Zoned Robot End Effector for Vacuum Leak-Free Product Picking
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Solution Overview
Problem
Current robotic packaging systems face challenges in efficiently picking and arranging products of different shapes and sizes into standard containers due to limitations in vacuum flow management and the need for multiple end effectors, leading to vacuum leakage and increased costs.
Innovation Solution
A programmable zoned end effector with independently controlled suction cups, allowing selective application of sub-atmospheric air pressure to only the required zones, minimizing vacuum loss and enabling the formation of various patterns for diverse product sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple end effectors with different pick zones are provided for different products, then the ability to pick different shaped and sized products is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The suction surface of the end effector is divided into multiple independently controllable zones with individual vacuum control. Each zone can be selectively activated or deactivated to match the shape and size of different products, allowing a single end effector to handle multiple product types without requiring multiple specialized effectors.
Solution Approach 2:
The end effector incorporates dynamic vacuum control where the vacuum level in each zone can be independently adjusted in real-time. This dynamic adjustment allows the same end effector to adapt to different product geometries by modifying the vacuum distribution pattern, eliminating the need for multiple static end effectors designed for specific product types.
2Quantity of substance
If a large plenum with multiple suction cups is used to allow high flow, then the vacuum flow capacity is improved, but the ability to perform multiple picks and zone control is lost
Solution Approach 1:
The large plenum is segmented into multiple zones, each with its own subset of suction cups that can be independently controlled. This segmentation maintains the high flow capacity of the large plenum while enabling selective activation of specific zones for multiple pick operations, combining the advantages of both large plenum and zoned control systems.
Solution Approach 2:
Different zones within the plenum can have different vacuum levels and flow characteristics optimized for specific product types. This local quality control allows high vacuum flow to be directed to specific areas when needed, while other areas remain inactive, enabling both high flow capacity and multiple pick capability simultaneously.
3Speed
If vacuum is applied to all suction cups simultaneously, then the picking speed is improved, but vacuum loss occurs through unsealed suction cups
Solution Approach 1:
The suction cups are organized into zones with independent vacuum control, allowing vacuum to be applied only to the specific zone where a product is present. This eliminates vacuum loss through unsealed cups in other zones while maintaining fast picking speed by immediately activating the needed zone without waiting for other zones.
Solution Approach 2:
The vacuum parameter is dynamically changed by activating or deactivating specific zones based on product detection. When a product is detected in a particular zone, vacuum is rapidly applied to that zone only, achieving fast picking speed while preventing energy loss in zones where no product is present.
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
Enables efficient and flexible picking and placement of products in desired patterns without vacuum leakage, reducing the need for multiple end effectors and maintaining high vacuum flow, thus accommodating a wide range of product sizes and shapes effectively.
Implementation Method 1
applying a sub-atmospheric air pressure to the vacuum retrievers in the first zone of vacuum retrievers
Data Source
AI summary
An end effector for a robot having an array of suction cups includes an air control valve connected to each suction cup. Each valve can be individually operated so that specific zones of suction cups may be activated while others are dormant. The dormant suction cups are closed to the sub-atmospheric pressure, so that leakage of air through unused suction cups is avoided, while only the suction cups of the selected zone perform the picking of the work products. This allows the end effector to provide accurate and constant sub-atmospheric pressure to the work products during the picking process.