Vacuum Hood End Effector for Leaky Pallet Layer Picking
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Solution Overview
Problem
Existing end effector systems for handling and moving articles, particularly those with multiple layers or sensitive items, face challenges in efficiently lifting and moving articles without manual intervention, especially when dealing with varying sizes and leaky or misaligned pallets, and lack effective detection of slip sheets and dropped products.
Innovation Solution
A hood enclosure end effector system with a suction generator, pivotally connected side walls, and corner members for air leakage control, equipped with vacuum cups and sensors for detecting slip sheets and dropped products, allowing for flexible size accommodation and secure lifting of articles, including partial layers and slip sheets, using a robotic arm for precise movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a hood enclosure end effector system is used to lift and move articles, then handling efficiency and automation are improved, but the system complexity and cost increase
Solution Approach 1:
The patent replaces traditional mechanical gripping systems with a suction-based hood enclosure system. The suction generator creates negative pressure within the hood to lift and hold articles, eliminating the need for complex mechanical clamps, grippers, or linkages. This substitution reduces mechanical complexity while maintaining effective article handling capability.
Solution Approach 2:
The hood enclosure system serves multiple functions: it lifts articles from pallets, holds them during transport, and can accommodate various article sizes and configurations. The same basic hood structure handles different product types by adjusting suction parameters rather than requiring different mechanical end effectors, improving versatility without increasing system complexity.
2Force
If suction is applied to lift multiple tiers of articles, then lifting capacity is improved, but air leakage through the articles reduces suction effectiveness
Solution Approach 1:
The patent introduces a permeable barrier (such as a mesh or screen material) within the hood enclosure that acts as an intermediary. This barrier allows air to pass through while blocking articles, creating a seal that prevents air leakage around the articles. The barrier mediates between the suction force needed to lift multiple tiers and the air leakage that would otherwise reduce suction effectiveness.
Solution Approach 2:
The hood enclosure utilizes flexible side walls and a permeable barrier that can conform to the shape of the articles being lifted. This flexibility allows the enclosure to adapt to different article configurations and maintain an effective seal against air leakage, enabling sustained suction force for lifting multiple tiers without energy loss.
3Strength
If the hood enclosure is made rigid for structural stability, then structural strength is improved, but adaptability to varying article sizes is reduced
Solution Approach 1:
The patent employs side walls with variable rigidity that can dynamically adjust their stiffness. The side walls are constructed to be rigid when structural strength is needed (such as when supporting heavy loads) but can become more flexible to conform to different article sizes and shapes. This dynamic property allows the same structure to maintain strength while adapting to varying configurations.
Solution Approach 2:
Different portions of the hood enclosure have different rigidity characteristics. The top closure and critical structural joints maintain high rigidity for strength, while the side walls incorporate flexible segments that can adapt to varying article dimensions. This local variation in quality allows the structure to be strong where needed and adaptable where flexibility is required.
4Measurement precision
If sensors are added to detect slip sheets and dropped products, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The patent implements sensors that leverage the existing suction field and hood structure to detect slip sheets and dropped products. Rather than adding independent detection systems, the sensors utilize the natural air flow and pressure differentials created by the suction process itself. This self-service approach improves detection accuracy while minimizing additional complexity by reusing existing system elements.
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 system effectively lifts and moves articles of varying sizes with high accuracy, detects and handles slip sheets, and prevents product loss by maintaining a consistent suction level and providing real-time feedback on product integrity during handling.
Implementation Method 1
A suction generator is coupled in fluid communication with the hood enclosure and provides a negative pressure within the hood
Implementation Method 2
a permeable barrier extending across the opening. The opening and the collation of flexible packages are brought together at the first location. Suction is applied to the enclosure drawing air into the enclosure through the permeable barrier
Data Source
AI summary
A system, method and apparatus for handling and moving a layer of articles, such as cased products. The system and apparatus comprise a hood enclosure having four side panels, and four interconnected corner member. The side walls and corner members interoperate to form an adjustable enclosure to pick the layer of articles. A vacuum generate is utilized to evacuate air from the hood enclosure to assist in lifting the layer of articles. The hood enclosure may utilize an array of vacuum cups to assist in the lifting of articles into the hood enclosure. The method is directed towards utilizing the hood layer end effector to move and hand articles.