Hybrid Composite End Effector for Vacuum-Electrostatic Pickup

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing pick and place end effectors for composite materials are inefficient due to the need to switch between different types, which is time-consuming and space-prohibitive, especially in automated layup processes.

Innovation Solution

A single end effector utilizing both vacuum and electrostatic mechanisms, allowing for seamless switching between vacuum suction and electrostatic adhesion, reducing the need for multiple end effectors and minimizing downtime.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If different end effectors are used for different types of composite material, then the handling precision and suitability for specific materials are improved, but the device complexity and switching time increase

Engineering Contradiction:

Improvehandling precisionVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The end effector integrates both vacuum suction capability and electrostatic adhesion capability into a single device. The vacuum pogos can switch between direct vacuum pickup and supporting an electrostatic membrane, allowing the same end effector to handle different composite materials (single plies and preforms) with appropriate pickup mechanisms without requiring multiple specialized end effectors.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The electrostatic membrane is designed to be removably held by the vacuum pogos. When electrostatic pickup is needed, the membrane is attached to the vacuum pogos; when vacuum pickup is needed, the membrane is removed. This nested configuration allows one mechanism to be contained within or attached to the other, enabling versatile functionality without increasing overall device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If multiple end effectors are maintained for different materials, then the adaptability is improved, but the space required and switching time increase

Engineering Contradiction:

Improvematerial adaptabilityVSAvoidswitching time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The end effector employs dynamic switching between two pickup mechanisms. The vacuum pogos can dynamically transition between vacuum pickup mode and electrostatic membrane support mode based on the material being handled. This dynamic adaptability eliminates the need for physical swapping of end effectors, significantly reducing switching time.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If vacuum pickup is used for all composite materials, then the device complexity is reduced, but the handling precision for single plies deteriorates

Engineering Contradiction:

Improvedevice complexityVSAvoidhandling precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Different pickup mechanisms are applied locally based on the material type. Vacuum pickup is used for thicker composite preforms where it provides sufficient holding force, while electrostatic pickup is used for thinner single plies where precise handling is critical. This local differentiation of pickup quality ensures optimal handling precision for each material type without unnecessarily complicating the overall device.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The end effector changes the pickup mechanism parameter based on the material being handled. For single plies, the system switches to electrostatic pickup mode which provides gentler, more precise handling. For composite preforms, the system switches to vacuum pickup mode. This parameter change allows the same physical device to achieve optimal handling precision for different material types.

Inventive Principle:

Principle #35Parameter changes

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

Enables efficient and space-saving composite material handling by allowing a single end effector to adapt to different materials and shapes, reducing switching time and costs.

Implementation Method 1

a vacuum end effector with a plurality of vacuum pogos configured to pick and place a composite preform

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

an electrostatic membrane configured to be removably held by the plurality of vacuum pogos and pick and place a single ply composite material

Methodology Applied

Scientific EffectElectrostatic adhesion: Electrostatics

Data Source

PatentEP4667180A1Pick and place end effector

Publication Date: 2025.12.24 THE BOEING CO

Figure 1
Figure 2
Figure 3

AI summary

An end effector configured to lift composite material through two different mechanisms and methods of picking and placing composite material are presented. The end effector comprises a vacuum end effector with a plurality of vacuum pogos configured to pick and place a composite preform in contact with the plurality of vacuum pogos, and an electrostatic membrane configured to be removably held by the plurality of vacuum pogos and pick and place a single ply composite material while the electrostatic membrane is held by the plurality of vacuum pogos.