Compliant Perimeter End Effector for Sewing Robots

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Solution Overview

Problem

In automated production of sewn materials, improper handling by robotic end effectors leads to out-of-spec products due to material slip, especially prevalent with non-slip or high friction materials like mats and rugs, resulting in economic losses.

Innovation Solution

The implementation of compliant perimeter end effectors with distributed compliant material contact elements around the perimeter, which provide spring-like functionality to evenly distribute force and adapt to surface variations, preventing pinching and ensuring consistent material handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional rigid end effectors are used to handle high friction materials, then the gripping force can be increased, but material slip occurs due to uneven force distribution and inability to adapt to surface variations

Engineering Contradiction:

Improvematerial handling consistencyVSAvoidmaterial slip prevention

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The end effector is divided into multiple independent compliant contact elements distributed around the perimeter. Each element can independently deflect and apply force, allowing the system to handle high friction materials without slip by distributing gripping force across multiple segments rather than relying on a single rigid contact point.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contact elements are designed with compliant properties that allow them to change their mechanical parameters (deflection, contact force) in response to surface variations. This compliance enables the end effector to adapt to uneven surfaces and maintain consistent gripping force on high friction materials, preventing material slip.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If increased force is applied by the end effector to prevent material slip, then gripping reliability improves, but pinching and damage to the material occurs due to uneven force distribution

Engineering Contradiction:

Improvegrip stabilityVSAvoidmaterial pinching and damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

By segmenting the gripping force into multiple compliant contact elements, the system can apply increased total force while distributing it evenly across the material surface. Each element applies localized force, preventing concentration of stress that would cause pinching or damage to the material.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The compliant contact elements dynamically adjust their deflection and force application based on real-time contact conditions. This dynamic response allows the system to apply sufficient force for stable gripping while automatically adapting to prevent excessive force concentration that would cause material damage.

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If rigid contact elements are used to ensure precise force application, then control precision improves, but adaptability to surface variations decreases leading to inconsistent material handling

Engineering Contradiction:

Improveforce application precisionVSAvoidsurface variation adaptation

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The compliant contact elements change their mechanical parameters (deflection angle, contact force magnitude) in response to surface variations. This parameter adaptability allows the system to maintain precise force control while accommodating uneven surfaces, resolving the contradiction between precision and adaptability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The compliant elements automatically adjust their own position and force application based on contact conditions without external intervention. This self-adjusting capability enables the system to adapt to surface variations while maintaining consistent force application precision.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution effectively reduces material slip and ensures consistent force application, preventing production of flawed products and minimizing economic losses by improving the handling of materials with high friction or non-slip surfaces.

Implementation Method 1

compliant material contact elements around a perimeter of the contact mounting flange. The compliant material contact elements can be distributed about a perimeter of the contact mounting flange

Methodology Applied

Scientific EffectSpring: Spring

Implementation Method 2

Material slip can be especially prevalent for products with non-slip or high friction backings

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12157222B2Compliant perimeter end effectors

Publication Date: 2024.12.03 SOFTWEAR AUTOMATION INC

AI summary

Various examples are provided related to end effectors for use in, e.g., automation of sewing robots. In one example, among others, a compliant perimeter end effector includes a mounting bracket having a contact mounting flange, a plurality of compliant material contact elements coupled about a perimeter of the contact mounting flange. The mounting bracket can couple to a manipulator including, e.g., an industrial robot or other manipulation assembly. The compliant material contact elements can include a contact interface that can engage with a piece of material. The compliant material contact elements can precisely transfer material on a workspace with surface irregularities while equally distributing force to the material.