Vacuum Gripper Leakage Detection via Secondary Chamber
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Solution Overview
Problem
Existing vacuum grippers struggle with detecting incorrect alignment of objects and creased or folded areas, leading to uneven stacking and interstices in the stack.
Innovation Solution
The vacuum gripper incorporates a secondary internal vacuum chamber with a flow-restriction connecting it to the primary vacuum chamber, and a pressure sensor monitoring the pressure in the secondary chamber to detect leakage and misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional vacuum gripper with a single vacuum chamber is used, then the structure is simple, but the ability to detect leakage and misalignment is insufficient
Solution Approach 1:
The single vacuum chamber is segmented into a primary vacuum chamber and a secondary vacuum chamber that are fluidly connected but functionally distinct. The secondary chamber is specifically designed for leakage detection while the primary chamber provides the main vacuum gripping function, allowing independent monitoring of vacuum levels in each chamber to detect misalignment and leakage conditions.
Solution Approach 2:
A flow restriction element is introduced as an intermediary component between the primary and secondary vacuum chambers. This flow restriction creates a controlled pressure differential that enables the secondary chamber to detect leakage conditions while maintaining the gripping function in the primary chamber, serving as a mediator that translates leakage events into detectable pressure changes.
2Reliability
If the suction holes are directly connected to the vacuum source, then the vacuum grip is strong, but leakage cannot be detected
Solution Approach 1:
The direct connection between suction holes and vacuum source is segmented by introducing the secondary vacuum chamber as an intermediate monitoring zone. The primary chamber maintains strong gripping through direct vacuum application, while the secondary chamber monitors for leakage through its restricted connection, enabling both strong grip and leakage detection simultaneously.
Solution Approach 2:
The secondary vacuum chamber acts as an intermediary monitoring system that detects leakage without compromising the primary gripping function. It provides a separate detection pathway that monitors vacuum integrity while the primary chamber maintains reliable gripping through direct vacuum application to the suction holes.
3Measurement precision
If the flow restriction cross-sectional area is much smaller than the suction hole area, then leakage detection sensitivity is high, but the false positive rate increases due to normal pressure variations
Solution Approach 1:
The cross-sectional area of the flow restriction is optimized to a specific range (0.1-10 mm²) that balances detection sensitivity with false positive reduction. This parameter is carefully selected based on the suction hole area to create an appropriate pressure differential that detects actual leakage while filtering out normal pressure variations, preventing false positives while maintaining sensitivity.
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
This design allows for effective detection of leakage and misalignment, ensuring correct engagement and stacking of sheet-formed objects by stopping the automated process when high pressure is detected.
Implementation Method 1
a flow-restriction (37) connecting the primary vacuum chamber (25) to the secondary vacuum chamber (35), wherein the size of the cross-sectional area of the flow restriction (37) is similar to the size of the cross-sectional area of one hole of the at least one hole (3)
Implementation Method 2
the pressure in the secondary vacuum chamber is higher than the pressure in the primary vacuum chamber when merely a single hole of a suction area is not covered by an engaged object
Implementation Method 3
an opening (30) for connection to a pressure sensor (33) configured to sensing a pressure inside the gripper body (20)
Implementation Method 4
an internal primary vacuum chamber (25); an opening (15) for connecting the internal primary vacuum chamber (25) to a source of vacuum (17)
Data Source
AI summary
A vacuum gripper having a suction area with improved leakage detection, a method of detecting leakage of surrounding fluid into such vacuum gripper, a method of detecting leakage of surrounding fluid into a gripper, and an automated operation involving engaging a sheet-formed object with the vacuum gripper are disclosed.