Cylindrical Vacuum Pick Head for Flexible Material Separation
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Solution Overview
Problem
Existing automated methods for picking cut pieces from flexible sheets are inefficient and prone to material damage due to the need for large numbers of individually controllable vacuum orifices and issues with needle-and-hook type grippers, which increase costs and risk of error in high-volume operations.
Innovation Solution
A pick head with a cylindrical surface featuring a lateral region of individually selectable vacuum orifices that apply vacuum only to the leading edge of the cut piece, allowing it to be rolled onto the cylinder while maintaining the vacuum, reducing the need for extensive vacuum control and minimizing force required for separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flat arrays of vacuum orifices are used to engage specific workpieces, then selective picking capability is achieved, but the number of individually controllable vacuum orifices increases significantly, raising device complexity and cost
Solution Approach 1:
The cylindrical surface is divided into multiple independently controllable vacuum orifices arranged circumferentially. Each orifice can be activated or deactivated independently to engage only the specific workpiece located at the desired angular position, thereby achieving selective picking with a manageable number of orifices rather than requiring a dense flat array.
Solution Approach 2:
The vacuum orifices are arranged on a cylindrical surface rather than a flat plane. This dimensional change from 2D flat array to 3D cylindrical arrangement allows the same number of orifices to cover a larger effective area and provides angular positioning capability, reducing the need for excessive orifices while maintaining selective engagement capability.
2Adaptability or versatility
If needle-and-hook type grippers are used for engaging material, then selective engagement is achieved, but issues with engaging and releasing material occur, reducing reliability
Solution Approach 1:
The invention replaces mechanical needle-and-hook grippers with a pneumatic vacuum-based engagement system. Vacuum orifices on the cylindrical surface create negative pressure to engage the workpiece, and by controlling vacuum activation at specific orifices, reliable engagement and release is achieved without the mechanical complexity and reliability issues of needle-and-hook mechanisms.
3Quantity of substance
If large numbers of individually controllable vacuum orifices are used in flat arrays, then complete coverage for engagement is achieved, but the cost and complexity of the system increases
Solution Approach 1:
By arranging vacuum orifices on a cylindrical surface rather than a flat plane, the system achieves broader coverage area with fewer orifices. The cylindrical geometry allows orifices to be distributed over a larger spatial extent while maintaining a manageable number of individually controllable elements, thus reducing overall system complexity.
Solution Approach 2:
The cylindrical vacuum array serves multiple functions: it provides selective engagement capability, achieves broad coverage area, and enables angular positioning of the workpiece. This multi-functionality reduces the need for additional separate systems or components, thereby lowering overall device complexity despite the requirement for individual orifice control.
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 reduces the number of costly selectively controlled coupling elements and minimizes the risk of lifting surrounding material, enhancing efficiency and reducing material damage during the picking process.
Implementation Method 1
A vacuum is enabled at those orifices that are in contact with a portion of the flexible sheet to hold a leading edge portion of the cut piece against the cylinder
Data Source
AI summary
The disclosure relates to a method and apparatus for uncut material detection while lifting from an automated cutting table select pieces of thin, flexible material. The apparatus comprises a structured energy source and a structured energy sensor. The structured energy can be used to detect undesired lifting of a peripheral portion of the flexible material resulting from the presence of uncut material.