Vacuum Gripper End-Pad Pickup for Randomly Stacked Workpieces
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Solution Overview
Problem
Conventional vacuum grippers struggle to selectively hold and transport the uppermost workpiece from a stack, especially when workpieces are randomly arranged, as they require magnetic separation, which can magnetize workpieces and fail to separate non-magnetic materials like aluminum plates or austenitic stainless steel, and necessitate aligned end faces.
Innovation Solution
A vacuum gripper system equipped with multiple vacuum pads and an electric slider, controlled by a proximity sensor and air cylinder, allows for the detection and suction of the uppermost workpiece without the need for magnetic separation, enabling the handling of non-magnetic materials and randomly arranged workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnet floater is used to separate workpieces, then magnetic workpieces can be separated, but non-magnetic workpieces cannot be separated and workpieces may be magnetized
Solution Approach 1:
The patent replaces the magnetic field-based separation system with a mechanical vision-guided positioning system. A camera captures images of workpieces on the pallet, and the control unit processes these images to identify the uppermost workpiece position, enabling separation and selection based on visual detection rather than magnetic properties.
Solution Approach 2:
The patent introduces a camera and control unit as intermediary components between the workpieces and the vacuum gripper. The camera captures visual information about workpiece arrangement, and the control unit processes this information to determine the correct positioning, acting as an intermediary that enables intelligent selection without direct magnetic interaction.
2Reliability
If a magnet floater is used to separate workpieces, then workpieces can be separated, but aligned end faces are required
Solution Approach 1:
The patent transitions from a static magnetic separation approach requiring fixed alignment to a dynamic vision-guided system. The camera and control unit can adapt to various workpiece arrangements and positions on the pallet, allowing the system to dynamically identify and select the uppermost workpiece regardless of initial alignment.
Solution Approach 2:
The patent changes the detection parameter from magnetic field interaction (which requires specific geometric alignment) to visual detection through camera imaging. This parameter change allows the system to identify workpiece positions and orientations based on visual features rather than magnetic properties, eliminating the alignment requirement.
3Reliability
If multiple vacuum pads are used to detect and suction workpieces, then the uppermost workpiece can be identified, but the system complexity increases
Solution Approach 1:
The patent makes the vacuum pad system multi-functional by equipping it with both suction capability and detection capability. The same vacuum pad assembly that holds the workpiece also contains proximity sensors that detect the presence and position of workpieces, eliminating the need for separate detection hardware and reducing overall system complexity.
Solution Approach 2:
The patent merges the detection function and suction function into a single integrated vacuum pad assembly. The proximity sensors are built into the vacuum pad structure, allowing simultaneous detection and handling of workpieces through one component rather than requiring separate sensor arrays and actuator systems.
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 reliable suction and transport of the uppermost workpiece from a stack, regardless of material type or arrangement, without magnetization and without requiring aligned end faces, improving flexibility and versatility in workpiece handling.
Implementation Method 1
a vacuum pad 303 for sucking the uppermost workpiece W
Data Source
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AI summary
A plurality of first vacuum pads (35a to 35h) for suctioning a workpiece (W) are directly or indirectly attached to a main body (support columns 31 to 33). A slider (301) is configured to slide in an outward direction of the main body. When the slider (301) slides to protrude in the outward direction of the main body while the first vacuum pads are suctioning the workpiece (W), a sensor (305) detects an end portion of the workpiece (W). While the sensor (305) detects the end portion of the workpiece (W) and the slider (301) is stopped, a second vacuum pad (303) holds up the end portion of the workpiece (W) by suctioning the workpiece (W) at a position outside from positions at which the first vacuum pads suction the workpiece (W).