Vacuum Tool With Switchable Plate For Flexible Material Handling
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Solution Overview
Problem
Current robotic means for picking and placing parts in manufacturing lack the control, dexterity, and cost-effectiveness required for various manufacturing systems, particularly when handling flexible or porous materials.
Innovation Solution
A vacuum tool with a switchable plate that can be adapted with different aperture configurations, allowing for the distribution of vacuum force across a larger surface area to prevent bending or creasing of materials, and enabling effective manipulation of diverse materials through a removably coupled plate mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional robotic means are used for picking and placing parts, then automation is achieved, but control and dexterity are insufficient
Solution Approach 1:
The vacuum tool is divided into multiple independently controllable vacuum zones, each with its own vacuum source or control mechanism. This segmentation allows selective activation of specific zones to match the size and position of different parts, providing both automation and fine-grained control for dexterous manipulation.
Solution Approach 2:
The vacuum tool employs dynamic control of vacuum zones, where individual zones can be selectively activated or deactivated based on real-time requirements. This dynamic capability enables the system to adapt to different part sizes, shapes, and positions, achieving both automated operation and precise control.
2Productivity
If vacuum force is concentrated on a small area, then picking effectiveness is improved, but material bending or creasing occurs
Solution Approach 1:
The vacuum surface is segmented into multiple zones that can be independently controlled. When picking up large or flexible materials, multiple zones are activated to distribute the vacuum force across a broader area, preventing localized stress that would cause bending or creasing while maintaining effective picking.
Solution Approach 2:
Different vacuum zones can be activated with different vacuum levels based on local requirements. Areas requiring gentle handling use lower vacuum levels or fewer active zones, while areas needing secure grip use higher vacuum levels, thus preventing material deformation while maintaining picking effectiveness.
3Ease of manufacture
If a fixed vacuum tool design is used, then manufacturing simplicity is maintained, but adaptability to different materials is reduced
Solution Approach 1:
The vacuum tool incorporates dynamically controllable zones that can be selectively activated based on the material being handled. This allows a single tool design to adapt to various materials and part configurations without requiring multiple specialized tools, maintaining manufacturing simplicity while achieving high versatility.
Solution Approach 2:
The multi-zone vacuum tool is designed to handle multiple types of materials and parts through a single unified structure. By controlling which zones are active and at what vacuum levels, the same tool can effectively pick and place diverse materials ranging from flexible sheets to rigid components.
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 vacuum tool effectively picks and places a wide range of materials, including flexible and porous ones, by distributing suction force uniformly, reducing material deformation and enabling efficient handling with reduced material and energy usage.
Implementation Method 1
The vacuum distributor has an exterior top surface, an interior top surface, an exterior side surface, and an interior side surface. The vacuum distributor further has a vacuum aperture extending through the exterior top surface and the interior top surface. The vacuum distributor additionally has a vacuum distribution cavity formed, at least in part, by the interior top surface and the interior side surface.
Implementation Method 2
The vacuum tool is effective for picking and placing one or more manufacturing parts utilizing a vacuum force.
Data Source
AI summary
The present invention provides systems, methods, and apparatus for a vacuum tool having a switchable plate, such that a common vacuum tool may be adapted with different plates. A switchable plate may form the entirety of the vacuum tool's material contacting surface or a switchable plate may form a portion of the material contacting surface. The vacuum tool is effective for picking and placing one or more manufacturing parts utilizing a vacuum force.