Concentric Suction Cup Assembly With Integrated Air Chambers
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Solution Overview
Problem
Fulfillment centers face challenges in efficiently handling and processing large volumes of packages due to complex logistics, including manual efforts required for picking, sorting, and packing, especially when dealing with items of varying shapes, sizes, and packaging types, which complicates robotic handling in cluttered environments.
Innovation Solution
Concentric suction cup picking assemblies with integrated air chambers and brake assemblies are used to grasp items securely, allowing robotic manipulators to handle objects of various shapes and sizes with improved grasp strength and reduced manufacturing complexity, featuring a vacuum manifold to supply vacuum and air pressure for reliable picking and releasing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional suction cup tools are used, then the structure is simple, but the grasp strength is insufficient and reliability is low
Solution Approach 1:
The tool is divided into multiple independent piston subassemblies (first piston subassembly, second piston subassembly, etc.), each capable of independent extension and retraction. This segmentation allows the tool to adapt to items of varying shapes and sizes while maintaining reliable grasp strength through coordinated action of multiple suction cups.
Solution Approach 2:
Multiple piston subassemblies are arranged concentrically within a shell structure, with each piston subassembly containing its own suction cup. The nested arrangement maximizes the use of internal space and allows multiple suction cups to be compactly organized to provide combined grasp strength.
2Adaptability or versatility
If multiple separate air and vacuum lines are used for each piston subassembly, then each piston can be controlled independently, but the device complexity and manufacturing cost increase
Solution Approach 1:
Multiple air lines and vacuum lines are merged into a single integrated air chamber and vacuum manifold structure. The air chamber serves as a common air supply for all piston subassemblies, while the vacuum manifold distributes vacuum to each suction cup. This merging reduces the number of separate lines while maintaining independent control capability through valve mechanisms.
Solution Approach 2:
The air chamber and vacuum manifold serve multiple functions simultaneously: they provide air supply to multiple pistons, distribute vacuum to multiple suction cups, and enable independent control of each piston subassembly through integrated valves. This multi-functionality reduces overall system complexity.
3Volume of moving object
If a single shell encloses all piston subassemblies, then the tool has a compact form factor, but the manufacturing precision requirements increase
Solution Approach 1:
Each piston subassembly is designed as a separate module with its own suction cup, allowing for easier manufacturing and assembly. The segmentation enables tolerance accumulation to be managed at each stage rather than requiring perfect concentric alignment of all components in a single monolithic structure.
Solution Approach 2:
The suction cups are extracted as separate components from the piston subassemblies, allowing them to be manufactured and assembled independently. This extraction simplifies manufacturing by separating the sealing elements from the actuation mechanisms, reducing the overall manufacturing precision requirements for the shell structure.
4Productivity
If the suction cups are always extended, then the tool can immediately grasp items, but the tool cannot accommodate items of varying sizes and the shell structure becomes overly complex
Solution Approach 1:
The piston subassemblies are designed to be dynamically controllable, transitioning between extended and retracted positions based on the size and shape of the item being handled. This dynamic capability allows the tool to adapt to varying item dimensions while maintaining a relatively simple shell structure, as the complexity is managed through control logic rather than structural over-engineering.
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
Enhances throughput and efficiency in fulfillment centers by improving the speed and accuracy of handling items, reducing manual effort, and enabling robust object handling in cluttered conditions with extended tool life and flexibility.
Implementation Method 1
a vacuum manifold to supply vacuum and air pressure for reliable picking and releasing
Implementation Method 2
integrated air chambers and brake assemblies are used to grasp items securely
Data Source
AI summary
Systems and methods are disclosed for concentric suction cup tools with integrated air chambers. In one embodiment, an example picking assembly may include a vacuum manifold having a first integrated air pressure path and a second integrated air pressure path, and a first piston subassembly that includes a first air pipe, a first vacuum pipe, a first bushing disposed between the first air pipe and the first vacuum pipe, and a first suction cup, where the first piston subassembly is configured to independently actuate from a retracted position to an extended position. The picking assembly may include a second piston subassembly having a second air pipe, a second vacuum pipe, a second bushing disposed between the second air pipe and the second vacuum pipe, and a second suction cup, where the second piston subassembly is configured to independently actuate from the retracted position to the extended position.