 1 to 11, wherein the vacuum system comprises a vacuum generator, the vacuum generator further comprising an airflow direction control piston that responds to an airflow control signal output from a robot control logic electronics unit, the airflow direction control piston comprising an extendable shaft having a stopper, aligned to the exhaust port of a chamber, and during the execution of a capture operation, the robot control logic electronics unit operates the airflow direction control piston to retract the extendable shaft in order to set the vacuum generator to draw a negative pressure vacuum airflow at the gripping port of the suction gripping mechanism, and during the execution of a capture operation, the robot control logic electronics unit also operates the airflow direction control piston to extend the extendable shaft to close the exhaust port of the chamber in order to set the vacuum generator to push a positive pressure airflow out of the gripping port of the suction gripping mechanism.

[0041]

[0049] Example 13 includes any system from Examples 1 to 12, wherein the suction gripping mechanism further comprises a plurality of body assemblies, each housing a linear bearing component and a linear shaft element fixed within each linear bearing assembly, the linear shaft element comprising an internal airflow passage configured to transmit airflow between an airflow application port located at a first end of the linear shaft element and a gripping port located at a second end opposite the linear shaft element.

[0042]

[0050] Example 14 includes a suction gripping mechanism comprising: a body assembly housing a linear bearing component; a linear shaft element fixed within the linear bearing and having the freedom to move axially up and down with respect to the axis of the linear bearing; an internal airflow passage within the linear shaft element configured to transmit airflow between an airflow application port located at a first end of the linear shaft element and a gripping port located at a second end on the opposite side of the linear shaft element; and an interchangeable coupler configured to be mechanically coupled to the gripping port and to fix a flexible suction cup to the interchangeable coupler.

[0043]

[0051] Example 15 includes the mechanism of Example 14, wherein the interchangeable coupler comprises a latched lip or recess for securing a flexible suction cup.

[0044]

[0052] Example 16 includes any mechanism of Examples 14-15, further comprising a vacuum generator incorporated within a body assembly, wherein an internal air passage passes through the vacuum generator, an air flow application port is coupled to the vacuum generator, and the vacuum generator includes structural features configured to draw a vacuum through the internal air passage when compressed air is applied to the air flow application port.

[0045]

[0053] Example 17 includes the mechanism of Example 16, where the vacuum generator is configured to draw at least 5 SCFM (approximately 141.6 liters) of air per minute through the gripping port.

[0046]

[0054] Example 18 includes any mechanism from Examples 14-17, wherein the intake opening of the gripping port has an area greater than or equal to the area of ​​an opening with a diameter of 1 / 4 inch (0.635 cm).

[0047]

[0055] Example 19 includes a robotic vacuum sorting system comprising: a suction gripping mechanism pivotably mounted on one or more robotic arms of a sorting robot; a reversible vacuum system coupled to the suction gripping mechanism; a robotic control logic electronics unit coupled to the sorting robot and the reversible vacuum system; and an imaging device coupled to the robotic control logic electronics unit, wherein the robotic control logic electronics unit outputs one or more robotic control signals for controlling one or more robotic arms of the sorting robot in response to an image signal from the imaging device, and outputs one or more airflow control signals to the reversible vacuum system to perform a capture operation on an object using the suction gripping mechanism, wherein during the capture operation, the robotic control logic electronics unit outputs control signals such that the reversible vacuum system first draws a vacuum at the gripping port of the suction gripping mechanism and then reverses the air pressure to purge air from the gripping port of the suction gripping mechanism when the suction gripping mechanism is applied to capture and hold the object, and the vacuum system comprises a vacuum generator incorporated within the suction gripping mechanism.

[0048]

[0056] Example 20 includes the system of Example 19, wherein the suction gripping mechanism comprises a body assembly housing a linear bearing component; a linear shaft element fixed within the linear bearing and having freedom to move axially up and down with respect to the axis of the linear bearing; an internal airflow passage within the linear shaft element configured to transmit airflow between an airflow application port located at a first end of the linear shaft element and a gripping port located at a second end on the opposite side of the linear shaft element; and an interchangeable coupler configured to be mechanically coupled to the gripping port and to fix a flexible suction cup to the interchangeable coupler.

[0049]

[0057] Example 21 includes any of the systems from Examples 19-20, wherein the vacuum generator includes a compressed air-driven Venturi vacuum system or a compressed air-driven Coanda vacuum system.

[0050]

[0058] Example 22 includes any system from Examples 19–21, where the vacuum generator is configured to draw at least 5 SCFM (approximately 141.6 liters) of air per minute through the gripping port.

[0051]

[0059] Example 23 includes any system from Examples 19-22, wherein the intake opening of the gripping port has an area greater than or equal to the area of ​​an opening with a diameter of 1 / 4 inch (0.635 cm).

[0052]

[0060] In various alternative embodiments, the system elements, method steps, or examples described herein (e.g., sorting robots, robot control logic electronics, imaging devices, and / or any sub-components thereof) may be implemented using one or more computer systems, field-programmable gate arrays (FPGAs), or similar devices, and / or comprising a processing unit coupled to a memory device that executes code to implement those elements, processes, steps, or examples, the code being stored on a non-temporary data storage device. Thus, other embodiments of the herein may include elements that include program instructions residing on a computer-readable medium, which, when implemented by such a computer system, enable those elements to implement the embodiments described herein. In this specification, the term “computer-readable medium” means a tangible storage device having a non-temporary physical form. Such non-temporary physical forms may include, but are not limited to, computer memory devices such as punch cards, magnetic disks or tapes, any optical data storage system, flash read-only memory (ROM), non-volatile ROM, programmable ROM (PROM), erasable programmable ROM (E-PROM), random access memory (RAM), or any other form of permanent, semi-permanent, or temporary memory storage system or device having a physical, tangible form. Program instructions include, but are not limited to, computer executable instructions executed by computer system processing units, and hardware description languages ​​such as the Very High Speed ​​Integrated Circuit (VHSIC) Hardware Description Language (VHDL).

[0053]

[0061] While specific embodiments are illustrated and described herein, it will be understood by those skilled in the art that any configuration planned to achieve the same objective may be substituted for the specific embodiments shown. This application is intended to cover any adaptation or variation of the presented embodiments. Accordingly, the embodiments are expressly intended to be limited only by the claims and their equivalents.

Claims

1. A sorting system comprising:

1. A processor comprising: Receives an image signal from an imaging device; In response to the image signal, positioning one or more robotic arms of the sorting system over an object; having the one or more robotic arms lower a suction gripper mechanism toward the target object, the suction gripper mechanism comprising an adjustably positionable linear shaft coupled to the one or more robotic arms and coupled to a corresponding suction cup; causing a vacuum system to pull a vacuum through the suction gripper mechanism to pick up the target object; a processor configured to reverse air pressure in the vacuum system to direct a positive air flow through the suction gripper mechanism to propel the target object; a memory coupled to the processor and configured to operate with the instructions; A sorting system comprising:

2. The sorting system of claim 1, wherein the processor is further configured to pick up the target object by causing the vacuum system to pull a vacuum through the suction gripper mechanism and selecting a corresponding supply of pressurized air.

3. A sorting system as described in claim 1, wherein the vacuum system is equipped with a reversible air flow generating device.

4. The processor further comprises: Receives vacuum pressure from the pressure sensor, Comparing the vacuum pressure to a predetermined threshold. The sorting system of claim 1 , configured as follows:

5. The processor further comprises: determining that the vacuum pressure is greater than or equal to the predetermined threshold; Determining that the target object is successfully grasped The sorting system according to claim 4, configured as follows.

6. The processor further comprises: determining that the vacuum pressure is below the predetermined threshold; Determining that the target object is not successfully grasped The sorting system according to claim 4, configured as follows.

7. The sorting system of claim 6, wherein the processor is further configured to cause the vacuum system to pull the vacuum through the suction gripper mechanism in a subsequent attempt to pick up the target object.

8. The sorting system of claim 6, wherein the processor is further configured to store in the memory the determination that the target object was not successfully grasped.

9. The processor is further configured to determine whether an obstruction is present in the vacuum system; determining that the one or more robotic arms are not lowered toward the target object; activating the vacuum system; Determine if the vacuum is detected by the suction gripper mechanism. The sorting system of claim 1 , configured as follows:

10. The processor further comprising: determining that the vacuum has been detected by the suction gripper mechanism; 10. The sorting system of claim 9, configured to determine that the obstruction is present in the vacuum system in response to the determining that the vacuum has been detected by the suction gripper mechanism.

11. The processor further comprising: determining that the vacuum is not detected by the suction gripper mechanism; 10. The sorting system of claim 9, configured to determine that the obstruction is not present in the vacuum system in response to determining that the vacuum is not detected by the suction gripper mechanism.

12. The sorting system of claim 1, wherein the vacuum system is associated with an air source, the air source comprising one or more of a blower, an air compressor, and a compressed air storage tank.

13. The sorting system of claim 1, wherein the vacuum system comprises a vacuum generating device, the vacuum generating device comprising a compressed air driven Venturi vacuum system.

14. The sorting system of claim 1, wherein the vacuum system comprises a vacuum generating device, the vacuum generating device comprising a compressed air driven Coanda vacuum system.

15. The sorting system of claim 1, wherein the linear shaft is adjustable in a compressed position, and in response to contact with the target object, the linear shaft is configured to slide by a linear bearing and a spring mechanism wrapped around the linear shaft and configured to compress it.

16. The sorting system of claim 1, wherein the vacuum system is integrated with the straight shaft.

17. A robotic vacuum sorting system comprising: a suction gripper mechanism pivotally mounted to one or more robotic arms of the sorting robot, the suction gripper mechanism comprising an adjustably positionable linear shaft coupled to a corresponding suction cup; a vacuum system coupled to the suction gripper mechanism; a robot control logic electronics device coupled to the sorting robot and to the vacuum system; an imaging device coupled to the robot control logic electronics; the vacuum system is configured to couple to an air source and to selectively convert a positive air flow provided by the air source into a vacuum suction at the suction gripper mechanism; the robot control logic electronics is responsive to image signals from the imaging device to output one or more robot control signals for controlling the one or more robot arms of the sorting robot and output one or more air flow control signals to the vacuum system to perform a grab operation on a target object using the suction gripper mechanism; During the capturing operation, the robot control logic electronics outputs a first set of control signals such that the vacuum system draws a vacuum at a gripping port of the suction gripper mechanism when the suction gripper mechanism is applied to capture and hold the target object; and after completion of the capture operation, the robot control logic electronics outputs a second set of control signals to cause the vacuum system to reverse air flow through the suction gripper mechanism to propel the target object.

18. The robotic vacuum sorting system of claim 17, wherein the linear shaft is adjustable in a compressed position, and in response to contact with the target object during the capture operation, the linear shaft is configured to slide via a linear bearing and a spring mechanism wrapped around the linear shaft and configured to compress.

19. The robot control logic electronics further configured to determine whether an obstacle is present in the vacuum system; determining that the one or more robotic arms are not lowered toward the target object; activating the vacuum system; Determining if the vacuum is detected by the suction gripper mechanism 20. The robotic vacuum sorting system of claim 18 configured to:

20. The robot control logic electronic device comprises: determining that the vacuum has been detected via the suction gripper mechanism; 20. The robotic vacuum sorting system of claim 19, further configured to determine that the obstruction is present in the vacuum system in response to the determining that the vacuum is detected via the suction gripper mechanism.

21. The robot control logic electronic device comprises: determining that the vacuum is not detected via the suction gripper mechanism; 20. The robotic vacuum sorting system of claim 19, further configured to determine that the obstruction is not present in the vacuum system in response to the determining that the vacuum is not detected via the suction gripper mechanism.

22. The robotic vacuum sorting system of claim 17, wherein the vacuum system is integrated with the linear shaft.

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