Vacuum Gripper with Magnetic Shutter Control for Complex Shapes
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Solution Overview
Problem
Existing vacuum grippers are inefficient, inaccurate, and unreliable for picking up objects with complex shapes or flexible materials, particularly in selectively removing strips of cut sheet materials like leather, and lack a reliable activation/deactivation system for suction cups.
Innovation Solution
A vacuum gripper with a manifold system that includes a central hub connected to a handling device, an extraction conduit for creating a vacuum, and a by-pass conduit with a one-way valve and filter, along with a magnetic shutter mechanism to control suction cup activation and deactivation, allowing precise and efficient picking up and laying down of objects with complex shapes or flexible materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional vacuum gripper system is used, then the structure is simple, but the picking precision and reliability for complex shapes and flexible materials deteriorates
Solution Approach 1:
The suction plate is divided into multiple independently controllable suction cups, each with its own activation and deactivation capability. This segmentation allows selective engagement of specific suction cups based on the object geometry, improving picking reliability for complex shapes and flexible materials while maintaining manageable system complexity through modular control
Solution Approach 2:
The suction cups are equipped with movable shutters that can dynamically open or close the suction ports based on real-time requirements. This dynamic adjustment capability enables the gripper to adapt to varying object shapes and materials, enhancing picking reliability without requiring a completely complex reconfigurable structure
2Productivity
If suction cups are continuously activated, then the gripping force is maintained, but the energy consumption increases and the picking speed decreases
Solution Approach 1:
The suction cups operate in periodic cycles of activation and deactivation rather than continuous operation. The movable shutters enable rapid opening and closing of suction ports, allowing the gripper to engage objects quickly, maintain grip during transport, and release efficiently at destination. This periodic action significantly reduces energy consumption compared to continuous activation while maintaining high picking speed
Solution Approach 2:
Only the specific suction cups needed for the current task are activated, while others remain deactivated. This localized activation approach, enabled by individual shutter control for each suction cup, reduces overall energy consumption by limiting vacuum generation to only the necessary regions, thereby improving picking speed and reducing energy use simultaneously
3Adaptability or versatility
If multiple suction cups are used for complex shapes, then the versatility improves, but the control system complexity increases
Solution Approach 1:
The suction plate is divided into multiple independently controllable suction cups, each with its own activation and deactivation capability. This segmentation allows selective engagement of specific suction cups based on the object geometry, improving picking reliability for complex shapes and flexible materials while maintaining manageable system complexity through modular control
Solution Approach 2:
The system includes automatic control means that can autonomously determine which suction cups to activate based on pre-programmed parameters related to object shape and material properties. This self-service capability reduces the complexity of manual control while maintaining high versatility, as the system automatically adapts to different object types without requiring complex real-time decision-making infrastructure
4Productivity
If the suction cups are rapidly activated and deactivated, then the picking efficiency improves, but the system reliability may deteriorate due to wear
Solution Approach 1:
The movable shutters are actuated by pneumatic or electromagnetic means rather than pure mechanical systems, reducing friction and wear. The rapid opening and closing of shutters is achieved through controlled pressure differential or electromagnetic force, which minimizes mechanical contact and wear on moving parts. This substitution maintains rapid activation/deactivation capability while improving system reliability by reducing wear-related failures
Solution Approach 2:
The system includes damping elements and controlled pressure release mechanisms that cushion the impact and stress on the shutter mechanism during rapid opening and closing operations. By providing beforehand protection against shock loads and excessive wear, the system maintains high picking efficiency while preserving component life and overall system reliability
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 provides a versatile, efficient, and reliable vacuum gripper capable of accurately picking up and stacking objects with complex shapes or flexible materials, ensuring rapid and precise activation/deactivation of suction cups, enhancing the efficiency and reliability of the picking process.
Implementation Method 1
an extraction conduit (23) which is suitable for being connected to an extraction source for creating a vacuum in the chamber (11)
Implementation Method 2
a magnetic shutter mechanism to control suction cup activation and deactivation
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
Vacuum gripper (100) comprising: a frame (1) that defines a chamber (11) for vacuum; a plate assembly (G) that supports suction caps (3), valves (V) provided with a shutter (73) in correspondence of each suction cup (3) that can be moved from a closing position, wherein the suction cup is deactivated, to an opening position, wherein the suction cup is activated, an actuation device (4) suitable for individually actuating the shutter (73) from the closing position to the opening position in order to activate the desired suction cup, a plotter (5) connected to the actuation device (4) and deactivation means (N) to deactivate all the activated suction cups simultaneously.