Vacuum End Effector with Foam and Elastomeric Cups
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Solution Overview
Problem
Current vacuum-based end effectors are inadequate for grasping parcels of varying shapes, sizes, and materials, particularly flexible plastic bags and paper-based materials, due to their inability to effectively engage non-uniform surfaces.
Innovation Solution
A vacuum-based end effector with a combination of foam and elastomeric vacuum cups, each configured to suit different materials, and adjustable spacing, along with sensors for pneumatic engagement and proximity detection, to enhance the chances of successful contact with parcels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single type of vacuum cup is used in the end effector, then the device complexity is reduced, but the adaptability to different parcel materials and shapes deteriorates
Solution Approach 1:
The end effector is divided into multiple vacuum cup units, each with specialized lips for different materials. The array includes foam lips for flexible materials, elastomeric lips for paper-based materials, and thermoplastic lips for rigid materials, allowing the system to handle diverse parcel types without requiring a completely different end effector for each material type.
Solution Approach 2:
Different regions of the vacuum cup array are equipped with locally optimized lip materials and geometries. Each vacuum cup unit has lips specifically designed for its intended material type, creating local quality variations that enhance overall adaptability while maintaining a relatively simple global structure.
2Adaptability or versatility
If vacuum cups are fixed in position, then the device complexity is reduced, but the ability to engage parcels of varying shapes and sizes deteriorates
Solution Approach 1:
The vacuum cup units are mounted on adjustable mechanisms that allow repositioning along the base plate. This dynamic positioning capability enables the end effector to adapt to parcels of varying shapes and sizes by optimizing the spatial distribution and orientation of vacuum cups, while the adjustability mechanisms remain relatively simple in design.
3Reliability
If the end effector uses a fixed configuration of vacuum cups, then the ease of operation is improved, but the reliability of engagement across different parcel types deteriorates
Solution Approach 1:
The end effector is pre-configured with multiple vacuum cup units featuring different lip materials and geometries arranged in specific patterns. This preliminary configuration ensures that appropriate vacuum cups are already in position and ready for different parcel types, eliminating the need for complex real-time adjustments or selections during operation while maintaining high engagement reliability.
4Adaptability or versatility
If the end effector includes multiple types of vacuum cups with different lip materials, then the adaptability to different materials is improved, but the manufacturing complexity deteriorates
Solution Approach 1:
The manufacturing process is segmented into modular steps for each vacuum cup unit type. Each unit with its specific lip material (foam, elastomeric, or thermoplastic) can be manufactured independently using optimized processes for that material, then assembled into the complete end effector array. This modular segmentation simplifies the overall manufacturing complexity while maintaining material-specific performance characteristics.
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 end effector effectively engages a wide range of parcels by utilizing foam cups for flexible materials and elastomeric cups for paper-based materials, improving grasping capabilities and stability through adjustable positioning and sensor feedback for precise control.
Implementation Method 1
Each vacuum cup is configured to be placed in fluid communication with a vacuum source to provide the vacuum cup with a suction force
Implementation Method 2
provide the vacuum cup with a suction force which can be used to grasp parcels
Data Source
AI summary
A vacuum-based end effector for engaging parcels includes a base plate, one or more vacuum cups of a first type, and one or more vacuum cups of a second type. Each vacuum cup of the vacuum-based end effector is configured to be placed in fluid communication with a vacuum source to provide the vacuum cup with a suction force which can be used to engage and grasp parcels. Each vacuum cup includes a bellows defining a pathway for a flow of air and a lip connected to the bellows. Each lip of the one or more vacuum cups of the first type comprises a foam lip, and each lip of the one or more vacuum cups of the second type comprises an elastomeric lip. The vacuum-based end effector can be combined with a robot to provide an improved system for engaging parcels.