GRIPPERS AND PLY SEPARATION METHODS

An air gripper having a body, an upper cover releasably coupled to a first surface of the body, a lower cover releasably coupled to a second surface of the body, and a through-hole extending through the body, upper cover, and lower cover, is disclosed. An edge gripper having an upper body, a lower body releasably coupled to the upper body, a guide attachment releasably coupled to the front face of the upper body, and a vent positioned between the front face of the upper body and the guide body of the guide attachment, is disclosed. A destacker assembly having a carriage, an edge gripper coupled to the carriage, and a finger coupled to the carriage, is disclosed. Methods of using the air gripper, the edge gripper, and destacker assembly to move and/or a ply of material from a stack having a plurality of plies are disclosed.

FIELD

This disclosure relates to robotic arm end effectors, and more particularly to gripping devices and methods of using the gripping devices to lift, separate, and/or move objects.

BACKGROUND

A robotic arm is a programable, mechanical arm with functionality similar to a human arm. Robotic arms can be used in various manufacturing processes to handle (e.g., lift, transport) objects in its work environment. The device at the end of a robotic arm that interacts with the objects is called an end effector. There are different types of end effectors for carrying out particular functions, but the end effector will generally include a tool or gripper. Some objects are difficult to handle because they are inherently flexible, slippery, fragile, etc. Accordingly, there remains a need in the art for end effectors having improved functionality.

SUMMARY

In various embodiments, an air gripper configured to lift an object is described. In some embodiments, the gripper comprises a body having an annular shape modified by a joint projecting from a side of the body; an upper cover releasably coupled to a first surface of the body; a lower cover releasably coupled to a second surface of the body; and a through-hole extending through the body, the upper cover, and the lower cover, the through-hole having a truncated conical shape defined by a base at the second surface of the body and an apex at the first surface of the body; wherein the body comprises a pocket configured to receive an input of gas and an annular channel in fluid communication with the pocket; and wherein the annular channel is in fluid communication with a surface of the through-hole via a gap between the body and the lower cover.

In some embodiments, the truncated conical shape of the through-hole defines an interior annular surface of the body, the interior annular surface being pitched at an angle in a range of 30-80 degrees from the base to the apex.

In some embodiments, the interior annular surface has a slope at an angle in a range of 40-60 degrees from the base to the apex.

In some embodiments, the pocket is centered between lateral edges of the joint and positioned at least partially within the joint.

In some embodiments, the lower cover comprises one or more crossbars extending over the through-hole from one side of the lower cover to an opposite side.

In some embodiments, the gripper further comprises an annular spacer between the lower cover and the body.

In some embodiments, the spacer has a thickness that defines the gap between the body and the lower cover.

In some embodiments, a suction for lifting the object is created in the through-hole when the input of gas flows from the pocket through the annular channel, through the gap between the body and the lower cover, and to the interior annular surface of the body.

In various embodiments, an edge gripper configured to lift an edge of an object is described. In some embodiments, the edge gripper comprises an upper body comprising a top face having an access well configured to receive an input of gas, the well being in fluid communication with a gas storage located within an interior core of the upper body, and the gas storage being in fluid communication with a duct extending from the gas storage to a front face of the upper body; a lower body releasably coupled to the upper body at a bottom face opposite the top face, the lower body comprising a conduit having an first opening on a front face corresponding to the front face of the upper body, wherein the conduit extends through the lower body to a second opening adjacent to a rear face of the lower body opposite the front face; a guide attachment releasably coupled to the front face of the upper body, the guide attachment having a plurality of tines projecting downward from a guide body and curving toward a cross member positioned in proximity to the first opening of the conduit in the lower body; and a vent positioned between the front face of the upper body and the guide body of the guide attachment, the vent being in fluid communication with the duct in the upper body.

In some embodiments, the lower body comprises a sidelong J-shape with a curve of the sidelong J-shape ending at the second opening of the conduit; and wherein the lower body further comprises a curved protrusion on the front face, the curved protrusion being adjacent to the first opening of the conduit.

In some embodiments, respective tines of the plurality of tines on are spaced apart from one another by a spaced distance that defines a plurality of gaps, wherein respective gaps of the plurality of gaps are positioned between adjacent tines.

In some embodiments, the edge gripper further comprises a plurality of fins projecting outward from the front face of the upper body.

In some embodiments, the plurality of fins are spaced apart from one another by a spaced distance that defines a plurality of channels, wherein the respective channels are positioned between adjacent fins.

In some embodiments, the guide body of the guide attachment is in contact with the plurality of fins.

In some embodiments, a suction for lifting the edge of the object is created in the conduit of the lower body when the input of gas flows from the gas storage through the duct, through the vent between the upper body and the guide assembly, and along the curved protrusion on the front face of the lower body toward the first opening of the conduit.

In some embodiments, the edge gripper further comprises a spacer positioned between the upper body and the guide attachment, wherein the thickness of the spacer defines the vent between the front face of the upper body and the guide body of the guide attachment.

In various embodiments, a destacker assembly is described. In some embodiments, the destacker assembly comprises a carriage, an edge gripper coupled to a first face of the carriage, and a finger coupled to the first face of the carriage; wherein the edge gripper comprises: an upper body comprising a top face having an access well configured to receive an input of gas, the well being in fluid communication with a gas storage located within an interior core of the upper body, and the gas storage being in fluid communication with a duct extending from the gas storage to a front face of the upper body; a lower body releasably coupled to the upper body at a bottom face opposite the top face, the lower body comprising a conduit having an first opening on a front face corresponding to the front face of the upper body, wherein the conduit extends through the lower body to a second opening adjacent to a rear face of the lower body opposite the front face; a guide attachment releasably coupled to the front face of the upper body, the guide attachment having a plurality of tines projecting downward from a guide body and curving toward a cross member positioned in proximity to the first opening of the conduit in the lower body; and a vent positioned between the front face of the upper body and the guide body of the guide attachment, the vent being in fluid communication with the duct in the upper body; and wherein the finger comprises a top face having an access well for receiving an input of gas, the well being in fluid communication with a passage within an interior core of the finger, and the passage being in fluid communication with an outlet that can release the gas via a bottom face of the finger, the bottom face being opposite to the top face; and wherein the carriage comprises a first bracket for coupling the edge gripper to the first face of the carriage and a second bracket for coupling the finger to the first face of the carriage.

In some embodiments, the finger and second bracket are moveable about the first face of the carriage, and wherein the finger and second bracket are configured to move laterally toward and away from the edge gripper.

In some embodiments, the edge gripper and the finger are configured to lift and move a single ply of a material from a stack having multiple plies of the material.

In some embodiments, the edge gripper and the finger are configured to separate a first ply of a material from one or more other plies of the material.

The drawings are not necessarily to scale, and certain features and certain views of the drawings may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

DETAILED DESCRIPTION

Reference will now be made in detail to the exemplary embodiment(s), examples of which is/are illustrated in the present disclosure. An embodiment refers to a particular feature or characteristic used in connection with a product or method step described herein. References to an “embodiment” appear throughout the disclosure, and such references are not necessarily referring to the same embodiment or to separate, mutually exclusive embodiment. Generally, the embodiments reside in combinations of components, subcomponents, and/or procedures related to robotic arm devices. Accordingly, the product and method components have been represented where appropriate, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. The specific details of the various embodiments described herein are used for demonstration purposes only, and no unnecessary limitation or inferences are to be understood therefrom.

In various embodiments, as shown inFIGS.1-18D, one or more robotic arm devices are disclosed. In some embodiments, as shown inFIGS.1-7, an air gripper is disclosed. In some embodiments, as shown inFIGS.8-14, an edge gripper device is disclosed. In some embodiments, as shown inFIGS.15-16, a destacking system is disclosed. In some embodiments, as shown inFIGS.17A-18D, a method of using the destacking system is disclosed.

In various embodiments, as shown inFIGS.1-7, an air gripper100is disclosed. In some embodiments, the air gripper100comprises a plurality of components that are operatively coupled together to provide a functional gripping device. In some embodiments, for example, the gripper100comprises a body104, an upper cover102configured to releasably couple to an upper (first) surface of the body104, and a lower cover106configured to releasably couple to a lower (second) surface of the body104.

As used herein, the term “annular” is not limited to a circular ring structure. As used herein, “annular” refers to closed-loop structure having, e.g., a circular, oval, triangular, rectangular, pentagonal, hexagonal, heptagonal, octagonal, etc., cross-sectional shape. Each cross-sectional shape has a corresponding three-dimensional shape (e.g., circular and cylindrical; rectangular and rectangular prism). As used herein, the term “annular” refers to the general cross-sectional or three-dimensional shape of the body104, upper cover102, and lower cover106, and does not modify the other components, including the internal features of the air gripper100.

In various embodiments, as shown in the figures, the air gripper100comprises a generally annular or cylindrical three-dimensional shape. In some embodiments, the generally cylindrical three-dimensional shape is defined by a height h and a circumference c, as shown inFIGS.1and2. In some embodiments, the circumference c is substantially greater than the height h such that the gripper100has a puck shape. In some embodiments, for example, the gripper100has a height h in the range of 5 mm to 50 mm. In some embodiments, for example, the gripper100has a circumference c in the range of 20 mm to 200 mm.

In some embodiments, the generally annular or cylindrical shape is modified by a joint116projecting from a slightly elongated side of the body104. For example, as shown inFIGS.1-7, the joint116projects outward from the body104. In some embodiments, the joint116has a length l. In some embodiments, the joint116has a length l in the range of 10 mm to 100 mm. As shown inFIG.2, in some embodiments, the joint116has a thickness that is identical to that of the body104. In some embodiments, the joint116is sized and shaped for coupling to a robotic arm.

In some embodiments, the joint116includes an open-area pocket130embedded at least partially therein. In some embodiments, as shown inFIG.1, the pocket130is centered between the lateral edges of the joint116. In such embodiments, the pocket130is configured to receive and store a predetermined volume of gas, such as compressed air. In some embodiments, the pocket130is in fluid communication with an annular channel132that is embedded in the body104. In some embodiments, the joint116is configured so air contained within the pocket130can flow into the channel132. The pocket130and annular channel132can have any suitable shape and geometry. In some embodiments, the compressed air has pressure in the range of 10-150 PSI, 20-120 PSI, 30-100 PSI, or any subranges (e.g., 41-88 PSI) or specific values (e.g., 45, 55, 65) therein.

In various embodiments, the gripper100comprises a through-hole118. In some embodiments, the through-hole118extends throughout the gripper100, from an external surface on the upper, first surface of the body104, or an external surface of the upper cover102, to an external surface on the lower, second surface of the body104, or an external surface of the lower cover106, as shown inFIGS.1-7. In some embodiments, the through-hole118has a truncated conical shape as it extends throughout the gripper100, the conical shape having a base at the lower, second surface and an apex at the upper, first surface of the body104. In some embodiments, the circumference of the truncated conical shape of the through-hole118is defined by an angled interior surface122, whereby the circumference of the angled interior surface122decreases as the through-hole118extends from the lower, second surface of the body104to the upper, first surface of the body104and the upper cover102.

In some embodiments, as shown inFIG.4, the gripper100comprises a spacer110positioned between the body104and the lower cover106. In some embodiments, the spacer110is configured with a thickness that can create a thin gap between the body104and the lower cover106through which air may flow. In some embodiments, the thickness of the spacer110determines the size of the thin gap. In some embodiments, for example, the spacer110has a thickness in the range of 0.01 mm to 1 mm. In some embodiments, the spacer110is a discrete component. In alternative embodiments, the spacer110is integrated into and indivisible from the body104. In some embodiments, the spacer110is configured to provide an air-tight seal for the gripper100and prevent air from escaping through the thin gap.

In some embodiments, as shown inFIG.2, the thin gap created by the spacer110between the body104and the lower cover106creates a lip120. In some embodiments, the lip120is adjacent to a lower edge of the angled interior surface122. In such embodiments, the gripper100is configured to guide the flow of air along the surface of the lip120and then the angled interior surface122. In some embodiments, the lip120is in fluid communication with the annular channel132. In such embodiments, the gripper100is configured so air contained within the pocket130can flow into the channel132, then to the lip120, then along the angled interior surface122, before exiting through the through-hole118. The lip120can be any suitable length. In some embodiments, the lip120has a length in the range of 2-10 mm, or 3-8 mm, or any specific length therein, including, for example, 4 mm, 5 mm, 6 mm, etc. The angled interior surface122can have any suitable slope angle. In some embodiments, for example, the angled interior surface122has an angle in the range of 20-60 degrees, 30-50 degrees, any specific angle therein (e.g., 35, 38, 40, 42 degrees), or the slope can be comprised of two or more combinations of angles.

In various embodiments, as indicated by the arrow labeled “airflow” inFIG.2, the gripper100is configured to create a flow of air that can be used for gripping objects. During use, in some embodiments, the gripper100is configured to receive compressed air as an input and output a thin sheet of air that runs parallel to the lip120before being curved and exhausted upwards along the angled interior surface122. Specifically, compressed air fills the pocket130and the channel132and builds up pressure before exiting through a thin opening to the lip120. The exiting, thin sheet of air runs parallel to the lip120. When the thin sheet of air runs over the lip120it generates suction via Bernoulli effect. When the sheet of air reaches the angled interior surface122, the air attaches itself to the surface, rather than continuing straight, due to the Coanda effect. As a result, the air exhausts in the upward direction indicated by the arrow. The air flow generated using this process generates low pressure along lip120and the angled interior surface122, and generates low pressure under the through-hole118. The low pressure along with any entrained air creates a suction that enables an operator to lift and/or hold various objects (e.g., fabrics, metal sheets, plastic sheets) against the lower cover106.

In some embodiments, as shown inFIGS.1-4, the lower cover106has a generally ring structure and one or more crossbars108extending from one side of the ring structure to an opposite side. In some embodiments, the lower cover106includes a plurality of crossbars108, which collectively form a grill over the through-hole118. In some embodiments, for example, the lower cover106having a plurality of crossbars108is used to prevent flexible objects (such as fabric) from being sucked into the through-hole118and exhausted upwards following the airflow. The plurality of crossbars108can be arranged in any suitable manner. For example, configurations such as a grid pattern, diamond pattern, or other are contemplated.

The gripper100provides several advantages over existing devices. For example, the configuration of the pocket130, the channel132, the lip120, and angled interior surface122creates a low pressure zone that is strongest (lowest pressure) close to the edge of the lip120. Furthermore, when an object is actively held by the gripper100and the gripper is moved to another location, the motion of the surrounding air (i.e., the air coming in between the object and the gripper) due to that motion is aligned with and contributes to the flow of the air within the gripper, thereby increasing the suction rather than counteracting it. This is the opposite effect to what would happen if the air flowing through the gripper100exited at a position away from the center (i.e., from the center-to-periphery instead of from periphery-to-center). Another advantage is that more air is entrained due to the Coanda effect created by the lip120and angled interior surface122, which results in a larger airflow and a greater lift on the object.

In various embodiments, as shown inFIGS.8-14, an edge gripper200is provided. In some embodiments, the edge gripper200comprises a plurality of components that are operatively coupled together to provide a functional gripping device. In some embodiments, for example, the edge gripper200comprises an upper body202, a lower body204configured to releasably couple to the upper body202, and a guide attachment206configured to releasably couple to the upper body202.

In some embodiments, as shown inFIGS.8and12-14, the upper body202comprises a generally rectangular prism shape, including a top face201having an access well226. The well226can have any suitable size, shape, and/or geometry. In some embodiments, the well226is generally cylindrical. In some embodiments, the well226is an opening that is in fluid communication with a gas storage224located within the interior core of the upper body202. In some embodiments, for example, the edge gripper200is coupled to a gas feed line that is configured to be coupled to the well226and to deliver gas to the well226. In such embodiments, the gas (e.g., compressed air) can be forced into the well226and then delivered to the storage224. In some embodiments, the well226receives compressed air having has pressure in the range of 10-150 PSI, 20-120 PSI, or any subrange or value therein. In some embodiments, the well226provides access to the storage224. The storage224can have any suitable size and shape (e.g., generally cylindrical), wherein the suitability is based on the desired volume of gas and the desired pressure of the gas containing within the storage224. In some embodiments, the storage224comprises a duct222that allows the gas stored in the storage224to exit. In some embodiments, the duct222is oriented and positioned within the upper body202transverse to the orientation of the well226.

In some embodiments, as shown inFIGS.8,10, and14, the upper body202comprises a front face203having a plurality of fins212projecting outward from an upper portion of the front face. In such embodiments, the generally rectangular prism shape is modified by the plurality of fins212. In some embodiments, the fins212project outward from the front face203and have an first side (upper end) that is coplanar with the top face201, as shown in theFIGS.8-10and12-14. In some embodiments, the plurality of fins212are spaced apart and the spaced distance between adjacent fins defines a plurality of channels210. The size, i.e. width, of each respective channel210is defined by the spacing between adjacent fins212. In some embodiments, the width of each of the channels210is identical. In some embodiments, the respective channels210have different widths. In various embodiments, the plurality of fins212provide a surface for objects to contact and the plurality of channels210provide areas that allow air to flow between the object in contact with the fins and the front face.

In some embodiments, as shown inFIGS.8,9, and14, the lower body204is coupled via its top face232(FIG.14) to a bottom face of the upper body202, the bottom face being the side opposite the top face201. In some embodiments, the lower body204is removably coupled to the upper body202using one or more fasteners. For example, as shown inFIG.14, the upper body202comprises an abridged cylinder227(having a semi-circular cross-sectional shape) projecting outward from its left and right sides, and the lower body204comprises a corresponding loop234with a through-hole projecting outward from its left and right sides. In such embodiments, a fastener can be inserted through the through-holes on the cylinder227and the loop234to removably couple the upper body202and the lower body204to one another. In some embodiments, the left and right sides of the lower body204include a recess236that provides space for a fastener used to couple the upper body202and the lower body204to one another. In some embodiments, as shown inFIGS.8,9,13, and14, the lower body204comprises a sidelong J-shape in which the curve of the J corresponds to the curved edge240of the lower body204. The curved edge240can have a predetermined length and geometry. In some embodiments, for example, the curved edge240has a quarter cylinder shape having a radius in a range of 2-20, or 2.5-10 mm, or 3-8 mm, or any value therein (e.g., 4 mm, 5 mm, 6 mm). In some embodiments, for example, the curved edge240has a half cylinder shape. In some embodiments, for example, the curved edge240is comprised of a plurality of straight, sloped edges.

In some embodiments, as shown inFIGS.8,10, and14, the lower body204includes a conduit238having a first opening218on its front face, which corresponds to the front face203of the upper body202. In some embodiments, the first opening218has a height in a range of 5 mm to 50 mm, including any subranges (e.g., 5 mm to 30 mm) or specific values therein (e.g., 6 mm, 9.5 mm). As shown in the cross-section view inFIG.13, the conduit238extends from the first opening218on the front face, through the lower body, to a second opening216. The conduit238is configured to allow gases, such as air, to flow through the lower body204. During use, for example, air will enter the first opening218, pass through the conduit238, and exit the second opening216. In some embodiments, the second opening216is used to redirect the air upwards. In some embodiments, the second opening216causes an increase in the lift and airflow at the front of the edge gripper200. In some embodiments, the front face of the lower body204includes a curved protrusion230. As shown inFIGS.8,10, and14, the curved protrusion230is positioned above the first opening218, whereby the curved protrusion230includes a first end at the top face232, as shown inFIG.14, and a second end at the first opening218, as shown inFIG.13.

In some embodiments, a guide attachment206is coupled to the front face203of the edge gripper200. In some embodiments, the guide attachment206comprises one or more through-holes and is coupled to the front face203with one or more fasteners via the respective through-holes.

In some embodiments, the guide attachment206comprises a plurality of tines208that project downward from a guide body205to a cross member207. In some embodiments, the respective tines208are spaced apart from one another. In some embodiments, the tines208are each spaced apart by an equal distance. In some embodiments, the spacing between each of the adjacent tines208is different, or not identical. In some embodiments, the plurality of tines208are spaced apart and the spaced distance between adjacent tines defines a plurality of gaps228. The size, i.e. width, of each respective gap228is defined by the spacing between adjacent tines208. In some embodiments, the tines208have an elongate structure that projects downward from the guide body205and then curves inward toward the first opening218of the lower body204, as shown inFIGS.8,9,13, and14. In some embodiments, the curvature of the plurality of tines208is the same or substantially the same as the curved edge240of the lower body204. In some embodiments, as shown inFIGS.8,9,13, and14, the plurality of tines208extend to, without contacting, the front face of the lower body204. In such embodiments, there is a gap216between the respective tines208and the front face of the lower body204.

In some embodiments, as shown inFIGS.8,10, and12, one or more of the plurality of tines208are oriented and positioned in alignment with one or more of the plurality of fins212. For example, as shown in the front view ofFIG.10, one or more of the fins212and the tines208are oriented vertically and aligned with one another. In some embodiments, the positioning of one or more of the plurality of tines208overlaps with the positioning of one or more of the plurality of fins212. For example, as shown in the front view ofFIG.10, one or more of the fins212and the tines208are oriented vertically and aligned to overlap with one another. And, as shown in the top view ofFIG.12, one or more of the tines208is positioned about the front face203such that there is overlap with one or more of the fins212. In such embodiments, one or more of the channels210between adjacent fins212overlap with one or more gaps228of the guide attachment206.

In some embodiments, the edge gripper200comprises a spacer220positioned between the front face of the upper body202and the guide attachment206. In some embodiments, the spacer220is removable. In some embodiments, spacer220is integrated into the upper body202and indivisible from it. In various embodiments, the spacer220is configured to create a thin opening for air to exit the storage224via the duct222and the vent219. In some embodiments, the thickness of the spacer220will determines the size of the opening for the vent219. In various embodiments, the spacer220is configured to seal and prevent air from escaping anywhere except for the storage224via the duct222.

In various embodiments, during use, the edge gripper200receives compressed air as an input and produces a thin sheet of air as an output. In some embodiments, the compressed air fills the storage224and pressure builds up in the storage224before air exits through the duct222. In such embodiments, the air then passes toward the vent219and the thin sheet of air is created by the vent219. As the air exits the vent219, it encounters the curved protrusion230, which redirects the airflow via the Coanda effect. The redirected sheet of air and any air that is entrained therewith enters the conduit238via the first opening218, flows through the conduit238, and then is exhausted out of the second opening216. A low pressure of air created by the storage224and the duct222, along with entrained airflow, creates a lift on a nearby object (such as flexible and bendable piece of fabric) that causes an edge of the object to lift and be held against the lower body204and the guide attachment206. Furthermore, the guide attachment206includes a plurality of gaps228, which allow the entrained air to flow through them and between the plurality of tines208. The flow of air created by the tines and gaps also generates low pressure. In such embodiments, when the edge of an object (e.g., fabric) is flush against the plurality of tines208, the low pressure within gaps228generates enough force to hold the object against the edge gripper200while the air flows through the plurality of gaps228.

In some embodiments, for example, when the object to be lifted is relatively large or heavy, a clamp can is utilized with the edge gripper200to mechanically secure the edge of the object against the lower body204and/or the guide attachment206. In such embodiments, the clamp may be attached to a robotic arm (e.g., the same arm the edge gripper200is attached to).

In various embodiments, the edge gripper200provides advantages over existing systems. For example, the edge gripper200can lift the edge of a flexible object (e.g., a sheet of fabric) and pin it firmly against the lower body204and the guide attachment206without causing the object's edge to flap. Furthermore, depending on the porosity and stiffness of the object and its edge being lifted, the position of the second opening216can be adjusted relative to the curved surface230, for example, by increasing the radius of the curved surface230. In such embodiments, modifying the curved surface230creates a different pressure or lift profile that will be experienced by the object and result in a desirable lift of the edge of the object instead of the edge being crumpled and sucked towards the first opening218. Additionally, the height of the first opening218can be adjusted to modify the pressure or lift profile of the edge gripper200. For example, in some embodiments, the height of the first opening218is increased to accommodate lighter fabrics, or decreased to accommodate heavier fabrics. During use, an increase to the height of the opening218will modify the distance between the vent219and the object being lifted, which in turn modifies the pressure and air flow experienced by the object (e.g., a light and pliant fabric). In such embodiments, the object will experience a stronger vertical lift rather than a stronger horizontal lift. In this context, a strong horizontal lift would cause a relatively light fabric to crumple as it is being sucked towards218instead of curving, uncrumpled, over the components of the guide attachment206.

In various embodiments, as shown inFIG.15andFIG.16, a destacker assembly300is provided. In some embodiments, the destacker assembly300is a system configured to remove a single ply of material (e.g., a flexible piece of fabric) from a stack having multiple plies of material (e.g.,50plies). In some embodiments, the destacker assembly300comprises one or more edge grippers200and one or more fingers308. In some embodiments, the one or more edge grippers200and the one or more fingers308are independently coupled to a carriage303via a first bracket304and a second bracket306, respectively. In some embodiments, the destacker assembly300comprises a housing302that is configured to cover the upper surface of the carriage303and/or any components attached thereto.

In various embodiments of the destacker assembly300, the edge gripper200and/or the finger308is stationary. In various embodiments of the destacker assembly300, the edge gripper200and/or the finger308is moveable. In some embodiments, the edge gripper200is stationary and the finger308is moveable. In some embodiments, the edge gripper200is moveable and the finger308is stationary. In some embodiments, the destacker assembly300comprises a mechanism for moving an edge gripper of the one or more edge grippers200and a finger of the one or more fingers308toward and away from one another. In some embodiments, for example, when the edge gripper200is stationary and the finger308is moveable, the carriage303is configured with a track that allows the finger308to move laterally toward the edge gripper200.

In some embodiments, the finger308comprises a top face having an access well. The well can have any suitable size, shape, and/or geometry. In some embodiments, the well is generally cylindrical. In some embodiments, the well is an opening that is in fluid communication with a passage and/or a gas storage located within the interior core of the finger308. In some embodiments, for example, the finger308is coupled to a gas feed line that is configured to be coupled to the well and to deliver gas to the well. In such embodiments, the gas (e.g., compressed air) can be forced into the well. In some embodiments, the finger308comprises a nozzle for releasing the gas delivered to the finger. During use, the nozzle can be activated to deliver a stream of gas toward an object positioned below and/or in contact with the finger308.

In some embodiments, the destacker assembly300comprises one or more sensors. In some embodiments, one of more sensors can be configured to determine how close the edge gripper200is to the finger308during use. In some embodiments, one of more sensors can be configured to determine how close the edge gripper200and/or the finger308are to a target object. In some embodiments, one of more sensors can be configured to determine how many plies of material have been lifted by the one or more edge grippers200of the destacker assembly300.

In various embodiments, the destacker assembly300provides advantages over existing systems. For example, the destacker assembly300can pick up an edge of a ply of material from a stack having multiple plies of material, secure the edge in a fixed position, and then separate the ply of material from the ply or multiple plies beneath it in the stack. The destacker assembly300therefore increases the probability of a successful destacking operation because the edge gripper200is not engaging all the forces that may be binding two or more plies together at the same time. In some embodiments, a second edge gripper200or finger308can be used to remove any plies stuck to the top ply, which further increasing the probability of a successful destacking operation.

In various embodiments, a method of using the destacker assembly300to lift a single ply of fabric from a stack comprised of multiple fabrics is provided. In some embodiments, a sequence of method steps for a ply removal process is shown inFIGS.17A-17D. In some embodiments, as shown inFIG.17A, the method includes a step of lowering the destacker assembly300towards the stack of fabrics have a ply P on top. In some embodiments, the destacker assembly300has a sensor that signals to the system when the stack of fabrics has been reached. In some embodiments, the compressed air is activated and air is delivered to the edge gripper200via the gas feed line310, which causes the edge of the top ply P to lift upward, as shown inFIG.17B. In some embodiments, the destacker assembly300has a sensor configured to determine the presence of one or multiple lifted edges of ply. After the edge of the top ply P has been lifted toward the edge gripper200, the system moves the finger308towards the edge gripper200to mechanically clamp and secure the lifted edge of the ply P, as shown inFIG.17C. After the edge of the ply P is secured, the compressed air can be deactivated. Next, with the edge of the ply P mechanically clamped, the destacker assembly300can move in various directions to separate the top ply P from the stack. As shown inFIG.17D, the destacker assembly300can move upward to cause the separation.

In various embodiments, a method of using the destacker assembly300to separate a first ply P1of fabric from one or more other plies, including a second ply P2, is provided. This method is useful, for example, when the plies of fabric are stuck together, or prone to stick together, for one or more reasons, including the material the fabric is made of, static attractions, etc. The method is particularly useful in manufacturing processes to guarantee that only a single ply is picked up from a stack of plies.

FIGS.18A-18Dshows a sequence of method steps for a ply separation process when multiple fabric plies are stuck together. As shown inFIG.18A, the ply edges from the first ply P1and the second ply P2are stuck together when the edge gripper200is activated. In some embodiments, the destacker assembly300comprises a sensor that is configured to determine the presence of two or more plies have been lifted after the step inFIG.18A. In such embodiments, the sensor sends a signal to the system to initiate the ply separation procedure inFIGS.18B-18D. In some embodiments, the ply separation procedure inFIGS.18B-18Dis performed during each cycle (e.g., without a sensor). In some embodiments, as shown inFIG.18B, the finger308begins to move towards the edge gripper200. At a predetermined approach distance between the finger308and the edge gripper200, as shown inFIG.18C, the finger308receives compressed air via the gas supply line312and delivers a sequence of air bursts that separate the second ply P2from the first ply P1without removing the first ply P1from the edge gripper200. After the additional plies of material, including the second ply P2, have been separated from the first ply P1, the finger308completes its motion towards the edge gripper200and mechanically clamps the edge of the ply P1between the edge gripper200and the finger308. After the edge of the first ply P1is secured, the compressed air can be deactivated. Next, with the edge of the first ply P1mechanically clamped, the destacker assembly300can move in various directions to separate the first ply P1from the stack of plies. As shown inFIG.18D, the destacker assembly300can move upward to cause the separation.

As one of skill would appreciate that the methods disclosed herein may be carried out with or without one or more of the specific steps discussed in this disclosure. In various embodiments, one or more steps of the method may be omitted.

The foregoing embodiments are provided to aid in the understanding of the present disclosure, the true scope of which is set forth in the appended claims. One of skill in the art would appreciate that modifications can be made in the embodiments set forth without departing from the spirit of the disclosure.

Exemplary embodiments and examples of the products, systems, and methods are described above in detail. The products, systems, and methods are not limited to the specific embodiments described herein, but rather, components of the products and systems and/or steps of the method may be utilized independently and separately from other components and/or steps described herein. For example, the system may also be used in combination with other products and methods, and is not limited to practice with only a product as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other systems.

A recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. As will be understood by one skilled in the art, ranges disclosed herein encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. For example, a range of 2% to 3% includes 2.3% to 2.8%, 2.4% to 2.9%, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art, language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each endpoint and individual member. For example, a range of 4% to 10% includes the subranges 5% to 9%, 6% to 8%, etc., and each endpoint (e.g., 4%, 5%, 6%, 8%, 9%, 10%) can be recited as an individual limitation.

As used herein and in the appended claims, singular articles such as “a” and “an” and “the” and similar referents in the context of describing the elements (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context.

As used herein, the use of examples, or exemplary language (e.g., “such as”), is intended to illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.

As used herein, the terms “about” and “substantially” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” and “substantially” will mean up to plus or minus 10% of the particular term.

This written description uses examples to disclose the present embodiments, including the best mode, and to enable any person skilled in the art to practice the present embodiments, including carrying out the steps of the method. The patentable scope of the present embodiments is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have elements that do not differ from the literal language of the claims, or if they include equivalent elements with insubstantial differences from the literal language of the claims.