Decentralized Vacuum Gripper Control for Handling Devices
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Solution Overview
Problem
Existing workpiece handling systems require complex central control and long data lines for vacuum pressure management, leading to slow response times and increased downtimes during system changes or expansions.
Innovation Solution
A decentralized system with a control valve and evaluation unit on the handling device, which generates and transmits control signals locally to manage compressed air supply for vacuum grippers, reducing the need for central control and shortening response times by using short data lines and enabling flexible system configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a central control device with bus system is used to control vacuum generators, then coordinated control of functional units is achieved, but system complexity and configuration work increase when changing handling devices
Solution Approach 1:
The control system is segmented into decentralized control units, each assigned to individual vacuum generators or handling devices. These control units operate autonomously and communicate via short data lines, eliminating the need for a complex central control bus system while maintaining coordinated control through localized decision-making.
Solution Approach 2:
Each handling device or vacuum generator is equipped with its own control unit that autonomously manages its operation. The control units self-configure when devices are connected, automatically registering themselves with the system without requiring manual configuration work, thereby simplifying the overall control architecture.
2Reliability
If long data lines connect handling devices to central control, then system-wide monitoring is achieved, but response time increases
Solution Approach 1:
The monitoring function is segmented and distributed to local control units at each handling device or vacuum generator. These units monitor local parameters and transmit only relevant data via short data lines to neighboring units or directly to affected components, eliminating the need for long data lines to a central control point and significantly reducing response time.
Solution Approach 2:
Monitoring and control functions are performed locally at each device rather than centrally. Each control unit has the authority and capability to make immediate local decisions based on real-time sensor data, ensuring fast response times while maintaining system-wide awareness through selective data transmission over short distances.
3Ease of manufacture
If vacuum generators are located away from vacuum grippers, then centralized vacuum supply is achieved, but compressed air line length and response time increase
Solution Approach 1:
The vacuum generation function is segmented and distributed to individual vacuum generators positioned directly at or near each vacuum gripper. This decentralized arrangement eliminates long compressed air lines and evacuation paths, allowing each gripper to be evacuated and pressurized independently and rapidly, while maintaining the ease of manufacture through modular, plug-and-play vacuum generator units.
Solution Approach 2:
Small local vacuum generators act as intermediaries between the compressed air supply system and the vacuum grippers. They are positioned close to the grippers to minimize line lengths, yet can be supplied from centralized compressed air sources through short connection lines, effectively mediating between the needs for centralized supply and rapid local response.
4Reliability
If manual configuration is required when changing handling devices, then system registration is achieved, but downtime increases during system changes
Solution Approach 1:
Handling devices and vacuum generators are equipped with self-identifying control units that automatically register themselves with the system when connected. The control units exchange identification data and establish communication automatically through the short data lines, eliminating the need for manual configuration and significantly reducing downtime during device changes or system expansions.
Solution Approach 2:
Control units are pre-programmed with identification data and communication protocols before installation. When a handling device or vacuum generator is connected to the system, the control unit automatically initiates the registration process by transmitting its identification data and establishing communication links, performing the configuration action preliminarily and automatically without requiring system shutdown or manual intervention.
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 allows for faster workpiece handling, reduced downtimes during system changes, and cost savings by simplifying system control and eliminating the need for complex data transmission, enhancing productivity and reliability.
Implementation Method 1
at least one vacuum generator (26) that can be operated by means of a compressed air supply and is used to supply the vacuum grippers (16) with the required vacuum
Data Source
Figure 1~2
AI summary
The invention relates to a system (10) for handling workpieces, with a handling device (12) which comprises at least one vacuum gripper (16) for suctioning a workpiece, with at least one vacuum generator (26) operable by means of a compressed air supply for supplying the vacuum gripper (16) with vacuum, with at least one controllable control valve (28) by means of which the compressed air supply to the vacuum generator (26) can be controlled, wherein a control device (30) for controlling the control valve (28) as required is assigned to the control valve (28).The handling device has an evaluation unit (32) for evaluating operating data of the vacuum generator (26) and/or operating data of the handling device (12) and for generating control signals depending on the evaluated operating data, wherein the evaluation unit (32) is arranged on the handling device (12), and wherein the control device (30) controls the control valve (28) depending on the control signals transmitted by the evaluation unit (32).