Single-Source Vacuum Gripper for High-Flow Handling and Dead-Head Protection
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Solution Overview
Problem
Existing programmable motion systems face challenges in efficiently and economically accommodating a wide variety of objects, requiring either high vacuum or high flow, and often suffer from issues such as poor sealing, air leakage, and overheating due to dead-heading in vacuum sources.
Innovation Solution
A hybrid gripper system using a single vacuum source that switches between high vacuum and high flow modes, incorporating a dead-head limitation system to prevent overheating by maintaining airflow and employing relief valves and cooling mechanisms to manage dead-heading conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a Venturi ejector is used to provide high vacuum, then a large static pressure differential is achieved, but the maximum air flow is limited
Solution Approach 1:
The system dynamically switches between high vacuum mode (using Venturi ejector) and high flow mode (using air amplifier or blower) based on the gripping requirements. The controller monitors the vacuum cup pressure and object detection, then selects the appropriate vacuum source mode to optimize performance for different object types and sealing conditions.
Solution Approach 2:
The vacuum system is designed to perform multiple functions by incorporating both high vacuum sources (Venturi ejector) and high flow sources (air amplifier, blower) in a single gripper assembly. This multi-functional design allows the same gripper to handle diverse objects requiring different vacuum characteristics, eliminating the need for separate gripper assemblies.
2Quantity of substance
If high flow devices are used to maintain sufficient air flow, then air leakage is compensated, but the high vacuum level is reduced
Solution Approach 1:
The system dynamically switches between high vacuum mode (using Venturi ejector) and high flow mode (using air amplifier or blower) based on the gripping requirements. The controller monitors the vacuum cup pressure and object detection, then selects the appropriate vacuum source mode to optimize performance for different object types and sealing conditions.
Solution Approach 2:
The system changes the operating parameters of the vacuum source by switching between different vacuum sources (Venturi ejector for high vacuum, air amplifier/blower for high flow). This parameter change allows optimization of either vacuum level or air flow depending on the specific gripping task and seal quality.
3Device complexity
If a single vacuum source is used for both high vacuum and high flow modes, then device complexity is reduced, but dead-heading and overheating problems occur
Solution Approach 1:
The system dynamically switches between high vacuum mode (using Venturi ejector) and high flow mode (using air amplifier or blower) based on the gripping requirements. The controller monitors the vacuum cup pressure and object detection, then selects the appropriate vacuum source mode to optimize performance for different object types and sealing conditions.
Solution Approach 2:
A relief valve is introduced as an intermediary component that provides a bypass path for air flow. When the vacuum cup forms a tight seal during high vacuum operation, the relief valve prevents dead-heading conditions by allowing excess air to escape, thereby preventing blower overheating while maintaining the high vacuum necessary for effective gripping.
4Force
If vacuum cups are made larger to increase lifting force, then more objects can be handled, but the volume to be evacuated increases
Solution Approach 1:
The system dynamically switches between high vacuum mode (using Venturi ejector) and high flow mode (using air amplifier or blower) based on the gripping requirements. The controller monitors the vacuum cup pressure and object detection, then selects the appropriate vacuum source mode to optimize performance for different object types and sealing conditions.
Solution Approach 2:
The system changes the operating parameters of the vacuum source by switching between different vacuum sources (Venturi ejector for high vacuum, air amplifier/blower for high flow). This parameter change allows optimization of either vacuum level or air flow depending on the specific gripping task and seal quality.
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 handles diverse objects by adapting to sealing conditions, preventing blower damage and ensuring consistent operation through regulated airflow and cooling, thus enhancing the versatility and reliability of object manipulation.
Implementation Method 1
the lifting force is obtained by multiplying the static pressure differential by the area of the vacuum cup
Implementation Method 2
the lifting force is provided not by static pressure differential, but by aerodynamic drag, arising from a high velocity flow of air past the object
Implementation Method 3
a dead-head limitation system for limiting any effects of dead-heading on the vacuum source in the event that a flow of air to the vacuum source is interrupted
Data Source
AI summary
A system including a programmable motion device and an end effector for grasping objects to be moved by the programmable motion device is disclosed. The system includes a vacuum source that provides a high flow vacuum such that an object may be grasped at an end effector opening while permitting a substantial flow of air through the opening, and a dead-head limitation system for limiting any effects of dead-heading on the vacuum source in the event that a flow of air to the vacuum source is interrupted.