Vacuum End Effector With Internal Cup Valves for Selective Picking
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Solution Overview
Problem
Existing robotic packaging systems face challenges in efficiently collecting and arranging products of different shapes and sizes into standard shipping containers due to limitations in vacuum flow management and end effector design, leading to inefficiencies and increased costs.
Innovation Solution
A programmable end effector with a vacuum plenum housing and array of vacuum retrievers, each equipped with an air control valve that allows selective activation of suction cups to form desired patterns, ensuring high vacuum flow without air leakage and complex conduits, enabling efficient picking and placement of products in various configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple end effectors with different pick groups are provided for different product patterns, then the ability to handle various product shapes and sizes is improved, but the cost and device complexity increase significantly
Solution Approach 1:
The end effector is divided into multiple independently controllable zones, each with its own vacuum retrieval elements. Each zone can be selectively activated or deactivated to match different product patterns, allowing a single end effector to handle multiple product configurations without requiring multiple specialized effectors
Solution Approach 2:
The end effector incorporates dynamically controllable vacuum zones that can be activated or deactivated in real-time based on the product being handled. This dynamic control allows the same physical structure to adapt to different product shapes and sizes, eliminating the need for multiple static end effectors
2Ease of operation
If the vacuum source is split into several tubes with valves to control vacuum flow to different suction zones, then selective picking is enabled, but the vacuum flow becomes restricted and the system complexity increases
Solution Approach 1:
The valve mechanism is extracted and integrated directly into each individual suction cup or retrieval element rather than being located in central vacuum distribution tubes. This allows each suction element to have independent vacuum control without requiring complex tube networks, maintaining high vacuum flow while enabling selective zone activation
Solution Approach 2:
Each suction cup incorporates an internal valve mechanism that acts as an intermediary between the vacuum source and the suction opening. This internal valve allows selective activation of individual suction elements while maintaining direct, unrestricted vacuum flow paths, avoiding the flow restrictions that would result from multiple external valves in series
3Quantity of substance
If a large plenum with multiple suction retrievers is used to allow high vacuum flow, then vacuum flow is improved, but multiple picks fail due to air leakage through open cups and the vertical space occupied increases
Solution Approach 1:
Each suction cup is equipped with its own independent valve mechanism that controls vacuum flow locally at the suction element level. This allows individual suction cups to be activated or deactivated independently, preventing air leakage from open cups during multi-pick operations while maintaining high vacuum flow to active cups, thereby improving pick reliability
4Adaptability or versatility
If conventional vacuum systems with external hoses and conduits are used, then vacuum flow can be directed to multiple zones, but the end effector becomes heavy and occupies large vertical space
Solution Approach 1:
The valve mechanisms are nested within the suction cups themselves, with the valve components integrated into the internal structure of each suction element. This nesting eliminates the need for external hoses and conduits, significantly reducing the end effector's weight and vertical space occupation while maintaining the capability to direct vacuum flow to multiple zones
Solution Approach 2:
The system uses pneumatic valves integrated into each suction cup to control vacuum flow. These compact pneumatic components replace bulky external hose and conduit systems, achieving the same vacuum distribution function with much reduced weight and space requirements
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 enables flexible and efficient collection and arrangement of diverse products into standard containers, reducing the need for multiple end effectors and minimizing vacuum flow restrictions, resulting in a compact, durable, and cost-effective packaging system.
Implementation Method 1
a vacuum source connected to the vacuum plenum housing to draw a sub-atmospheric pressure within the vacuum plenum thereby enabling the vacuum retrievers to engage the work products
Implementation Method 2
A valve may be positioned in each vacuum retriever that separates each vacuum retriever into an upper chamber in communication with vacuum plenum housing and a lower chamber in communication with the atmosphere for engaging the work products
Data Source
AI summary
An air retriever, such as a bellows (24) is used in an end effector (18) for lifting work products (22) in prearranged configurations, and delivery to a container (20) in a predetermined pattern. An air flow control valve (50) is positioned in each bellows (24) for individually controlling the flow of air through each bellows so that the bellows in a pick zone may draw air for picking up work products while air flow is not applied to the other bellows out of the pick zone.