Vacuum Gripper End Detection for Randomly Stacked Workpieces
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Solution Overview
Problem
Existing vacuum grippers struggle to efficiently hold and transport one uppermost workpiece from a stack of randomly arranged workpieces, particularly non-magnetic materials like aluminum plates or austenitic stainless steel, without magnetizing them, and require precise alignment of workpiece ends.
Innovation Solution
A vacuum gripper with a main body, first vacuum pads, a slider, a sensor, and a second vacuum pad that detects and holds the end portion of the uppermost workpiece using a sensor, allowing it to be suctioned and held outside the initial suction points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a magnet floater is used to separate stacked workpieces, then magnetic workpieces can be separated, but non-magnetic workpieces such as aluminum plates or austenitic stainless steel cannot be separated
Solution Approach 1:
The patent replaces the magnetic field-based separation system with a sensor-based detection system. The sensor detects the presence and position of workpieces regardless of material composition, enabling reliable separation of both magnetic and non-magnetic workpieces through mechanical positioning rather than magnetic attraction.
Solution Approach 2:
The patent changes the detection parameter from magnetic properties to optical or electrical properties that work for all materials. The sensor detects workpiece presence based on physical position rather than material-specific magnetic characteristics, making the system universally applicable to all workpiece materials.
2Adaptability or versatility
If a magnet floater is used to separate workpieces, then workpiece separation is achieved, but the workpiece may be magnetized
Solution Approach 1:
The patent replaces the magnetic field-based separation system with a sensor-based detection system. The sensor detects the presence and position of workpieces regardless of material composition, enabling reliable separation of both magnetic and non-magnetic workpieces through mechanical positioning rather than magnetic attraction.
Solution Approach 2:
The patent extracts the magnetic field component from the separation system, eliminating the source of unwanted magnetization while retaining the workpiece separation function through sensor-based detection and mechanical positioning.
3Reliability
If workpieces are stacked with end faces aligned to use a magnet floater, then workpiece separation is possible, but precise alignment is required
Solution Approach 1:
The patent employs sensor feedback to detect the actual position of workpiece end faces. The sensor provides real-time information about workpiece placement, allowing the system to adapt to random arrangements and determine the uppermost workpiece based on detected positions rather than requiring pre-aligned stacking.
Solution Approach 2:
The patent transitions from a static alignment requirement to a dynamic detection system. The sensor-based system can adapt to varying workpiece positions and randomly arranged stacks, determining the uppermost workpiece based on real-time detection rather than fixed alignment constraints.
4Adaptability or versatility
If a camera system is used to detect workpiece positions, then random arrangement is permitted, but the magnet floater cannot be used for separation
Solution Approach 1:
The patent merges the camera-based detection system with a sensor-based separation system. The sensor detects workpiece positions and the system integrates this information to control the vacuum pads, combining detection flexibility with reliable separation capability for randomly arranged workpieces.
Solution Approach 2:
The patent introduces a sensor as an intermediary between the camera detection system and the vacuum pad actuation. The sensor translates optical detection data into actionable separation control, enabling reliable workpiece selection based on detected positions without requiring magnetic properties.
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
Enables the vacuum gripper to securely hold and transport the uppermost workpiece without magnetization, accommodating randomly arranged workpieces and eliminating the need for precise alignment.
Implementation Method 1
a plurality of first vacuum pads attached directly or indirectly to the main body and configured to suction a workpiece
Data Source
AI summary
A plurality of first vacuum pads for suctioning a workpiece are directly or indirectly attached to a main body. A slider is configured to slide in an outward direction of the main body. When the slider slides to protrude in the outward direction of the main body while the first vacuum pads are suctioning the workpiece, a sensor detects an end portion of the workpiece. While the sensor detects the end portion of the workpiece and the slider is stopped, a second vacuum pad holds up the end portion of the workpiece by suctioning the workpiece at a position outside from positions at which the first vacuum pads suction the workpiece.