Mixed-Size Suction End Effector for Variable-Item Grasping

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Solution Overview

Problem

Robotic end effectors face challenges in efficiently engaging items of varying sizes and shapes due to mobility restrictions and the difficulty in providing and programming robots for tasks like kitting and singulation, particularly in environments with arbitrary mixes of items.

Innovation Solution

A robotic arm equipped with a suction-based end effector featuring multiple suction cups of varying sizes and arrangements, controlled by a computer to selectively actuate individual cups based on grasping strategies, combined with a workspace environment state system using sensors for precise item engagement and sorting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a robotic arm uses a single-size suction cup end effector, then the device complexity is reduced, but it cannot efficiently engage items of varying sizes and shapes

Engineering Contradiction:

Improveability to engage items of varying sizes and shapesVSAvoidend effector configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The end effector is divided into multiple independent suction cups of different sizes that can be selectively actuated. Each suction cup is an independent unit that can be controlled separately, allowing the system to adapt to different item sizes by activating only the necessary cups, thus resolving the contradiction between versatility and complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the end effector are equipped with suction cups of varying sizes tailored to specific engagement needs. Larger suction cups are positioned for bigger items while smaller cups handle smaller items, creating local specialization that enables the end effector to handle diverse item sizes without requiring complete redesign.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If the end effector is designed to accommodate large items, then it can handle bigger packages, but it cannot reach into small bins or shelves

Engineering Contradiction:

Improveability to reach into bins and shelves of varying sizesVSAvoidend effector size

Core Design Contradiction:

Adaptability or versatilityVSLength of moving object

Solution Approach 1:

The end effector uses multiple independently controllable suction cups of different sizes, allowing selective activation of only the smaller cups when reaching into compact bins or shelves. This segmentation enables the robotic arm to adapt its effective reaching size dynamically, resolving the contradiction between handling large items and accessing small spaces.

Inventive Principle:

Principle #1Segmentation

3Productivity

If traditional robotics is used for kitting and singulation, then automation is achieved, but mobility restrictions and programming difficulties reduce productivity

Engineering Contradiction:

Improvekitting and singulation throughputVSAvoidrobot programming and mobility control

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent replaces complex mechanical grasping and positioning systems with a suction-based field effect system. Instead of mechanically manipulating each item individually, the robotic arm uses distributed suction cups to simultaneously engage multiple items, simplifying the mechanical interface and enabling higher throughput in kitting and singulation operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The end effector with multiple suction cups serves multiple functions simultaneously - it can grasp items of varying sizes, reach into different bin configurations, and perform both kitting (assembly) and singulation (separation) tasks. This multi-functionality eliminates the need for multiple specialized end effectors and programming configurations, thereby improving productivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 precise singulation and kitting of items with varying sizes and shapes, minimizing collisions and improving throughput by adapting to environmental conditions and item characteristics.

Implementation Method 1

A suction force is generated between the one or more suction cups and the item based at least in part on a pressure difference between an interior of the one or more suction cups and an exterior of the one or more suction cups

Methodology Applied

Scientific EffectPressure difference: Pressure Gradient

Data Source

PatentUS12403616B2Suction-based end effector with mixed cup sizes

Publication Date: 2025.09.02 DEXTERITY INC

AI summary

An end effector is disclosed. The end effector includes a first set of one or more suction cups of a first size having a first diameter, and a second set of one or more suction cups of a second size having a second diameter that is smaller than the first diameter. The end effector further includes a first actuation mechanism configured to apply suction to at least a subset of the first set of suction cups independently of actuation of the second set of suction cups and a second actuation mechanism configured to apply suction to at least a subset of the second set of suction cups independently of actuation of the first set of suction cups.