Vacuum Cup Sensor for Missing Material Detection
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Solution Overview
Problem
Automated systems for picking and stacking material, such as print media, often fail to detect missing material during transport, leading to incomplete stacks due to the lack of a means to monitor the presence of material being picked or transferred.
Innovation Solution
An apparatus comprising a vacuum cup and a sensor system that continuously monitors the area around the vacuum cup, generating an error signal when material is not detected, allowing for real-time detection of missing material and determination of its position within a sequence, enabling corrective action.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated vacuum cup picking system is used, then productivity is improved, but reliability deteriorates due to undetected missing material
Solution Approach 1:
The patent implements a sensor system that provides real-time feedback on material presence during the vacuum cup picking and stacking process. The sensor monitors whether material is successfully picked up and transported, and this information is fed back to the control circuit to trigger error signals when material is missing, enabling immediate detection and correction of picking failures.
Solution Approach 2:
The patent introduces a sensor as an intermediary element between the vacuum cup picking system and the control system. This sensor acts as a mediator that detects material presence and communicates this information to the control circuit, which then generates appropriate error signals, thereby bridging the gap between the mechanical picking system and the control mechanism.
2Device complexity
If no monitoring system is used, then device complexity is reduced, but loss of information increases due to undetected missing material
Solution Approach 1:
The patent implements preliminary monitoring action by placing sensors in strategic locations to detect material presence before and during the picking and stacking process. The sensor is positioned to monitor the area where material should be present, enabling early detection of missing material before it results in an incomplete stack, thereby preventing information loss about material transport status.
3Reliability
If continuous monitoring is implemented, then reliability is improved, but use of energy increases due to continuous sensor operation
Solution Approach 1:
The patent implements continuous monitoring during the critical picking and stacking operations to ensure reliable detection of material presence. The sensor operates continuously throughout the material handling process, from picking at the source location through transport to the stacking location, ensuring that no material absence goes undetected while maintaining energy efficiency by limiting monitoring to the active operational phases.
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 detects and identifies missing material during the picking and stacking process, reducing errors and allowing for quick remediation by indicating the specific missing sheets, thus ensuring complete and accurate stacking.
Implementation Method 1
at least one vacuum cup arranged to adhere, with a negative pressure and at a first location, at least one sheet of material to the at least one vacuum cup
Data Source
AI summary
An apparatus for picking a product, including a control circuit, at least one vacuum cup arranged to adhere at least one sheet of material to the at least one vacuum cup, and at least one sensor configured to monitor an area proximate the at least one vacuum cup, and transmit at least one signal regarding a presence of at least one sheet of material in the area, wherein the apparatus is arranged to displace to a second location while continuously monitoring the area proximate the at least one vacuum cup, the at least one sensor is configured to transmit the at least one signal, and the control circuit is arranged to determine, responsive to the at least one signal, the sheet of material is not present in the area, and generate an error signal indicating that the at least one sheet of material is not present in the area.