Suction Cup Holding Verification via Pressure Change Rate
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Solution Overview
Problem
Existing vacuum suction cups in packaging machines lack reliable methods to determine if a product is correctly held, as absolute vacuum measurements are unreliable and may involve sensitive or difficult-to-clean sensors.
Innovation Solution
Monitoring the flow quantity and flow rate of suction air over time to establish a parameter curve, which is compared to a tolerance band for each product type, allowing for qualitative assessment of correct product holding without absolute pressure or flow rate values, and generating a warning signal if the curve does not fit within the tolerance band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If absolute vacuum measurement is used to detect product presence, then the detection method is simple, but the reliability of detection is insufficient
Solution Approach 1:
The patent changes the measured parameter from absolute vacuum pressure to the change of vacuum pressure over time (dp/dt). By monitoring the rate of pressure change rather than the absolute pressure value, the system can reliably detect product presence and seal quality. This parameter transformation resolves the contradiction by providing both measurement simplicity and detection reliability.
2Measurement precision
If sensors are placed close to the suction device for accurate measurement, then measurement accuracy improves, but the risk of contamination and cleaning difficulty increases
Solution Approach 1:
The patent extracts the measurement function from the immediate suction area by placing the vacuum sensor in the supply line away from the product contact zone. The system measures the pressure change in the supply line (dp/dt) rather than directly at the suction cup, thereby maintaining measurement precision while eliminating sensor contamination risks.
3Reliability
If suction air is continuously supplied to maintain constant vacuum, then product holding is reliable, but suction air consumption increases
Solution Approach 1:
The patent implements periodic monitoring of the pressure change rate (dp/dt) to detect product presence and seal quality. Instead of continuous suction air supply for monitoring, the system periodically measures the pressure change characteristics, enabling reliable product holding while significantly reducing suction air consumption during the monitoring phase.
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
This method provides a more reliable detection of incorrectly held or missing products, avoids the need for absolute calibration, and reduces the risk of sensor contamination, enabling efficient operation and maintenance in packaging machines.
Implementation Method 1
in which the product is held on the suction device by means of suction air, i.e. by means of negative pressure
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
In order to determine as reliably as possible whether the product (P) is held as desired at an activated suction device (22), the flow rate per unit of time and/or the flow velocity and/or an alternative parameter representing one of the two parameters mentioned is determined with regard to the suction air (S) that is transported away by the suction device (22).This allows for a more reliable determination of the correct contact of the suction cup (22) with a correct product (P) than by measuring an absolute vacuum value, in particular by not determining an absolute value of one of the aforementioned parameters, but by determining the shape of the curve (PKH) of this parameter over time when grasping + holding and/or when holding + subsequent release of the product (P) by the suction cup (22), and by checking this parameter curve (PKH) to see if it lies within a tolerance range band (TP), which can also be determined very easily and automatically.