Pneumatic Control Valve for Suction Gripper
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing suction gripper control systems face challenges in efficiently managing suction pads for large or irregularly shaped objects, leading to unwanted air suction and potential damage, as they struggle to distribute pressure and extend only necessary suction pads during transport.
Innovation Solution
A control device with a piston-based mechanism that uses a restoring force and controlled compressed air to shift between rest and working positions, minimizing moving components and wear, while ensuring efficient air supply to the ejector and suction gripper, and maintaining the suction even in case of power failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If machine control is used to extend only necessary suction pads, then unoccupied suction pads are prevented from sucking ambient air and sealing lips are protected, but the control system becomes complex and requires multiple electrical connections
Solution Approach 1:
The patent replaces complex electrical control systems with a simple pneumatic control mechanism. A single pneumatic control line with a control valve directs compressed air to a piston that mechanically extends or retracts the suction pad, eliminating the need for complex electrical controls while achieving the same functional result of preventing unwanted air suction
Solution Approach 2:
The invention extracts the essential control function from a complex electrical system and isolates it into a simple pneumatic control mechanism. By separating the control function into a dedicated pneumatic circuit with a control valve and piston, the system achieves precise control with minimal components, reducing overall system complexity
2Device complexity
If a single piston is used to control both ejector supply and suction gripper extension, then the number of moving components is minimized and wear is reduced, but the force required to move the piston increases
Solution Approach 1:
The patent resolves the force contradiction by introducing a dimensional solution through surface area variation. The piston has different surface areas on opposite sides, allowing compressed air to generate sufficient force on the larger surface area to overcome the restoring force and move the piston, while maintaining a simple single-piston structure that minimizes moving components
3Force
If the control valve surface section for working compressed air is made large, then the force from working compressed air increases, but the piston cannot be held in rest position against the restoring force
Solution Approach 1:
The patent applies local quality by creating different surface areas in different locations on the piston. The first surface area (exposed to working compressed air) is smaller than the second surface area (exposed to control compressed air), allowing the system to achieve both stable rest position holding and sufficient force generation for piston movement through localized surface area differentiation
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 solution allows for precise control of suction pads, preventing unwanted air suction, reducing wear and maintenance, and ensuring secure grip of objects during transport and power outages, with a compact design that requires minimal space and electrical connections.
Implementation Method 1
an inlet for working compressed air for an ejector (34)... connected to the suction pad (22) and the ejector (34)... the ejector is supplied with working compressed air
Implementation Method 2
the force of the working compressed air on the surface section is smaller than the restoring force and the sum of the forces of the control compressed air on the control surface and the force of the working compressed air on the surface section is greater than the restoring force
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a controller for a suction gripper (22), comprising an inlet (12) for the working compressed air for an ejector (34), an inlet (18) for control compressed air for a control valve (32), a vacuum connector (24), to which the suction gripper (22) and ejector (34) are connected, whereby the control valve (32) comprises a piston (30) which may be displaced between a working position and an idle position, which, on subjection to a return force, is held against a front face in the idle position thereof and in said idle position is pressurised against the return force on a surface section (46) on the other front face (48) thereof by the working compressed air and comprises a control surface on which the control compressed air acts, whereby the control compressed air pressurizes the control surface (48) against the return force, the force of the working compressed air on the surface section (46) is less than the return force and the sum of the forces of the control compressed air on the control surface (48) and the force of the working compressed air on the surface section is greater than the return force and hence the control valve (32) is shifted from the idle position to the working position and hence the input (12) for working compressed air is connected to the ejector (34).