Flexible Bellows Suction Cup for Egg Handling
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Solution Overview
Problem
Existing egg handling robotic systems using vacuum-powered suction cups face contamination issues due to open-ended vacuum sources and plenums, and require increased vacuum power to compensate for unoccupied cups, leading to inefficiencies and contamination risks.
Innovation Solution
An egg pick-up and transfer system that uses individual, independently controlled valves for each suction cup, eliminating the need for a centralized vacuum source and incorporating a controlled air flow to prevent contamination, with optional disinfection features using fresh air or ozone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a centralized vacuum source is used for all suction cups, then the system can lift multiple objects simultaneously, but the vacuum source must be oversized to compensate for unoccupied cups, increasing power consumption and cost
Solution Approach 1:
The patent divides the centralized vacuum system into individual independent vacuum sources for each suction cup. Each suction cup has its own vacuum generator, allowing selective activation only for occupied cups, thereby eliminating the need for an oversized centralized vacuum source and reducing power consumption proportionally to the number of active cups.
Solution Approach 2:
The patent implements local vacuum generation at each suction cup location rather than distributing vacuum from a centralized source. This allows each suction cup to operate independently with appropriate vacuum power only where needed, optimizing energy efficiency while maintaining multi-object lifting capability.
2Ease of operation
If a centralized vacuum plenum is used above the suction cup array, then simultaneous vacuum distribution is achieved, but contamination from the vacuum source and plenum compromises sanitation
Solution Approach 1:
The patent removes the centralized vacuum plenum and its associated contamination risks from the system. By eliminating the common vacuum chamber that sits above the suction cups, the source of contamination is extracted from the egg handling environment, preventing bio-contaminants from entering the system through the vacuum source.
Solution Approach 2:
The patent introduces individual vacuum generators as intermediaries between the external environment and each suction cup, eliminating the need for a shared plenum. This intermediary approach allows vacuum to be generated locally without requiring a contamination-prone centralized chamber above the suction cups.
3Reliability
If vacuum power is increased to compensate for unoccupied suction cups, then all cups can maintain grip, but energy consumption and system cost increase
Solution Approach 1:
The patent segments the vacuum power supply so that each suction cup operates independently with its own vacuum generator. This ensures reliable grip on occupied cups without wasting energy on unoccupied cups, as each cup only consumes vacuum power when actually holding an object.
Solution Approach 2:
The patent changes the operational parameter of vacuum power from a fixed high level (required to compensate for all possible unoccupied cups) to a dynamic level that adjusts based on actual occupancy. Each suction cup activates its vacuum only when needed, optimizing the balance between grip reliability and energy consumption.
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
The system effectively lifts and releases eggs without a negative pressure source, reducing contamination and operational costs, while maintaining cleanliness and sanitation, and allowing for efficient handling of multiple eggs without the need for vacuum makeup.
Implementation Method 1
expansion and contraction of the bellows creates reduced pressure within the hollow interior
Implementation Method 2
A valve assembly is provided in communication with the hollow interior and is configured to control air flow to and from the hollow interior
Data Source
AI summary
An object pick-up, transfer and placement apparatus which does not employ a source of negative pressure. A flexible bellow defines a collapsible interior chamber and a top through-bore in communication with atmospheric or greater pressure via a valve. The bellow collapses when contacting an object, and the valve is closed, preventing air from entering the interior chamber. When the apparatus is used to lift the object, the bellow expands, causing reduced pressure in the interior chamber, securing the object to the apparatus. To release the object, the valve is opened, allowing entry of air to the interior chamber, and release of the object. This invention prevents contamination on egg shell surfaces to become air-born and cross-contaminate the entire egg pack, equipment surfaces, floors and other facility surfaces which in turn creates a hazardous working environment.