Multi-zone end effector for label-safe package handling
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Solution Overview
Problem
Robotic end effectors in materials handling facilities often deform or peel off labels on packages due to vacuum forces, preventing subsequent barcode reading and automation efficiency.
Innovation Solution
A multi-zone end effector assembly with independently controlled compression and vacuum zones, using source valves to adjust suction and pressure, and an image sensor to determine label location and dimensions for precise engagement and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If vacuum force is applied to pick up a package, then the package can be manipulated and moved, but labels on the package may deform or peel off
Solution Approach 1:
The end effector is divided into multiple independently controllable zones (first zone, second zone, third zone) that can apply vacuum force to different areas of the package separately. This segmentation allows the system to apply vacuum force only to areas away from labels, preventing label deformation while still securing the package for manipulation and movement.
Solution Approach 2:
Different zones of the end effector can apply different levels of vacuum force or no vacuum force at all, depending on the local characteristics of the package surface. By identifying label locations and adjusting vacuum application locally, the system maintains package grip while protecting label integrity in specific areas.
2Force
If compression force is applied to secure the package, then the package can be held firmly, but labels may be deformed or damaged
Solution Approach 1:
The end effector divides compression force application into multiple zones, allowing firm compression on package areas without labels while avoiding compression on label-containing areas. This selective zone-based compression secures the package firmly without deforming labels.
Solution Approach 2:
The system applies compression force with locally differentiated intensity based on the presence of labels. Areas with labels receive reduced or zero compression force, while areas without labels receive sufficient compression for secure handling, preventing label deformation while maintaining firm package grip.
3Reliability
If vacuum force is increased to improve package grip, then manipulation reliability improves, but label peeling increases
Solution Approach 1:
The end effector segments the vacuum application area into multiple zones with independent control. By distributing vacuum force across multiple zones away from labels, the system achieves reliable package grip through cumulative force while preventing concentrated pressure that would cause label peeling.
Solution Approach 2:
The system adjusts vacuum force locally based on label detection results. Areas with labels receive reduced or zero vacuum force to prevent peeling, while areas without labels receive sufficient vacuum force to ensure reliable package grip, achieving both objectives simultaneously.
4Device complexity
If the end effector uses a single uniform zone for vacuum application, then the device complexity is low, but the ability to handle packages with labels is poor
Solution Approach 1:
The end effector is segmented into multiple independently controllable zones while maintaining a relatively simple overall structure. Each zone can be independently activated or deactivated based on package characteristics, providing adaptability for handling various package types with or without labels without requiring a completely complex system redesign.
Solution Approach 2:
The end effector employs dynamic control of vacuum force distribution across multiple zones, allowing the system to adapt to different package configurations. The controller can dynamically adjust which zones are active and at what vacuum level, providing versatility for handling various packages while maintaining a manageable device structure.
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
Prevents label deformation and peeling, ensuring accurate reading and improving automation by allowing controlled vacuum and compression forces for precise package handling and placement.
Implementation Method 1
A vacuum source may be attached to the air connections to provide access to a vacuum source. The vacuum force can be used to attach the package to the compression cups.
Implementation Method 2
The compression cups can be configured to apply a compression force to a surface of the package.
Data Source
AI summary
A multi-zone end effector assembly is described in the present disclosure. As a non-limiting example, the multi-zone end effector assembly comprises a manifold that comprises a first interior chamber and a second interior chamber. A first port connects to the first interior chamber, and a second port connects to the second interior chamber. A first compression cup region can be connected to the first interior chamber. The first compression cup region is in air connection with the first port. The first compression cup region is configured to be independently activated in order to create a first vacuum zone. A second compression cup region is connected to the second interior chamber. The second compression region cup is in air connection with the second port. The second compression cup region is configured to be independently activated in order to create a second vacuum zone.