Vacuum Gripper Compensators for Even Pressure on Contoured Objects

Solution Overview

Problem

Current robotic grippers struggle with efficiently picking highly contoured or compliant objects due to the inability to apply even pressure across suction cups, leading to potential damage to objects, work cells, and robotic systems, and are hindered by externally routed hoses that cause inaccuracy and maintenance issues.

Innovation Solution

A robotic end effector with integrated pneumatic cylinders for each suction cup, allowing independent activation and vacuum control, reducing the need for external air routing and ensuring even pressure distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If excessive top-down force is applied via the gripper to compress the object, then an effective seal between the suction cups and the object is formed, but the object may be broken or damaged

Engineering Contradiction:

Improveseal effectivenessVSAvoidobject damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The gripper system is segmented into multiple independently controllable suction cup zones, each with its own vacuum control. This allows selective activation of only the necessary suction cups for each object, reducing unnecessary compression force and enabling even pressure distribution across contoured surfaces without excessive top-down force.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts vacuum pressure and suction cup activation based on real-time sensor feedback about object characteristics. The controller modulates the vacuum level and selects specific suction cups to engage, adapting the gripping force to match the object's contour and compliance, thereby achieving reliable sealing without damaging the object.

Inventive Principle:

Principle #15Dynamics

2Reliability

If excessive top-down force is applied via the gripper to compress the object, then an effective seal between the suction cups and the object is formed, but the work cell or conveyor belt may be broken or damaged

Engineering Contradiction:

Improveseal effectivenessVSAvoidwork cell structural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The gripper system is segmented into multiple independently controllable suction cup zones, each with its own vacuum control. This allows selective activation of only the necessary suction cups for each object, reducing unnecessary compression force and enabling even pressure distribution across contoured surfaces without excessive top-down force.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates sensors that provide real-time feedback on object characteristics and gripping conditions. The controller uses this feedback to dynamically adjust vacuum pressure and suction cup activation, preventing excessive force that could damage the work cell or conveyor belt while maintaining effective sealing.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If an array of suction cups is used to pick objects of various masses, shapes, and sizes, then versatility is improved, but it becomes difficult to apply even pressure across all suction cups

Engineering Contradiction:

Improveobject handling capabilityVSAvoidpressure distribution uniformity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The gripper system is segmented into multiple independently controllable suction cup zones, each with its own vacuum control. This allows selective activation of only the necessary suction cups for each object, reducing unnecessary compression force and enabling even pressure distribution across contoured surfaces without excessive top-down force.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each suction cup or zone has independent vacuum control, allowing the system to apply locally optimized pressure distribution. The controller can adjust vacuum levels for individual suction cups based on their position and the object's local characteristics, ensuring even pressure across the entire array while maintaining versatility for different objects.

Inventive Principle:

Principle #3Local quality

Solution Approach 3:

The system incorporates sensors that provide real-time feedback on object characteristics and gripping conditions. The controller uses this feedback to dynamically adjust vacuum pressure and suction cup activation, preventing excessive force that could damage the work cell or conveyor belt while maintaining effective sealing.

Inventive Principle:

Principle #23Feedback

4Device complexity

If externally routed hoses are used for vacuum supply, then device complexity is reduced, but inaccuracy and maintenance issues increase

Engineering Contradiction:

Improvesystem structureVSAvoidpick location accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The vacuum supply system is merged with the robotic arm structure, integrating the vacuum pathways directly into the arm's internal architecture. This eliminates externally routed hoses and their associated flexibility issues, providing stable and accurate vacuum delivery while maintaining system compactness and reducing maintenance requirements.

Inventive Principle:

Principle #5Merging (Combining)

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 efficient and secure gripping of contoured objects without excessive force, minimizing damage and improving system reliability and maintainability.

Implementation Method 1

The system applies a pneumatic vacuum pressure within the sealed area of the bellows secured to the end effector of the object, thereby allowing the robot to lift and move the object

Methodology Applied

Scientific EffectPneumatic vacuum pressure: Vacuum

Implementation Method 2

the expansion volume within the compensator is filled with compressed air to move the compensator from the retracted position to the extended position

Methodology Applied

Scientific EffectCompressed air expansion: Pressure Increase

Implementation Method 3

A vacuum area is created inside the suction cup when the suction cup is in the extended position and the vacuum port is in communication with the vacuum pathway

Methodology Applied

Scientific EffectVacuum suction: Vacuum

Data Source

PatentUS20260061634A1Robotic picking apparatus and method for operating the same

Publication Date: 2026.03.05 PLUS ONE ROBOTICS INC

AI summary

A gripping system includes a gripper body having a vacuum pathway, a vacuum source connector, and an air source connector. A plurality of air lines are coupled to the air source connector and a respective plurality of valves are coupled to the air lines. Each one of the valves is configured for switching between a compressed air source and a vacuum source. A respective plurality of compensators are coupled to the plurality of air lines. Each compensator includes a cylinder and a piston configured for reciprocal linear translation within the cylinder. An expansion volume in the cylinder is in fluid communication with one of the air lines, and is configured to expand when the air line is coupled to the compressed air source and is configured to contract when the air line is coupled to the vacuum source, thereby extending and retracting the compensator relative to the gripper body.