Patent Description:
Composite structures may be used in a wide variety of applications, including in the manufacture of aircraft, due to their high strength-to-weight ratios, corrosion resistance and other favorable properties. In particular, in aircraft manufacturing, composite structures may be used to form the fuselage, wings, tail sections, and other parts of the aircraft.

Such composite structures may be formed from composite laminates comprising multiple stacked composite plies, or layers, laminated together. Prior to forming the composite laminates, the composite plies may be cut from rolls or sheets of dry, raw fiber material, for example, unidirectional fiber material, creating a ply nest, and then picked up and typically separated from adjacent waste material. Handling of cut composite plies made of unidirectional fiber material may be difficult due to lack of stiffness in a non-fiber direction. Further, when picking up such cut composite plies from within the ply nest, for example, with a robot, it is desirable for ply adhesion not to extend past the ply edges, so as to leave waste material behind and prevent disturbance of other cut composite plies in the ply nest. Additionally, such cut composite plies may present in any rotation or geometry. Thus, control of ply adhesion, including a very fine control over where adhesion is applied to a surface of a cut composite ply is desirable.

Pneumatic valves are typically used in industrial applications where the on/off flow of air, such as compressed air, is controlled. However, because such pneumatic valves are optimized for compressed air, they may not be suitable for pulling vacuum. Moreover, such pneumatic valves are typically individually controlled. Where multiple valves, such as multiple pneumatic valves, are used, valve blocks may be needed to consolidate electronic controls and the plumbing of the air supply. However, such valve blocks, as well as such pneumatic valves, may be bulky in size and heavy in weight, and it may be difficult to arrange them sufficiently close together to achieve a high density of adhesion zones to pick up less stiff materials.

In addition, the textile industry has a known method for automated material handling of flexible materials that includes adding temporary stiffening agents into the material during the manufacturing process. However, such known method is undesirable for aerospace applications, and in particular, it is undesirable to add temporary stiffening agents to primary aircraft structures, such as fuselage, wings, and tail sections.

Further, passive check valves are used in some area vacuum grippers that rely on air flow, where the object is not to restrict the air flow, to close the valve. However, such area vacuum grippers with passive check valves do not have discrete control of adhesion zones to pick up less stiff materials, and the entire pick surface of such area vacuum grippers is either active or inactive. Thus, such area vacuum grippers may not be suitable to selectively pick up multiple cut composite plies from across a ply nest.

Accordingly, there is a need for an automated bi-stable valve system and method for handling and selectively removing plies, such as cut composite plies, in composite manufacturing that control ply adhesion and provide a very fine control over where adhesion is applied to a surface of a cut composite ply, that allow multiple valves to be controlled by one control mechanism, that allow for multiple valves to be arranged closely together to enable significantly higher valve densities, and that allow multiple valves that are significantly less size, mass, and weight, as compared to known pneumatic valve systems and valve blocks, and that provide additional advantages over known systems and methods.

<CIT> and which is prior art according to Art. <NUM>(<NUM>) EPC, discloses a vacuum gripper comprising: a frame that defines a chamber for vacuum; a plate assembly that supports suction caps, valves provided with a shutter in correspondence of each suction cup 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 suitable for individually actuating the shutter from the closing position to the opening position in order to activate the desired suction cup, a plotter connected to the actuation device and deactivation means to deactivate all the activated suction cups simultaneously.

In <CIT> there is described a device for handling flat, contoured components with a plurality of bi-stable valves and a control system.

There is provided an automated bi-stable valve system and method for a material handling process in composite manufacturing. As discussed in the below detailed description, examples of the system and method may provide significant advantages over known systems and methods.

There is provided an automated bi-stable valve system. The automated bi-stable valve system comprises a bi-stable valve mechanism comprising a plurality of bi-stable valves. Each of the plurality of bi-stable valves is configured to switch between a valve closed state and a valve open state.

The automated bi-stable valve system further comprises a control system coupled to the bi-stable valve mechanism and configured to operably control the bi-stable valve mechanism. The control system comprises: (i) at least one traversable bridge apparatus; and (ii) a valve switch mechanism attached to the at least one traversable bridge apparatus, and movable, via the at least one traversable bridge apparatus, over the plurality of bi-stable valves.

The valve switch mechanism is configured to switch one or more of the plurality of bi-stable valves between the valve closed state and the valve open state and comprises a plurality of control actuators, wherein the plurality of bi-stable valves comprises a plurality of rows of bi-stable valves, and wherein each control actuator of the plurality of control actuators is configured to actuate one or more different rows of the plurality of rows of the plurality of bi-stable valves.

The valve switch mechanism allows for selective control of one or more adhesion zones on the bi-stable valve mechanism. The one or more adhesion zones correspond to one or more adhesion areas on a surface of a material to be selectively picked up and placed during a material handling process.

Optionally, the automated bi-stable valve system comprises a material to be picked up and placed during the material handling process comprising one or more plies comprised of unidirectional fiber material.

There is further provided an automated material handling system for a material handling process in composite manufacturing. The automated material handling system comprises one or more cut plies to be selectively picked up and removed from a work surface. The automated material handling system further comprises a robot having an arm with an end effector.

The automated material handling system further comprises a vacuum system coupled to the end effector. The automated material handling system further comprises the automated bi-stable valve system coupled to a first end of the end effector. The valve switch mechanism is configured to switch one or more of the plurality of bi-stable valves between the valve closed state and the valve open state, to allow for selective control of one or more adhesion zones on the bi-stable valve mechanism. The one or more adhesion zones correspond to one or more adhesion areas on a surface of the one or more cut plies to be selectively picked up and removed from the work surface during the material handling process in the composite manufacturing.

There is provided a method of using the automated bi-stable valve system in a material handling process for composite manufacturing. The method comprises selectively picking up and removing, with the automated bi-stable valve system, one or more cut plies from a work surface, by selectively switching, with the valve switch mechanism, one or more of the plurality of bi-stable valves from the valve closed state to the valve open state, to allow for selective control of one or more adhesion zones on the bi-stable valve mechanism. The one or more adhesion zones correspond to one or more adhesion areas on a surface of the one or more cut plies, and to increase valve densities.

The features, functions, and advantages that have been discussed can be achieved independently in various examples of the disclosure or may be combined in yet other examples further details of which can be seen with reference to the following description and drawings.

The disclosure can be better understood with reference to the following detailed description taken in conjunction with the accompanying drawings which illustrate preferred examples, but which are not necessarily drawn to scale. The drawings are examples and not meant as limitations on the description or claims.

The figures shown in this disclosure represent various examples, and only differences will be discussed in detail.

Disclosed examples will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all of the disclosed examples are shown. Indeed, several different examples may be provided and should not be construed as limited to the examples set forth herein. Rather, these examples are provided so that this disclosure will be thorough and fully convey the scope of the disclosure to those skilled in the art.

This specification includes references to "one example" or "an example". The instances of the phrases "one example" or "an example" do not necessarily refer to the same example. Particular features, structures, or characteristics may be combined in any suitable manner consistent with this disclosure.

As used herein, "comprising" is an open-ended term, and as used in the claims, this term does not foreclose additional structures or steps.

As used herein, "configured to" means various parts or components may be described or claimed as "configured to" perform a task or tasks. In such contexts, "configured to" is used to connote structure by indicating that the parts or components include structure that performs those task or tasks during operation. As such, the parts or components can be said to be configured to perform the task even when the specified part or component is not currently operational (e.g., is not on).

As used herein, the terms "first", "second", etc., are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.).

As used herein, the phrase "at least one of," when used with a list of items, means different combinations of one or more of the listed items may be used, and only one of each item in the list may be needed. In other words, "at least one of" means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item may be a particular object, a thing, or a category.

Now referring to the Figures, <FIG> is an illustration of a functional block diagram showing examples of an automated bi-stable valve system <NUM> of the disclosure, used in examples of an automated material handling system <NUM> of the disclosure. The blocks in <FIG> represent elements, and lines connecting the various blocks do not imply any particular dependency of the elements. Furthermore, the connecting lines shown in the various Figures contained herein are intended to represent example functional relationships and/or physical couplings between the various elements, but it is noted that other alternative or additional functional relationships or physical connections may be present in examples disclosed herein. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in other examples. Further, the illustrations of the automated bi-stable valve system <NUM> in FIG. 1A is not meant to imply physical or architectural limitations to the manner in which an example may be implemented. Other components in addition to or in place of the ones illustrated may be used. Some components may be unnecessary.

In some examples of the disclosure, as shown in <FIG>, there is provided the automated bi-stable valve system <NUM> that provides a <NUM>-to-many multiplexing valve system <NUM>. In other examples of the disclosure, as shown in <FIG>, there is provided the automated material handling system <NUM> for a material handling process <NUM> in composite manufacturing <NUM> of composite structures <NUM>, where the automated material handling system <NUM> includes the automated bi-stable valve system <NUM>.

As shown in <FIG>, in some examples, the automated material handling system <NUM> comprises a robot <NUM> (see also <FIG>), such as a pick-and-place (PNP) operations (OP) robot 22a. The robot <NUM> has an arm <NUM> (see <FIG>) with an end effector <NUM> (see <FIG>). The end effector <NUM> has a first end 28a (see <FIG>) and a second end 28b (see <FIG>). The automated bi-stable valve system <NUM> is coupled to the first end 28a of the end effector <NUM>, and the second end 28b of the end effector <NUM> is coupled to the arm <NUM> of the robot <NUM>. The automated bi-stable valve system <NUM> is held by the robot <NUM>, via the end effector <NUM>.

As shown in <FIG>, the automated material handling system <NUM> further comprises a vacuum (VAC) system <NUM> having a portion coupled to the end effector <NUM> or another suitable part of the robot <NUM>, and having a portion coupled to the automated bi-stable valve system <NUM>. As shown in <FIG>, the vacuum system <NUM> comprises a vacuum manifold <NUM>, one or more vacuum lines <NUM>, a vacuum source <NUM>, and a vacuum power supply <NUM>. The vacuum source <NUM> may comprise a vacuum generator 35a (see <FIG>), a blower, or another suitable vacuum source, configured to pull air <NUM> in an air flow 38a, or vacuum flow, through the one or more vacuum lines <NUM>, the vacuum manifold <NUM>, and the automated bi-stable valve system <NUM>. The vacuum system <NUM> may further comprise one or more control valves, shutoff valves, and/or other suitable vacuum system components. The vacuum manifold <NUM> is coupled to the automated bi-stable valve system <NUM>, via one or more vacuum lines <NUM>, and the vacuum manifold <NUM> is coupled to the vacuum source <NUM>, via one or more vacuum lines <NUM>.

As shown in <FIG>, the automated material handling system <NUM> further comprises a material <NUM>, such as a composite material 40a, for example, raw composite material 40b, in the form of one or more plies <NUM>, or layers, such as one or more cut plies 42a, to be picked up by the robot <NUM> using the automated bi-stable valve system <NUM> during the material handling process <NUM> in the composite manufacturing <NUM>. The robot <NUM> positions the automated bi-stable valve system <NUM> over the top of the material <NUM>, such as the composite material 40a, for example, the raw composite material 40b, in the form of one or more plies <NUM>, such as one or more cut plies 42a, prior to pick up and removal.

The material <NUM>, such as the composite material 40a, for example, raw composite material 40b, is supplied in the form of carbon or non-carbon dry fabric rolls <NUM> (see <FIG>, <FIG>), dry fabric sheets <NUM>, or another suitable form, comprised of fiber material (FM) <NUM>, such as unidirectional (UD) fiber material (FM) 48a, for example, unidirectional (UD) carbon fiber material (FM) 48b. As shown in <FIG>, the fiber material <NUM> comprises fibers <NUM>, such as unidirectional (UD) fibers 50a, for example, unidirectional (UD) carbon fibers 50b. The fibers <NUM> may be stitched together with threads <NUM> (see <FIG>) to form a stitched unidirectional fabric <NUM> (see <FIG>), may have tackifiers to hold the fibers <NUM> together, or may be held together in another suitable manner. The fibers <NUM> may be made from natural and/or man-made materials such as carbon, fiberglass, graphite, and the like. The material <NUM>, such as the composite material 40a, for example, the raw composite material 40b, has stiffness in a fiber direction <NUM> (see <FIG>) but has a low bending stiffness, or no stiffness, in a non-fiber direction <NUM> (see <FIG>), or in any direction relative to the fibers <NUM>. The composite material 40a may further comprise carbon fiber reinforced polymer (CFRP) materials, including plastic or thermoplastic materials, known in the art.

Prior to the plies <NUM>, or layers, of the material <NUM>, such as the composite material 40a, being picked up by the robot <NUM> using the automated bi-stable valve system <NUM>, the plies <NUM> are cut from the dry fabric rolls <NUM>, dry fabric sheets <NUM>, or other suitable form, into net shapes <NUM> (see <FIG>) with a cutter apparatus <NUM> (see <FIG>), such as an automated cross-cutter apparatus 60a (see <FIG>), to form cut plies 42a (see <FIG>, <FIG>) arranged in a ply nest <NUM> (see <FIG>, <FIG>). The plies <NUM>, such as the cut plies 42a, in the ply nest <NUM> are adjacent to non-cut material or non-cut composite material, comprising waste material <NUM>, also referred to as skeleton material, or scrap material. The plies <NUM>, such as the cut plies 42a, in the ply nest <NUM> are configured to be picked up and placed by the robot <NUM> using the automated bi-stable valve system <NUM>, and separated from the remaining material, such as the remaining composite material, comprising the waste material <NUM> (see <FIG>, <FIG>) that is not picked up. One or more portions 64a (see <FIG>) of the waste material <NUM> may be discarded or recycled for re-use.

One or more plies <NUM>, such as one or more cut plies 42a, in the ply nest <NUM> can be selectively picked up from a work surface <NUM> (see <FIG>) by the robot <NUM> using the automated bi-stable valve system <NUM>, and removed or moved from the work surface <NUM>, to a tool or mold for laying up, or to a carrier apparatus, a kitting tray, a mobile apparatus, or another suitable apparatus for transport. The work surface <NUM> may comprise a cutting table, a mobile table, a carrier apparatus, a conveyor belt, a tool, or another suitably flat surface. The material <NUM>, such as the composite material 40a, in the form of one or more plies <NUM>, such as one or more cut plies 42a, is selectively picked up from the work surface <NUM> by the robot <NUM>, using the automated bi-stable valve system <NUM>, and the waste material <NUM>, or skeleton material or scrap material, is not picked up and is left on the work surface <NUM> for removal and discarding or reuse. The automated bi-stable valve system <NUM> picks up and holds each ply <NUM>, such as each cut ply 42a, to edges <NUM> (see <FIG>) of the ply <NUM>, such as the cut ply 42a, and does not go past the edges <NUM>, thus avoiding picking up the waste material <NUM>, or skeleton material or scrap material.

The automated bi-stable valve system <NUM> allows for selective and discrete control of one or more adhesion zones <NUM> (see <FIG>, <FIG>) on the bi-stable valve mechanism <NUM>. The one or more adhesion zones <NUM> correspond to one or more adhesion areas <NUM> (see <FIG>, <FIG>) on a surface <NUM> (see <FIG>, <FIG>) of the material <NUM> (see <FIG>, <FIG>), such as the ply <NUM> (see <FIG>, <FIG>), for example, the cut ply 42a (see <FIG>, <FIG>), to be picked up and placed during the material handling process <NUM>. to increase a density <NUM> (see <FIG>) of the adhesion areas <NUM> on the surface <NUM>, to enable selective pick up the one or more plies <NUM>, such as one or more cut plies 42a. Thus, the automated bi-stable valve system <NUM> provides a very fine control over where ply adhesion <NUM> (see <FIG>) is applied to the surface <NUM> (see <FIG>) of each ply <NUM>, such as each cut ply 42a, from the ply nest <NUM>, without disturbing or picking up the waste material <NUM>.

After the one or more plies <NUM>, such as the one or more cut plies 42a, are picked up by the robot <NUM> using the automated bi-stable valve system <NUM>, the one or more plies <NUM>, such as the one or more cut plies 42a, may be placed on a tool or mold for layup and forming to form a composite layup. The one or more plies <NUM>, such as the one or more cut plies 42a may get vacuum bagged, infused with resin, and placed into an autoclave or oven to undergo a curing process, to form a composite laminate. The dry fabric rolls <NUM> or dry fabric sheets <NUM> may be preimpregnated or infused with a resin material, such as a resin binder, for example, a thermoset material or a thermoplastic material, prior to, or during, the curing process.

The composite laminate is used to form a composite part <NUM> (see <FIG>), such as an aircraft composite part <NUM> (see <FIG>), for example, a spar, such as a wing spar or another type of spar, a rib, a stiffening member, a stringer, a beam, or another suitable composite part. In some examples, the composite part <NUM>, such as the aircraft composite part <NUM>, is used in the manufacture of a vehicle <NUM> (see <FIG>), such as an aircraft 280a (see <FIG>). The composite part <NUM> may also be made in the manufacture of vehicles <NUM>, including rotorcraft, spacecraft, watercraft, automobiles, trucks, and other suitable vehicles, or in the manufacture of suitable structures.

As shown in <FIG>, the automated material handling system <NUM> comprises the automated bi-stable valve system <NUM>. The automated bi-stable valve system <NUM> comprises a bi-stable valve mechanism <NUM> (see <FIG>) comprising a plurality of bi-stable valves <NUM> (see <FIG>). Each of the plurality of bi-stable valves <NUM> is configured to switch between a valve closed state <NUM> (see <FIG>) and a valve open state <NUM> (see <FIG>). The bi-stable valves <NUM> are switched to selectively apply ply adhesion <NUM> to the surface <NUM> of each of the plies <NUM>, such as the cut plies 42a. The structure of the bi-stable valves <NUM> is discussed in further detail below with respect to <FIG>.

As used herein, "bi-stable valve" means a valve that has two stable states or positions, including the valve closed state <NUM>, to block or deny air flow 38a or vacuum flow, and the valve open state <NUM>, to allow air flow 38a or vacuum flow.

As shown in <FIG>, the automated bi-stable valve system <NUM> further comprises a control system <NUM> coupled to the bi-stable valve mechanism <NUM> and configured to operably control the bi-stable valve mechanism <NUM>. As shown in <FIG>, the control system <NUM> comprises at least one traversable bridge apparatus <NUM> and a valve switch mechanism <NUM>. The valve switch mechanism <NUM> is attached to the at least one traversable bridge apparatus <NUM>, and movable, via the at least one traversable bridge apparatus <NUM>, over the plurality of bi-stable valves <NUM>. The valve switch mechanism <NUM> is configured to switch one or more of the plurality of bi-stable valves <NUM> between the valve closed state <NUM> and the valve open state <NUM>, to allow for selective control of one or more adhesion zones <NUM> (see <FIG>) on the bi-stable valve mechanism <NUM>. The one or more adhesion zones <NUM> correspond to one or more adhesion areas <NUM> (see <FIG>) on the surface <NUM> of the material <NUM>, such as the composite material 40a, in the form of one or more plies <NUM>, such as one or more cut plies 42a, to be selectively picked up and placed during the material handling process <NUM>.

As shown in <FIG>, the valve switch mechanism <NUM> comprises a plurality of control actuators <NUM>. In some examples, the plurality of bi-stable valves <NUM> comprises a plurality of rows 78a (see <FIG>) of bi-stable valves <NUM>, and each control actuator <NUM> of the plurality of control actuators <NUM> is configured to actuate one or more different rows 78b (see <FIG>) of the plurality of rows 78a of bi-stable valves <NUM>.

In some examples, as shown in <FIG>, the valve switch mechanism <NUM> comprises at least one actuating control magnet assembly <NUM> (see also <FIG>). Alternatively, in other examples, as shown in <FIG>, the valve switch mechanism <NUM> comprises at least one actuating compliant mechanism assembly <NUM> (see also <FIG>). In examples where the valve switch mechanism <NUM> comprises the at least one actuating control magnet assembly <NUM>, it does not comprise the at least one actuating compliant mechanism assembly <NUM>. In examples where the valve switch mechanism <NUM> comprises the at least one actuating compliant mechanism assembly <NUM>, it does not comprise the at least one actuating control magnet assembly <NUM>.

With the actuating control magnet assembly <NUM>, the control actuator <NUM> comprises an actuator <NUM> (see <FIG>) attached to the at least one traversable bridge apparatus <NUM>. As shown in <FIG>, the actuator <NUM> comprises one of, an electric solenoid <NUM>, a pneumatic solenoid <NUM>, an electric motor <NUM>, or another suitable actuator. The electric motor <NUM> may comprise a servo motor <NUM> (see <FIG>), a stepper motor <NUM> (see <FIG>), or another suitable electric motor.

As shown in <FIG>, the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, further comprises a control magnet <NUM> coupled to the actuator <NUM>. The control magnet <NUM> has a control magnet (CM) polarity <NUM>. The actuator <NUM> is configured to operably actuate the control magnet <NUM> between an up position <NUM> (see <FIG>) and a down position <NUM> (see <FIG>). The control magnet <NUM> is configured to impart a magnetic force <NUM> (see <FIG>) on a floating magnet <NUM> of each bi-stable valve <NUM>, to push the floating magnet <NUM> down, to switch the bi-stable valve <NUM> between the valve closed state <NUM> and the valve open state <NUM>, discussed in further detail below. Each floating magnet <NUM> has a floating magnet (FM) polarity <NUM> (see <FIG>).

As shown in <FIG>, the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, may further optionally comprise one or more wiping magnets <NUM> attached to the at least one traversable bridge apparatus <NUM> and movable over the plurality of bi-stable valves <NUM>. The one or more wiping magnets <NUM> are configured to reset one or more of the plurality of bi-stable valves <NUM> to be in the valve closed state <NUM> or the valve open state <NUM>, prior to the control magnet <NUM> moving over the plurality of bi-stable valves <NUM> to selectively switch one or more of the plurality of bi-stable valves <NUM> between the valve closed state <NUM> and the valve open state <NUM>.

Alternatively, instead of including one or more wiping magnets <NUM>, the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, may further optionally include or comprise one of, as shown in <FIG>, an electromagnet <NUM>, a solenoid-mounted control magnet <NUM> with a polarity <NUM> that is opposite the control magnet polarity <NUM> of the control magnet <NUM> and that is the same as the wiping magnet polarity <NUM> of the wiping magnet <NUM>, a mechanism <NUM> to move a magnetic pole <NUM>, or a mechanism <NUM> to block or decrease a magnetic strength <NUM>.

The actuating control magnet assembly <NUM> is discussed in further detail below with respect to <FIG>.

Now referring to the valve switch mechanism <NUM> comprising the at least one actuating compliant mechanism assembly <NUM> (see <FIG>, <FIG>), with the actuating compliant mechanism assembly <NUM>, the control actuator <NUM> comprises an actuator 95a (see <FIG>) comprising a linear actuator 95b, a rotary actuator 95c, or another suitable actuator. The actuator 95a may further comprise an electric actuator, a pneumatic actuator, or another suitable type of actuator. In some examples, the actuator 95a is attached to the at least one traversable bridge apparatus <NUM>.

As shown in <FIG>, with the valve switch mechanism <NUM>, in the form of the actuating compliant mechanism assembly <NUM>, the plurality of bi-stable valves <NUM> of the bi-stable valve mechanism <NUM> comprise a plurality of vacuum ports <NUM> with a plurality of vacuum port covers <NUM> configured to open and close between the valve closed state <NUM> and the valve open state <NUM>. The additional components of the actuating compliant mechanism assembly <NUM> are discussed in further detail below with respect to <FIG>.

The automated bi-stable valve system <NUM> splits the control system <NUM> from the bi-stable valve mechanism <NUM> to enable a valve density <NUM> (see <FIG>), or valve densities, of the bi-stable valves <NUM> that is/are significantly higher than valve densities of known valve systems, thus providing a more scalable solution. With valve densities <NUM> that are higher, ply adhesion <NUM> to the plies <NUM>, such as the cut plies 42a, is easier to control. The closer the ply adhesion <NUM> is the edges <NUM> of the plies <NUM>, such as the cut plies 42a, the less chance there is of disturbing or picking up the waste material <NUM>, or skeleton material or scrap material.

Now referring to <FIG> is an illustration of a front perspective view of an example of material <NUM>, such as fiber material <NUM>, having fibers <NUM>, such as unidirectional fibers 50a, stitched together with threads <NUM>, to form a stitched preform <NUM>, that may be used with examples of the automated material handling system <NUM> discussed above, and picked up with examples of the automated bi-stable valve system <NUM> discussed above. The material <NUM>, such as the fiber material <NUM> comprises dry fabric sheets <NUM> to form plies <NUM> (see <FIG>). The fibers <NUM> may be made from natural and/or man-made materials such as carbon, fiberglass, graphite, and the like. The material <NUM>, such as the fiber material <NUM> has stiffness in a fiber direction <NUM> (see <FIG>) but has a low bending stiffness, or no stiffness, in a non-fiber direction <NUM> (see <FIG>).

Now referring to <FIG> is an illustration of a side perspective view of an example of a dry fabric roll <NUM> of material <NUM>, such as composite material 40a, for example, raw composite material 40b, showing plies <NUM>, such as cut plies 42a, cut into net shapes <NUM> of various geometric configurations and arranged in a ply nest <NUM>. <FIG> further shows waste material <NUM>, also referred to as skeleton material or scrap material, adjacent the plies <NUM>, such as the cut plies 42a. The plies <NUM>, such as the cut plies 42a, are cut and nested from the dry fabric roll <NUM> and are cut with a cutter apparatus <NUM> (see <FIG>), such as an automated cross-cutter apparatus 60a (see <FIG>), or another suitable cutter apparatus. The plies <NUM>, such as the cut plies 42a, are configured to be picked up and placed by the robot <NUM> using the automated bi-stable valve system <NUM>, and are configured to be separated from the remaining material, such as the remaining composite material, comprising the waste material <NUM>, or skeleton material, that is not picked up. The plies <NUM>, such as the cut plies 42a, that are selectively picked up from, for example, the work surface <NUM> (see <FIG>) by the robot <NUM> using the automated bi-stable valve system <NUM>, may be laid directly on a tool or mold for laying up, or on a carrier apparatus, a mobile apparatus, or another suitable apparatus for forming or transport.

Now referring to <FIG> is an illustration of a front perspective view of a production cell <NUM> for performing the material handling process <NUM> (see <FIG>) for composite manufacturing <NUM> (see <FIG>), where the production cell <NUM> incorporates examples of the automated material handling system <NUM> and the automated bi-stable valve system <NUM> of the disclosure, as discussed above.

As shown in <FIG>, the production cell <NUM> includes a dry fabric roll <NUM> of material <NUM>, such as composite material 40a, for example, carbon fabric, from which plies <NUM>, such as cut plies 42a, are cut. As shown in <FIG>, the production cell <NUM> further includes the cutter apparatus <NUM>, such as the automated cross-cutter apparatus 60a, for cutting plies <NUM>, such as the cut plies 42a, from the dry fabric roll <NUM>, into net shapes <NUM> of various geometric configurations and arranged in the ply nest <NUM>. The production cell <NUM> further includes the work surface <NUM> (see <FIG>), such as a conveyor belt surface 65a, from which the plies <NUM>, such as the cut plies 42a, in the ply nest <NUM> are moved after being cut with the cutter apparatus <NUM>, such as the automated cross-cutter apparatus 60a.

As shown in <FIG>, the production cell <NUM> further includes the automated material handling system <NUM> comprising the robot <NUM>, such as the pick-and-place operations robot 22a, and the vacuum system <NUM>. As shown in <FIG>, the robot <NUM>, such as the pick-and-place operations robot 22a, includes the arm <NUM> with the end effector <NUM>. The automated bi-stable valve system <NUM> (see <FIG>) is coupled to the first end 28a (see <FIG>) of the end effector <NUM>, and the second end 28b (see <FIG>) of the end effector <NUM> is coupled to the arm <NUM> of the robot <NUM>. The automated bi-stable valve system <NUM> is held by the robot <NUM>, via the end effector <NUM>. As shown in <FIG>, the end effector <NUM> is mounted to a gantry <NUM>. The gantry <NUM> is configured to move, and moves, the end effector <NUM> of the robot <NUM> over the one or more plies <NUM>, such as one or more cut plies 42a, to be picked up, and lowers the end effector <NUM> with the attached automated bi-stable valve system <NUM>, so that a bottom surface <NUM> (see <FIG>) of a bottom portion <NUM> (see <FIG>) of the automated bi-stable valve system <NUM> is in contact with the surface <NUM> of each of the one or more plies <NUM>, such as the one or more cut plies 42a, to be picked up from the work surface <NUM>, and removed from the waste material <NUM>, or skeleton material.

As shown in <FIG>, the vacuum system <NUM> has the vacuum manifold <NUM> coupled to the automated bi-stable valve system <NUM>, and the vacuum manifold <NUM> is coupled to the vacuum source <NUM>, via a vacuum line <NUM>. The vacuum manifold <NUM> distributes air <NUM> (see <FIG>, <FIG>) from the vacuum line <NUM> to the entire end effector <NUM>. In some examples, the vacuum manifold <NUM> is part of the end effector <NUM>. In other examples, the vacuum manifold <NUM> is coupled prior to the end effector <NUM>. The vacuum power supply <NUM> (see <FIG>) is coupled to the vacuum source <NUM>. The vacuum source <NUM> comprises a vacuum generator 35a (see <FIG>). However, the vacuum source <NUM> may comprise a blower or another suitable vacuum source. The vacuum system <NUM> is configured to pull air <NUM> (see <FIG>, <FIG>) in an air flow 38a (see <FIG>, <FIG>), or vacuum flow, through the automated bi-stable valve system <NUM> to pick up, and adhere or secure, the desired plies <NUM>, such as cut plies 42a, to the bottom surface <NUM> of the bottom portion <NUM> of the automated bi-stable valve system <NUM>.

The automated material handling system <NUM> and the automated bi-stable valve system <NUM> of the production cell <NUM> may be operated by an operator using a controller <NUM> (see <FIG>) for operatively controlling operations of the automated material handling system <NUM> and the automated bi-stable valve system <NUM>, and other components of the production cell <NUM>, including coordinating and controlling movements of the dry fabric roll <NUM>, the cutter apparatus <NUM>, such as the automated cross-cutter apparatus 60a, the work surface <NUM>, such as the conveyor belt, the vacuum system <NUM>, the gantry <NUM>, and the end effector <NUM> with the attached the automated bi-stable valve system <NUM>. The controller <NUM> may comprise a computer <NUM> (see <FIG>). The computer <NUM> may comprise a portable computer (PC), a programmable logic controller (PLC), or another suitable computer. In some examples, the computer <NUM> uses a control program which may include a software program, or an algorithm, that determines how the material handling process <NUM> should progress and the sequential operation of the components of the production cell <NUM>.

Now referring to <FIG> is an illustration of an enlarged front perspective view of an example of an automated bi-stable valve system <NUM> coupled to the end effector <NUM> of the robot <NUM> used in the production cell <NUM> of <FIG>. As shown in <FIG>, the automated bi-stable valve system <NUM> is coupled to the first end 28a of the end effector <NUM>. As further shown in <FIG>, the automated bi-stable valve system <NUM> has a ply <NUM>, such as a cut ply 42a, adhered, or coupled, to the bottom surface <NUM> of the bottom portion <NUM> of the automated bi-stable valve system <NUM>. The automated bi-stable valve system <NUM> with the bi-stable valves <NUM> (see <FIG>) provides selective and discrete control of one or more adhesion zones <NUM> (see <FIG>, <FIG>) on the bi-stable valve mechanism <NUM>. The one or more adhesion zones <NUM> correspond to adhesion areas <NUM> (see <FIG>, <FIG>) on the surface <NUM> (see <FIG>) of the ply <NUM>, such as the cut ply 42a. <FIG> further shows power supply chains <NUM> coupled to the automated bi-stable valve system <NUM>. The power supply chains <NUM> are mechanical machine elements made of plastic or metal that are configured to safely and reliably supply power, energy, signals, and/or vacuum to components on the traversable bridge apparatus <NUM> (see <FIG>). The power supply chains <NUM> are used to guide and protect one or more of, electrical wiring, cables, hoses, vacuum lines, and/or optical conductors that supply the power, energy, signals, and/or vacuum to components on the traversable bridge apparatus <NUM> that are in motion.

Now referring to <FIG> show an examples of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, where the valve switch mechanism <NUM> comprises the actuating control magnet assembly <NUM>.

Now referring to <FIG>, <FIG> is an illustration of a front perspective view of an example of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, of the disclosure, showing the traversable bridge apparatus <NUM> at a start position <NUM>. The traversable bridge apparatus <NUM> is configured to travel, or traverse, across a plurality of rows 78a of bi-stable valves <NUM>, in a first direction <NUM>, such as a right-to-left- direction 150a. <FIG> is an illustration of a front perspective view of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, of <FIG>, showing the traversable bridge apparatus <NUM> at an end position <NUM>, and configured to travel, or traverse, back across the plurality of rows 78a of bi-stable valves <NUM>, in a second direction <NUM>, such as a left-to-right direction 154a. Now referring to <FIG> is an illustration of a top view of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, of <FIG>, where the traversable bridge apparatus <NUM> is in the end position <NUM>.

<FIG> show the bi-stable valve mechanism <NUM> comprising the plurality of bi-stable valves <NUM> in the plurality of rows 78a. <FIG> further show the control system <NUM> coupled to the bi-stable valve mechanism <NUM>, and configured to operably control the plurality of bi-stable valves <NUM> of the bi-stable valve mechanism <NUM>. The control system <NUM> comprises the traversable bridge apparatus <NUM> and the valve switch mechanism <NUM>. The valve switch mechanism <NUM> is attached to the traversable bridge apparatus <NUM>, and movable, via the traversable bridge apparatus <NUM>, over the plurality of bi-stable valves <NUM>. The traversable bridge apparatus <NUM> is coupled to a plurality of rails <NUM> (see <FIG>) that are spaced apart from each other and run parallel to each other. Each rail <NUM> has a first end 156a (see <FIG>) coupled to a side <NUM> (see <FIG>), such as a first side 158a (see <FIG>), of the bottom portion <NUM> (see <FIG>), and has a second end 156b (see <FIG>), coupled to a side <NUM>, such as a second side 158b (see <FIG>), of the bottom portion <NUM>. The bottom portion <NUM> further has sides <NUM>, including a third side 158c (see <FIG>) and a fourth side 158d (see <FIG>).

In some examples, as shown in <FIG>, the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, has one traversable bridge apparatus <NUM>. However, in other examples the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, has more than one traversable bridge apparatus <NUM> positioned parallel to each other and traversing across the bi-stable valves <NUM> in parallel.

The valve switch mechanism <NUM> is configured to switch one or more of the plurality of bi-stable valves <NUM> between the valve closed state <NUM> (see <FIG>, <FIG>) and the valve open state <NUM> (see <FIG>, <FIG>), to allow for selective control of one or more adhesion zones <NUM> (see <FIG>, <FIG>) on the bi-stable valve mechanism <NUM>, the one or more adhesion zones <NUM> corresponding to one or more adhesion areas <NUM> (see <FIG>, <FIG>) on the surface <NUM> (see <FIG>, <FIG>) of the material <NUM> (see <FIG>), such as composite material 40a (see <FIG>), in the form of one or more plies <NUM> (see <FIG>, <FIG>), such as one or more cut plies 42a (see <FIG>, <FIG>), to be selectively picked up and placed during the material handling process <NUM> (see <FIG>). The automated bi-stable valve system <NUM> is designed to split the control system <NUM> from the bi-stable valve mechanism <NUM> to enable significantly higher valve densities <NUM> (see <FIG>).

<FIG> show the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, comprising control magnets <NUM>. The control magnets <NUM> are carried by the traversable bridge apparatus <NUM>. As shown in <FIG>, the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, comprises the bottom portion <NUM> with the rows 78a of bi-stable valves <NUM>. As shown in <FIG>, the bottom portion <NUM> is in the form of a plate structure 144a housing rows 78a of bi-stable valves <NUM>. The bottom portion <NUM> may also be in another suitable form or structure.

As shown in <FIG>, the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, further comprises a top portion <NUM>, such as in the form of a cross-bar structure 160a. The top portion <NUM> may also be in another suitable form or structure. As shown in <FIG>, the top portion <NUM>, such as in the form of the cross-bar structure 160a, comprises elongated bar portions <NUM> with bracket ends <NUM> attached to sides <NUM> of the bottom portion <NUM>, such as the plate structure 144a. The top portion <NUM>, such as in the form of the cross-bar structure 160a, further comprises an attachment portion <NUM> (see <FIG>) positioned at the intersection of the elongated bar portions <NUM> and coupled to one or both of the elongated bar portions <NUM>. The attachment portion <NUM> is configured for attachment to the first end 28a (see <FIG>) of the end effector <NUM> (see <FIG>) of the robot <NUM> (see <FIG>).

As shown in <FIG>, the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, further comprises power supply chains <NUM> coupled to the third side 158c (see <FIG>) and the fourth side 158d (see <FIG>), respectively, of the bottom portion <NUM> (see <FIG>) of the automated bi-stable valve system <NUM>. The power supply chains <NUM> are configured to safely and reliably supply power, energy, signals, and/or vacuum to components on the traversable bridge apparatus <NUM> (see <FIG>). The power supply chains <NUM> are used to guide and protect one or more of, electrical wiring, cables, hoses, vacuum lines, and/or optical conductors that supply the power, energy, signals, and/or vacuum to components on the traversable bridge apparatus <NUM> that are in motion. <FIG> further shows an orthogonal x, y, z coordinate system <NUM>, in which the x-axis corresponds to the direction of travel of the traversable bridge apparatus <NUM>, and the y-axis corresponds to the direction of the length of the traversable bridge apparatus <NUM>.

Now referring to <FIG> is an illustration of an enlarged cross-section view of a portion <NUM> of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, taken along lines 5D-5D, of <FIG>. <FIG> shows the control system <NUM> comprising the traversable bridge apparatus <NUM> and the valve switch mechanism <NUM>. The power supply chain <NUM> is coupled to the traversable bridge apparatus <NUM>. The traversable bridge apparatus <NUM> is in the end position <NUM>. <FIG> further shows the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, showing a control magnet <NUM> within the traversable bridge apparatus <NUM>. <FIG> further shows the control actuator <NUM> comprising the actuator <NUM>, in the form of an electric solenoid <NUM>, attached to, and housed within, the traversable bridge apparatus <NUM>. The electric solenoid <NUM> comprises a push type tubular linear electric solenoid 96a (see <FIG>). In other examples, the electric solenoid <NUM> may comprise a pull type solenoid, a rotary solenoid, or another suitable type of electric solenoid. Alternatively, the actuator <NUM> may comprise a pneumatic solenoid <NUM> (see <FIG>), an electric motor <NUM> (see <FIG>), such as a servo motor <NUM> (see <FIG>) or a stepper motor <NUM> (see <FIG>), or another suitable actuator.

As shown in <FIG>, the control magnet <NUM> is coupled to, or mounted to, the electric solenoid <NUM> and is in the form of a solenoid-mounted control magnet 122a. The control magnet <NUM> coupled to, or mounted to, the electric solenoid <NUM> is also referred to as a control magnet/solenoid assembly <NUM> (see <FIG>) and has a first end 174a (see <FIG>) and a second end 174b (see <FIG>). As shown in <FIG>, the control magnet <NUM> has a first end 175a and a second end 175b, and is positioned in a lower slot portion <NUM> of the control magnet/solenoid assembly <NUM>. As further shown in <FIG>, the electric solenoid <NUM>, such as the push type tubular linear electric solenoid 96a, comprises a first end 176a, a second end 176b, and a cylindrical body <NUM> formed between the first end 176a and the second end 176b. The cylindrical body <NUM> has an interior central channel <NUM> formed through a portion of the cylindrical body <NUM> and extends through the interior central channel <NUM> from an opening <NUM> at the second end 176b of the electric solenoid <NUM>.

As further shown in <FIG>, the electric solenoid <NUM>, such as the push type tubular linear electric solenoid 96a, comprises a plunger <NUM>, such as a steel plunger, having a first end 185a, a second end 185b, and an elongated shaft body <NUM> formed between the first end 185a and the second end 185b. The first end 185a of the plunger <NUM> is positioned within the interior central channel <NUM> of the cylindrical body <NUM> of the electric solenoid <NUM>, and the second end 185b of the plunger <NUM> is coupled, or attached, to the first end 175a of the control magnet <NUM>. The plunger <NUM> is configured to push out through the opening <NUM> in the second end 176b of the electric solenoid <NUM>.

As further shown in <FIG>, the electric solenoid <NUM>, such as the push type tubular linear electric solenoid 96a, comprises a coil <NUM> within the cylindrical body <NUM> of the electric solenoid <NUM> and surrounding the first end 185a of the plunger <NUM> within the interior central channel <NUM>. The control magnet/solenoid assembly <NUM> further comprises a spring <NUM> attached at the first end 185a of the plunger <NUM> of the electric solenoid <NUM>. The spring <NUM> acts as a spring return to move the plunger <NUM> upward from an energized position, to a de-energized position on loss of power, and in turn, to move the control magnet <NUM> upward from the down position <NUM> (see <FIG>, <FIG>), to the up position <NUM> (see <FIG>, <FIG>). Alternatively, the control magnet/solenoid assembly <NUM> may comprise other means to move the plunger <NUM> upward to a de-energized position. The control magnet/solenoid assembly <NUM> may further comprise a plunger stop to limit travel of the plunger <NUM>, seals, bushings, or other suitable components of known push type tubular linear electric solenoids.

The electric solenoid <NUM>, such as the push type tubular linear electric solenoid 96a, is configured to operably actuate the plunger <NUM> between an up position <NUM> (see <FIG>) and a down position <NUM> (see <FIG>), which in turn, actuates the control magnet <NUM> between the up position <NUM> (see <FIG>, <FIG>) and the down position <NUM> (see <FIG>, <FIG>). When the coil <NUM> is energized, for example, with electricity or current, a magnetic field is generated, which induces a magnetic field in the plunger <NUM> and causes the plunger <NUM> to move downwardly from the up position <NUM> to the down position <NUM>, and push the control magnet <NUM> from the up position <NUM> to the down position <NUM>. When the coil <NUM> is de-energized, the plunger <NUM> moves upwardly from the down position <NUM> to the up position <NUM>, and returns to the original position, and the control magnet <NUM> is moved from the down position <NUM> back up to the up position <NUM>.

<FIG> further shows the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, having one or more wiping magnets <NUM> attached to, and housed within a base portion <NUM>, or lower portion, of the traversable bridge apparatus <NUM>. As shown in <FIG>, the base portion <NUM>, or lower portion, of the traversable bridge apparatus <NUM> is attached to an upper portion <NUM> of the traversable bridge apparatus <NUM>, via one or more attachment elements <NUM>, such as one or more screws 195a, or other suitable attachment elements.

Each of the one or more wiping magnets <NUM> is in a fixed position <NUM>, and when the traversable bridge apparatus <NUM> moves across the plurality of bi-stable valves <NUM>, the traversable bridge apparatus <NUM>, in turn, moves the one or more wiping magnets <NUM> over the plurality of bi-stable valves <NUM> (see <FIG>), which include the floating magnets <NUM>. The one or more wiping magnets <NUM> traverse in the right-to-left direction 150a (see <FIG>) or the left-to-right direction 154a (see <FIG>), and not in an up-and-down vertical direction <NUM> (see <FIG>). The one or more wiping magnets <NUM> are configured to reset one or more of the plurality of bi-stable valves <NUM> to be in the valve closed state <NUM> (see <FIG>, <FIG>) or the valve open state <NUM> (see <FIG>, <FIG>), prior to the control magnet <NUM> moving over the plurality of bi-stable valves <NUM>, to selectively switch one or more of the plurality of bi-stable valves <NUM> between the valve closed state <NUM> and the valve open state <NUM>. Alternatively, instead of using the wiping magnet <NUM>, the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, may further optionally include or comprise one of, as shown in <FIG>, an electromagnet <NUM>; a solenoid-mounted control magnet <NUM> with a polarity <NUM> that is opposite the control magnet polarity <NUM> of the control magnet <NUM>, and with a polarity <NUM> that is the same as the wiping magnet polarity <NUM> of the wiping magnet <NUM>; a mechanism <NUM> to move a magnetic pole <NUM>; or a mechanism <NUM> to block or decrease a magnetic strength <NUM>. <FIG> further shows a row 78a of bi-stable valves <NUM> housed in the bottom portion <NUM> of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a. Adjacent bi-stable valves 78c (see <FIG>) are separated by gap areas <NUM> (see <FIG>, <FIG>).

Now referring to <FIG> is an illustration of an enlarged sectional perspective side view of a portion <NUM> of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, of <FIG>. <FIG> shows the control system <NUM> comprising the traversable bridge apparatus <NUM> and the valve switch mechanism <NUM>. <FIG> shows the traversable bridge apparatus <NUM> in the end position <NUM>, and shows the base portion <NUM> and the upper portion <NUM> of the traversable bridge apparatus <NUM> connected together with the attachment elements <NUM>, such as the screws 195a.

<FIG> shows the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, with the control magnets <NUM> carried and housed by the traversable bridge apparatus <NUM>. <FIG> further shows rails <NUM> on which the traversable bridge apparatus <NUM> traverses or moves. The traversable bridge apparatus <NUM> has guide elements <NUM> (see <FIG>) coupled to the traversable bridge apparatus <NUM>. The guide elements <NUM> are configured to slide, or move, along the rails <NUM>, and in turn, slide, or move, the traversable bridge apparatus <NUM> along the rails <NUM>.

<FIG> further shows the control actuator <NUM> comprising the actuator <NUM>, in the form of the electric solenoid <NUM>, such as the push type tubular linear electric solenoid 96a, attached to the traversable bridge apparatus <NUM>. <FIG> shows the control magnet <NUM> within the lower slot portion <NUM> of the control magnet/solenoid assembly <NUM>, and shows the control magnet <NUM> coupled to, or mounted to, the electric solenoid <NUM>. <FIG> further shows the first end 176a, the second end 176b, the cylindrical body <NUM>, the interior central channel <NUM>, the opening <NUM>, the plunger <NUM> with the elongated shaft body <NUM>, the coil <NUM>, and the spring <NUM>.

<FIG> further shows the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, having one or more wiping magnets <NUM> in the fixed position <NUM> and attached to, and housed within, the base portion <NUM> of the traversable bridge apparatus <NUM>. The one or more wiping magnets <NUM> are configured to move over the bi-stable valves <NUM>. <FIG> further shows a bi-stable valve <NUM> with a floating magnet <NUM> housed in the bottom portion <NUM> of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a. <FIG> further shows bi-stable valve openings <NUM> arranged in rows 202a. Each bi-stable valve opening <NUM> is configured to receive and house a bi-stable valve <NUM> containing a floating magnet <NUM>.

Now referring to <FIG> is an illustration of an enlarged sectional side view of a portion <NUM> of the control system <NUM> comprising the valve switch mechanism <NUM> in the form of the actuating control magnet assembly <NUM> of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, of <FIG>. <FIG> shows magnetic poles <NUM> of the control magnet <NUM>, the wiping magnet <NUM>, and the floating magnets <NUM>. <FIG> shows the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, with the control magnet <NUM> coupled to, or mounted to, the actuator <NUM> comprising the electric solenoid <NUM>, such as the push type tubular linear electric solenoid 96a. As shown in <FIG>, the control magnet <NUM> has a control magnet polarity <NUM> (see <FIG>) with magnetic poles <NUM> comprising a north (N) pole 206a at a first end 175a, or upper end, and a south (S) pole 206b at a second end 175b, or lower end, of the control magnet <NUM>. The actuator <NUM>, such as the electric solenoid <NUM>, is configured to operably actuate the control magnet <NUM> between the up position <NUM> (see <FIG>, <FIG>) and the down position <NUM> (see <FIG>, <FIG>), and the plunger <NUM> is in a down position <NUM> (see <FIG>) and is configured to move in an up-and-down vertical direction <NUM> (see <FIG> further shows the spring <NUM> coupled to the plunger <NUM>.

<FIG> shows the control magnet <NUM> positioned directly above a floating magnet <NUM> and in line with the floating magnet <NUM>. The control magnet <NUM> is configured to impart a magnetic force <NUM> (see <FIG>) on the floating magnet <NUM> of each bi-stable valve <NUM> (see <FIG>), to push the floating magnet <NUM> down, to switch the bi-stable valve <NUM> between the valve closed state <NUM> and the valve open state <NUM>. <FIG> further shows the floating magnets <NUM> each having a floating magnet polarity <NUM> (see <FIG>) with magnetic poles <NUM> comprising the south (S) pole 206b at a first end 210a, or upper end, and the north (N) pole 206a at a second end 210b, or lower end, of the floating magnets <NUM>.

<FIG> further shows the wiping magnet <NUM> having a wiping magnet polarity <NUM> (see <FIG>) with magnetic poles <NUM> comprising the south (S) pole 206b at a first end 212a, or upper end, and the north (N) pole 206a at a second end 212b, or lower end, of the wiping magnet <NUM>. As shown in <FIG>, the wiping magnet <NUM> has the same polarity, with the magnetic poles <NUM> in the same positions as the floating magnets <NUM>, and the control magnet <NUM> has the opposite polarity, with the magnetic poles <NUM> in opposite positions to the wiping magnet <NUM> and the floating magnets <NUM>. The wiping magnet <NUM> travels in front of the control magnet <NUM> and closes or opens all the bi-stable valves <NUM>. The control magnet <NUM> follows and is able to selectively open or the bi-stable valves <NUM>, as needed.

Now referring to <FIG> is an illustration of an enlarged sectional side view of a bi-stable valve <NUM>, with a floating magnet <NUM>, of the actuating control magnet assembly <NUM>, of the automated bi-stable valve system <NUM>, such as in the form of the automated bi-stable valve system 10a, of <FIG>, showing the bi-stable valve <NUM> in the valve closed state <NUM>. <FIG> is an illustration of an enlarged sectional side view of a bi-stable valve <NUM> with a floating magnet <NUM> of the actuating control magnet assembly <NUM> of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, of <FIG>, showing the bi-stable valve <NUM> in the valve open state <NUM>.

As shown in <FIG>, the bi-stable valve <NUM> has a first end 214a, a second end 214b, and a cylindrical valve body <NUM> formed between the first end 214a and the second end 214b. As further shown in <FIG>, the cylindrical valve body <NUM> has an interior portion <NUM> that houses the floating magnet <NUM>. As further shown in <FIG>, the bi-stable valve <NUM> has a non-ferrous sleeve <NUM> coupled to, or integral with, an exterior <NUM> of the bi-stable valve <NUM>. The non-ferrous sleeve <NUM> is made of a non-ferrous material that is not magnetic. The non-ferrous material may comprise a metal or alloy that does not have iron (non-iron metal or non-iron alloy), does not have steel (non-steel metal or non-steel alloy), or does not have iron or steel components. For example, the non-ferrous material may comprise a metal such as copper, aluminum, nickel, zinc, lead, tin, manganese, brass, bronze, or another suitable non-ferrous metal material. The non-ferrous material may also comprise plastics, composites, or other suitable non-ferrous materials. Further, the cylindrical valve body <NUM> is preferably made of a non-ferrous material that is not magnetic, and similar to the non-ferrous material of the non-ferrous sleeve <NUM>.

As shown in <FIG>, the non-ferrous sleeve <NUM> is coupled, or attached, to a first ferrous element <NUM>, such as a first ferrous plate 222a, for example, an upper ferrous plate, attached at the first end 214a of the bi-stable valve <NUM>. The first ferrous element <NUM>, such as the first ferrous plate 222a, is magnetic and is made of a ferrous material, such as iron, steel, an alloy of iron or steel, or another suitable ferrous material. The first ferrous element <NUM>, such as the first ferrous plate 222a, has an opening <NUM> (see <FIG>) formed through the first ferrous element <NUM>, such as the first ferrous plate 222a.

As shown in <FIG>, the non-ferrous sleeve <NUM> is coupled, or attached, to a second ferrous element <NUM>, such as a second ferrous plate 225a, for example, a lower ferrous plate, attached at the second end 214b of the bi-stable valve <NUM>. The second ferrous element <NUM>, such as the second ferrous plate 225a, is magnetic and is made of a ferrous material, such as iron, steel, an alloy of iron or steel, or another suitable ferrous material. The second ferrous element <NUM>, such as the second ferrous plate 225a, has an opening <NUM> (see <FIG>) formed through the second ferrous element <NUM>, such as the second ferrous plate 225a.

As shown in <FIG>, each bi-stable valve <NUM> further comprises a seal <NUM> adjacent to the first ferrous element <NUM>, such as the first ferrous plate 222a. The seal <NUM> has an opening <NUM> (see <FIG>) formed through the seal <NUM>. The opening <NUM> in the first ferrous element <NUM> and the opening <NUM> in the seal <NUM> are preferably aligned and open to a channel <NUM> (see <FIG>) through which air flow 38a (see <FIG>), for example, vacuum flow, flowing in an air flow path 38b (see <FIG>) can flow, when the floating magnet <NUM> is in the valve open state <NUM>. The first end 214a of each of the bi-stable valves <NUM> is open at the top and connected, via the channel <NUM>, that runs along the top of the bi-stable valves <NUM>. The seal <NUM> may be made of rubber, silicone rubber, nylon, plastic, or another suitably flexible and air tight material.

As shown in <FIG>, each bi-stable valve <NUM> further comprises a bottom bumper <NUM> attached to the bottom end of the interior portion <NUM> of the cylindrical valve body <NUM>. The bottom bumper <NUM> is designed to prevent, or avoid, damage to the floating magnet <NUM>, when the floating magnet <NUM> contacts the bottom end of the interior portion <NUM> and moves downwardly within the bi-stable valve <NUM>. The bottom bumper <NUM> may be made of rubber, silicone rubber, nylon, plastic, or another suitably flexible material.

As shown in <FIG>, the bi-stable valve <NUM> further comprises a magnetic shielding <NUM>, or ferrous shielding, positioned on, and covering, sides of the non-ferrous sleeve <NUM> of the bi-stable valve <NUM>, to limit, or avoid, magnetic interference of adjacent bi-stable valves 78c (see <FIG>). In some examples, the magnetic shielding <NUM> may also cover part of the upper surface at the first end 214a of the bi-stable valve <NUM> and may also cover part of the lower surface at the second end 214b of the bi-stable valve <NUM>. The design of the magnetic shielding <NUM> is dependent on the valve density <NUM> (see <FIG>) and overall design of the bi-stable valve <NUM>. The magnetic shielding <NUM> is magnetic and is made of a ferrous material, such as iron, steel, an alloy of iron or steel, or another suitable ferrous material.

As further shown in <FIG>, the bi-stable valves <NUM> have gap areas <NUM> between adjacent bi-stable valves 78c (see <FIG>). The gap areas <NUM> are formed between sides of the magnetic shielding <NUM> between adjacent bi-stable valves 78c. The gap areas <NUM> act to limit, or avoid, magnetic interference between adjacent bi-stable valves 78c.

As shown in <FIG>, the bi-stable valve <NUM> further comprises the floating magnet <NUM> within the non-ferrous sleeve <NUM> that is movable between the first ferrous element <NUM>, or first ferrous plate 222a, and the second ferrous element <NUM>, or second ferrous plate 225a. As shown in <FIG>, the floating magnet <NUM> is in an up position <NUM> and prevents air flow 38a (see <FIG>), when the bi-stable valve <NUM> is in the valve closed state <NUM>. In the up position <NUM>, as shown in <FIG>, the first end 210a of the floating magnet <NUM> is adjacent the bottom of the seal <NUM> and the floating magnet <NUM> blocks the opening <NUM> in the seal <NUM> and blocks the opening <NUM> in the first ferrous element <NUM>, to cause the bi-stable valve <NUM> to be in the valve closed state <NUM>.

As shown in <FIG>, the floating magnet <NUM> is in a down position <NUM> and allows air flow 38a, when the bi-stable valve <NUM> is in the valve open state <NUM>. In the down position <NUM>, as shown in <FIG>, the second end 210b of the floating magnet <NUM> is adjacent the top of the bottom bumper <NUM>, and the first end 210a of the floating magnet <NUM> is away from the bottom of the seal <NUM> to unblock the opening <NUM> in the seal <NUM> and to unblock the opening <NUM> in the first ferrous element <NUM>, to cause the bi-stable valve <NUM> to be in the valve open state <NUM>. <FIG> further shows that when the bi-stable valve <NUM> is in the valve open state <NUM>, the air flow 38a, for example, vacuum flow, flows in the air flow path 38b from the opening <NUM> in the second ferrous element <NUM> at the second end 214b of the bi-stable valve <NUM>, through the interior portion <NUM> of the cylindrical valve body <NUM>, out the opening <NUM> in the seal <NUM>, out the opening <NUM> in the first ferrous element <NUM>, and into the channel <NUM>, where it connects with the vacuum system <NUM> (see <FIG>).

The control magnet <NUM> has a strength <NUM> (see <FIG>) sufficient to overcome coupling of each floating magnet <NUM> and the floating magnet's <NUM> associated first ferrous element <NUM>, such as the first ferrous plate 222a. The control magnet <NUM> is configured to impart a magnetic force <NUM> (see <FIG>) on the floating magnet <NUM>, to push the floating magnet <NUM> down to the down position <NUM> (see <FIG>), to switch the bi-stable valve <NUM> between the valve closed state <NUM> and the valve open state <NUM>.

As the wiping magnet <NUM> traverses across the bi-stable valves <NUM>, the floating magnet's <NUM> magnetic attraction to the wiping magnet <NUM> is greater than the floating magnet's magnetic attraction to the second ferrous element <NUM>, such as the second ferrous plate 225a, for example, the lower ferrous plate. The floating magnet <NUM> therefore is pulled up to the up position <NUM> (see <FIG>), and towards the wiping magnet <NUM>, and thus closes the bi-stable valves <NUM> to the valve closed state <NUM>. The control magnets <NUM>, for example, the solenoid-mounted control magnets 122a, are outside of the magnetic area of effect of the floating magnets <NUM>, when the plunger <NUM> of the actuator <NUM>, such as the electric solenoid <NUM>, is in the up position <NUM> (see <FIG>), and thus the control magnets <NUM>, for example, the solenoid-mounted control magnets 122a, do not affect the state of the bi-stable valves <NUM>. When the plunger <NUM> of the actuator <NUM>, such as the electric solenoid <NUM>, is in the down position <NUM> (see <FIG>), the control magnet <NUM> imparts the magnetic force <NUM> (see <FIG>) on the floating magnet <NUM> that is greater than the floating magnet's <NUM> magnetic attraction to the first ferrous element <NUM>, such as the first ferrous plate 222a, for example, the upper ferrous plate. That magnetic force <NUM> pushes the floating magnet <NUM> down, switching the bi-stable valve <NUM> to the valve open state <NUM>.

Now referring to <FIG> is an illustration of an enlarged cross-section view of a portion 172a of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, of <FIG>, showing bi-stable valves <NUM> in the valve closed state <NUM> and showing bi-stable valves <NUM> in the valve open state <NUM>. As shown in <FIG>, the bi-stable valves <NUM> include floating magnets <NUM>. <FIG> shows a first set 78d of bi-stable valves <NUM> in the valve closed state <NUM> with a first set 114a of floating magnets <NUM> in the up position <NUM>. <FIG> further shows a second set 78e of bi-stable valves <NUM> in the valve closed state <NUM> with a second set 114b of floating magnets <NUM> in the up position <NUM>. The first set 78d and the second set 78e of bi-stable valves <NUM> are each positioned above a ply <NUM>, such as a cut ply 42a, on a work surface <NUM>, such as a table or a conveyor belt, or another suitable surface, where each ply <NUM>, such as the cut ply 42a, is to be picked up with the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a.

<FIG> further shows a third set 78f of bi-stable valves <NUM> in the valve open state <NUM> with a third set 114c of floating magnets <NUM> in the down position <NUM>. <FIG> further shows a fourth set <NUM> of bi-stable valves <NUM> in the valve open state <NUM> with a fourth set 114d of floating magnets <NUM> in the down position <NUM>. The third set 78f and the fourth set <NUM> of bi-stable valves <NUM> are each positioned above portions 64a of waste material <NUM>, on the work surface <NUM>, that will not be picked up with the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, and will be left on the work surface <NUM> and separated from the plies <NUM>, such as the cut plies 42a, when the plies <NUM>, such as the cut plies 42a are picked up by the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a.

<FIG> further shows the control system <NUM> with the traversable bridge apparatus <NUM> and the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, showing the control magnet <NUM> within the traversable bridge apparatus <NUM>. <FIG> further shows the control actuator <NUM> comprising the actuator <NUM>, in the form of an electric solenoid <NUM>, attached to, and housed within, the traversable bridge apparatus <NUM>. As further shown in <FIG>, the plunger <NUM> of the electric solenoid <NUM>, such as the push type tubular linear electric solenoid 96a, is coupled to the control magnet <NUM>, and shows the control magnet <NUM> in the up position <NUM>. <FIG> further shows the cylindrical body <NUM>, the interior central channel <NUM>, the coil <NUM>, and the spring <NUM> of the control magnet/solenoid assembly <NUM>. <FIG> further shows the power supply chain <NUM>.

<FIG> further shows the one or more wiping magnets <NUM> attached to, and housed within the base portion <NUM>, or lower portion, of the traversable bridge apparatus <NUM>. As shown in <FIG>, the base portion <NUM>, or lower portion, of the traversable bridge apparatus <NUM> is attached to the upper portion <NUM> of the traversable bridge apparatus <NUM>, via the one or more attachment elements <NUM>, such as one or more screws 195a, or other suitable attachment elements.

Now referring to <FIG> is an illustration of a top perspective view of plies <NUM>, such as a cut plies 42a, to be picked up from a ply nest <NUM> on a work surface <NUM>, using the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10a, of <FIG>, and for example, can be positioned under the first set 78d (see <FIG>) and the second set 78e (see <FIG>) of bi-stable valves <NUM> in the valve closed state <NUM>, having the first set 114a and the second set 114b of floating magnets <NUM> in the up position <NUM>. <FIG> further shows portions 64a of waste material <NUM> adjacent the plies <NUM>, such as the cut plies 42a, that can be positioned under the third set 78f (see <FIG>) and the fourth set <NUM> (see <FIG>) of bi-stable valves <NUM> in the valve open state <NUM>, having the third set 114c and the fourth set 114d of floating magnets <NUM> in the down position <NUM>.

Now referring to <FIG> show another example of components of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10b, where the valve switch mechanism <NUM> comprises at least one actuating compliant mechanism assembly <NUM>. In this and other examples of the automated bi-stable valve system 10b, the actuating control magnet assembly <NUM> of the automated bi-stable valve system 10a, is replaced with the actuating compliant mechanism assembly <NUM>, and the bi-stable valves <NUM> with floating magnets <NUM> of the automated bi-stable valve system 10a are replaced with bi-stable valves <NUM> with a plurality of vacuum ports <NUM>, and the control magnets <NUM> of the automated bi-stable valve system 10a are replaced with an actuator 95a (see <FIG>), or another suitable physical contact mechanism. In this and other examples of the automated bi-stable valve system 10b, the actuating compliant mechanism assembly <NUM> provides a mechanical solution using a sliding connecting rod element <NUM> (see <FIG>) that is pushed and pulled to cover and uncover a vacuum port <NUM> (see <FIG>), discussed in further detail below.

Now referring to <FIG> is an illustration of a top schematic view of an example of an automated bi-stable valve system <NUM>, such as in the form of an automated bi-stable valve system 10b, of the disclosure. <FIG> shows the automated bi-stable valve system <NUM>, such as in the form of the automated bi-stable valve system 10b, comprising the bi-stable valve mechanism <NUM>. As shown in <FIG>, the bi-stable valve mechanism <NUM> comprises a plurality of bi-stable valves <NUM>, such as in the form of a plurality of vacuum ports <NUM>. Each of the plurality of bi-stable valves <NUM>, such as the vacuum ports <NUM>, is configured to switch between the valve closed state <NUM> (see <FIG>) and the valve open state <NUM> (see <FIG>).

The automated bi-stable valve system <NUM>, such as in the form of an automated bi-stable valve system 10b, further comprises a control system <NUM> (see <FIG>) coupled to the bi-stable valve mechanism <NUM> and configured to operably control the bi-stable valve mechanism <NUM>. The control system <NUM> comprises a traversable bridge apparatus 86a (see <FIG>), coupled to the bi-stable valve mechanism <NUM>, and a valve switch mechanism <NUM> (see <FIG>, <FIG>), such as in the form of an actuating compliant mechanism assembly <NUM> (see <FIG>, <FIG>), attached to the at least one traversable bridge apparatus 86a, and movable, via the at least one traversable bridge apparatus 86a, over the plurality of bi-stable valves <NUM>, such as the plurality of vacuum ports <NUM>. The valve switch mechanism <NUM> is configured to switch one or more of the plurality of bi-stable valves <NUM>, such as the plurality of vacuum ports <NUM>, between the valve closed state <NUM> and the valve open state <NUM>, to allow for selective control of one or more adhesion zones <NUM> (see <FIG>, <FIG>) on the bi-stable valve mechanism <NUM>, the one or more adhesion zones <NUM> corresponding to one or more adhesion areas <NUM> (see <FIG>, <FIG>) on a surface <NUM> (see <FIG>, <FIG>) of a material <NUM> (see <FIG>, <FIG>) to be selectively picked up and placed during a material handling process <NUM> (see <FIG>). For example, during the material handling process <NUM> (see <FIG>), a ply <NUM> (see <FIG>), such as a cut ply 42a (see <FIG>, <FIG>), to be picked up, is positioned underneath the vacuum ports <NUM> that are in an open position <NUM> (see <FIG>).

The automated bi-stable valve system <NUM>, such as in the form of the automated bi-stable valve system 10b, is configured for attachment to an end effector <NUM> (see <FIG>) attached to a robot <NUM> (see <FIG>). The automated bi-stable valve system <NUM>, such as in the form of the automated bi-stable valve system 10b, is a <NUM>-to-many multiplexing valve system <NUM> (see <FIG>). As further shown in <FIG>, the traversable bridge apparatus 86a is configured to traverse, or travel, across the bi-stable valve mechanism <NUM> in a first direction <NUM>, such as a right-to left direction 150a, and in a second direction <NUM>, such as a left to right direction 154a.

Now referring to <FIG> are illustrations of a valve switch mechanism <NUM>, such as in the form of an actuating compliant mechanism assembly <NUM>, of the automated bi-stable valve system <NUM> (see <FIG>), such as the automated bi-stable valve system 10b (see <FIG>). <FIG> is an illustration of a perspective back view of the actuating compliant mechanism assembly <NUM> of the automated bi-stable valve system <NUM> (see <FIG>), such as the automated bi-stable valve system 10b (see <FIG>), of <FIG>. <FIG> is an illustration of a side view of the actuating compliant mechanism assembly <NUM> of <FIG>. <FIG> is an illustration of a perspective top front view of a portion 94a of the actuating compliant mechanism assembly <NUM> of <FIG>.

As shown in <FIG>, the actuating compliant mechanism assembly <NUM> comprises an actuating column structure <NUM>, such as an actuating center column structure 240a, having a first end 242a and a second end 242b, and a body <NUM> formed between the first end 242a and the second end 242b. The actuating column structure <NUM> is preferably a rigid structure. In some examples, the body <NUM> comprises a curved top portion 244a (see <FIG>) with a straight bottom portion 244b (see <FIG>) extending from the curved top portion 244a. The curved top portion 244a may be in the form of a C-shaped structure. The first end 242a of the actuating column structure <NUM> has cam surfaces <NUM> (see <FIG>) that, in some examples, are configured to couple to, and couple to, a control actuator <NUM> (see <FIG>, <FIG>), such as an actuator 95a (see <FIG>, <FIG>). The actuator 95a may comprise a linear actuator 95b (see <FIG>), a rotary actuator 95c (see <FIG>, <FIG>), or another suitable type of actuator. The actuator 95a may further comprise an electric actuator, a pneumatic actuator, or another suitable type of actuator. In some examples, the actuator 95a is attached to the at least one traversable bridge apparatus 86a.

As shown in <FIG>, the actuating compliant mechanism assembly <NUM> further comprises a plurality of hinged beams <NUM> connected between the actuating column structure <NUM> and one or more fixed column structures <NUM>. As shown in <FIG>, the fixed column structures <NUM> may comprise vertical shoulder beams, or another suitable structure, parallel to the straight bottom portion 244b of the body <NUM> of the actuating column structure <NUM>. The fixed column structures <NUM> are preferably rigid in structure. <FIG> shows four fixed column structures <NUM> and one actuating column structure <NUM>. In other examples, the actuating compliant mechanism assembly <NUM> may comprise less than four fixed column structures <NUM> or more than four fixed column structures <NUM>, and may comprise more than one actuating column structure <NUM>.

Each of the plurality of hinged beams <NUM> has compliant rotational hinged portions <NUM> (see <FIG>) at the ends of each hinged beam <NUM>. The compliant rotational hinged portions <NUM> are thinned out portions where the material is thinner, narrower, and more compliant than the material of the remaining portion of the hinged beam <NUM>. The compliant rotational hinged portions <NUM> function as rotational hinges. The plurality of hinged beams <NUM> and the fixed column structures <NUM> and the actuating column structure <NUM> provide the actuating compliant mechanism assembly <NUM> with two equilibrium positions <NUM> (see <FIG>). As shown in <FIG>, the two equilibrium positions <NUM> include an up position 256a of the actuating column structure <NUM> and a down position 256b of the actuating column structure <NUM>, where the actuating column structure <NUM> is moved downwardly from the up position 256a to the down position 256b, when a downward force <NUM> is applied to the first end 242a of the actuating column structure <NUM>.

As shown in <FIG>, the actuating compliant mechanism assembly <NUM> further comprises a sliding connecting rod element <NUM> having a first end 254a, a second end 254b, and a curved body <NUM> formed between the first end 254a and the second end 254b. The first end 254a of the sliding connecting rod element <NUM> is coupled to, or connected to, the second end 242b of the actuating column structure <NUM>. The second end 254b of the sliding connecting rod element <NUM> is coupled to, or connected to, a vacuum port cover <NUM> (see <FIG>). As shown in <FIG>, the sliding connecting rod element <NUM> has compliant rotational hinged portions <NUM> at the ends.

As shown in <FIG>, the actuating compliant mechanism assembly <NUM> further comprises a pair of guides <NUM>, or notched portions, formed at a bottom end <NUM> (see <FIG>, <FIG>) of two of the fixed column structures <NUM>. The pair of guides <NUM> are configured to guide the vacuum port cover <NUM> over the vacuum port <NUM> between an open position <NUM> (see <FIG>, <FIG>) and a closed position <NUM> (see <FIG>). <FIG> further show the actuating compliant mechanism assembly <NUM> coupled, or attached, to a base plate <NUM> through which the vacuum ports <NUM> are formed through. <FIG> further shows the bi-stable valve mechanism <NUM> with a bi-stable valves <NUM>, such as in the form of a vacuum port <NUM>.

Each actuating compliant mechanism assembly <NUM> may be made out of a metal material or a polymer material, such as a plastic material. If the actuating compliant mechanism assembly <NUM> is made of a metal material, the actuating compliant mechanism assembly <NUM> may be manufactured or formed using a three-dimensional (3D) printing process, such as a titanium three-dimensional (3D) printing process, or another suitable manufacturing process for metal materials. If the actuating compliant mechanism assembly <NUM> is made of a polymer material, the actuating compliant mechanism assembly <NUM> may be manufactured or formed using an injection molding process, or another suitable manufacturing process for polymer materials.

Now referring to <FIG> is an illustration of a cross-sectional side view of an array <NUM> of valve switch mechanisms <NUM>, such as actuating compliant mechanism assemblies <NUM>, of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10b. <FIG> shows the valve switch mechanisms <NUM>, such as the actuating compliant mechanism assemblies <NUM>, with a plurality of control actuators <NUM>, such as actuators 95a, in the form of rotary actuators 95c, configured to actuate the first end 242a of the actuating column structure <NUM>. <FIG> further shows the bi-stable valve mechanism <NUM> with a row 78a of bi-stable valves <NUM>, such as in the form of vacuum ports <NUM>. The actuators 95a, such as the rotary actuators 95c, are configured to operably actuate the actuating column structures <NUM> of each of the actuating compliant mechanism assemblies <NUM> from the up position 256a (see <FIG>) to the down position 256b (see <FIG>), which, in turn, slides each of the sliding connecting rod elements <NUM>, to push each vacuum port cover <NUM> (see <FIG>) of the plurality of vacuum port covers <NUM> over each vacuum port <NUM> (see <FIG>) of the plurality of vacuum ports <NUM>, and to switch the bi-stable valves <NUM> comprising the vacuum ports <NUM>, from the valve open state <NUM> to the valve closed state <NUM>, and to switch the vacuum port covers <NUM> from the open position <NUM> (see <FIG>, <FIG>) to the closed position <NUM> (see <FIG>). As the actuating column structure <NUM> is moved to the down position 256b, the sliding connecting rod element <NUM> effectively creates a sliding motion it converts a vertical motion into a horizontal motion to cover and uncover the vacuum port <NUM>.

As shown in <FIG>, adjacent actuating compliant mechanism assemblies 94b are separated by a vacuum duct <NUM> that is coupled to, or adjacent to, fixed column structures <NUM> of each adjacent actuating compliant mechanism assembly 94b. The vacuum ducts <NUM> are configured for connection to the vacuum system <NUM> (see <FIG>, <FIG>). <FIG> further shows the actuating column structure <NUM> with the curved top portion 244a and the straight bottom portion 244b, the plurality of hinged beams <NUM> connected between the actuating column structure <NUM> and the fixed column structures <NUM>, the compliant rotational hinged portions <NUM> of the hinged beams <NUM>, the sliding connecting rod element <NUM> with compliant rotational hinged portions <NUM> at the ends, one of the pair of guides <NUM>, and the base plate <NUM>.

Now referring to <FIG> is an illustration of a cross-sectional side view of in the form of an array <NUM> of valve switch mechanisms <NUM>, such as actuating compliant mechanism assemblies <NUM>, of the automated bi-stable valve system <NUM>, such as in the form of automated bi-stable valve system 10b. <FIG> shows the valve switch mechanisms <NUM>, such as the actuating compliant mechanism assemblies <NUM>, with the control system <NUM> comprising a traversable bridge apparatus 86a configured to traverse, or travel, over the actuating compliant mechanism assemblies <NUM>, and over the plurality of bi-stable valves <NUM>, such as the plurality of vacuum ports <NUM>. The traversable bridge apparatus 86a is configured to traverse or travel, and traverses or travels, across the first ends 242a of the actuating column structures <NUM>, to actuate the actuating column structures <NUM> of the actuating compliant mechanism assemblies <NUM> from the up position 256a (see <FIG>) to the down position 256b (see <FIG>), which, in turn, slides each of the sliding connecting rod elements <NUM>, to push each vacuum port cover <NUM> (see <FIG>) of the plurality of vacuum port covers <NUM> over each vacuum port <NUM> (see <FIG>) of the plurality of vacuum ports <NUM>, and to switch the bi-stable valves <NUM> comprising the vacuum ports <NUM>, from the valve open state <NUM> to the valve closed state <NUM>, and to switch the vacuum port covers <NUM> from the open position <NUM> (see <FIG>, <FIG>) to the closed position <NUM> (see <FIG>). The traversable bridge apparatus 86a traverses, or travels, across the actuating compliant mechanism assemblies <NUM> and sets the positions of the vacuum ports <NUM>. As further shown in <FIG>, the traversable bridge apparatus 86a is configured to traverse, or travel, across the adjacent actuating compliant mechanism assemblies 94b in a right-to left direction 150a or a left to right direction 154a.

<FIG> further shows the plurality of hinged beams <NUM> connected between the actuating column structure <NUM> and the fixed column structures <NUM>, the compliant rotational hinged portions <NUM> of the hinged beams <NUM>, the sliding connecting rod element <NUM> with compliant rotational hinged portions <NUM> at the ends, one of the pair of guides <NUM>, and the base plate <NUM>. <FIG> further shows adjacent actuating compliant mechanism assemblies 94b separated by the vacuum duct <NUM> that is coupled to, or adjacent to, fixed column structures <NUM> of each adjacent actuating compliant mechanism assembly 94b. The vacuum ducts <NUM> are configured for connection to the vacuum system <NUM> (see <FIG>, <FIG>).

Now referring to <FIG> is an illustration of a flow diagram of an example of a method <NUM> of the disclosure. In other examples of the disclosure, there is provided the method <NUM> of using an automated bi-stable valve system <NUM> (see <FIG>) in a material handling process <NUM> (see <FIG>) for composite manufacturing (see <FIG>).

The blocks in <FIG> represent operations and/or portions thereof, or elements, and lines connecting the various blocks do not imply any particular order or dependency of the operations or portions thereof, or elements. <FIG> and the disclosure of the steps of the method <NUM> set forth herein should not be interpreted as necessarily determining a sequence in which the steps are to be performed. Rather, although one illustrative order is indicated, it is to be understood that the sequence of the steps may be modified when appropriate. Accordingly, certain operations may be performed in a different order or simultaneously.

As shown in <FIG>, the method <NUM> comprises step <NUM> of providing an automated bi-stable valve system <NUM>. As discussed above, the automated bi-stable valve system <NUM> comprises a bi-stable valve mechanism <NUM> (see <FIG>) comprising a plurality of bi-stable valves <NUM> (see <FIG>). Each of the plurality of bi-stable valves <NUM> is configured to switch between a valve closed state <NUM> (see <FIG>) and a valve open state <NUM> (see <FIG>). The automated bi-stable valve system <NUM> further comprises a control system <NUM> (see <FIG>) coupled to the bi-stable valve mechanism <NUM> and configured to operably control the bi-stable valve mechanism <NUM>.

The control system <NUM> comprises at least one traversable bridge apparatus <NUM> (see <FIG>). The control system <NUM> further comprises a valve switch mechanism <NUM> (see <FIG>) attached to the at least one traversable bridge apparatus <NUM>, and movable, via the at least one traversable bridge apparatus <NUM>, over the plurality of bi-stable valves <NUM>. The valve switch mechanism <NUM> comprises a plurality of control actuators <NUM> (see <FIG>). The plurality of bi-stable valves <NUM> comprises a plurality of rows 78a (see <FIG>) of bi-stable valves <NUM>, and each control actuator <NUM> of the plurality of control actuators <NUM> is configured to actuate one or more different rows 78b of the plurality of rows 78a of bi-stable valves <NUM>.

The step <NUM> of providing the automated bi-stable valve system <NUM> may further comprise providing the automated bi-stable valve system <NUM>, wherein each of the plurality of bi-stable valves <NUM> of the bi-stable valve mechanism <NUM> further comprises a non-ferrous sleeve <NUM> (see <FIG>) having a first ferrous element <NUM> (see <FIG>), such as a first ferrous plate 222a (see <FIG>), for example, an upper ferrous plate, and a second ferrous element <NUM> (see <FIG>), such as a second ferrous plate 225a (see <FIG>), for example, a lower ferrous plate, and a seal <NUM> (see <FIG>) adjacent to the first ferrous element <NUM>. The first ferrous element <NUM> has an opening <NUM> (see <FIG>), and the second ferrous element <NUM> has an opening <NUM> (see <FIG>). The seal <NUM> has an opening <NUM> (see <FIG>). Each of the plurality of bi-stable valves <NUM> further comprises a floating magnet <NUM> (see <FIG>) within the non-ferrous sleeve <NUM> and movable between the first ferrous element <NUM>, to block the opening <NUM> of the seal <NUM> and the opening <NUM> of the second ferrous element <NUM>, and to cause the bi-stable valve <NUM> to be in the valve closed state <NUM> (see <FIG>), and the second ferrous element <NUM>, to unblock the opening <NUM> of the seal <NUM> and the opening <NUM> of the first ferrous element <NUM>, and to cause the bi-stable valve <NUM> to be in the valve open state <NUM> (see <FIG>). Each of the plurality of bi-stable valves <NUM> further comprises a magnetic shielding <NUM> (see <FIG>) around each of the plurality of bi-stable valves <NUM> to limit magnetic interference of adjacent bi-stable valves 78c.

The step <NUM> of providing the automated bi-stable valve system <NUM> may further comprise providing the automated bi-stable valve system <NUM>, wherein the valve switch mechanism <NUM> comprises, in some examples, at least one actuating control magnet assembly <NUM> (see <FIG>, <FIG>). With the actuating control magnet assembly <NUM>, the control actuator <NUM> comprises an actuator <NUM> (see <FIG>) attached to the at least one traversable bridge apparatus <NUM>. As shown in <FIG>, the actuator <NUM> comprises one of, an electric solenoid <NUM>, a pneumatic solenoid <NUM>, an electric motor <NUM>, or another suitable actuator. The electric motor <NUM> may comprise a servo motor <NUM> (see <FIG>), a stepper motor <NUM> (see <FIG>), or another suitable electric motor.

The actuating control magnet assembly <NUM> further comprises a control magnet <NUM> (see <FIG>) coupled to the actuator <NUM>. The control magnet <NUM> has a control magnet (CM) polarity <NUM> (see <FIG>). The actuator <NUM> is configured to operably actuate the control magnet <NUM> between an up position <NUM> (see <FIG>) and a down position <NUM> (see <FIG>). The control magnet <NUM> has a strength <NUM> (see <FIG>) sufficient to overcome coupling of each floating magnet <NUM> and its associated first ferrous element <NUM>. The control magnet <NUM> is configured to impart, and imparts, a magnetic force <NUM> (see <FIG>) on the floating magnet <NUM> of each bi-stable valve <NUM>, to push the floating magnet <NUM> down, to switch the bi-stable valve <NUM> between the valve closed state <NUM> and the valve open state <NUM>. Each floating magnet <NUM> has a floating magnet (FM) polarity <NUM> (see <FIG>).

The step <NUM> of providing the automated bi-stable valve system <NUM> may further comprise providing the automated bi-stable valve system <NUM>, wherein the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, may further optionally comprise one or more wiping magnets <NUM> (see <FIG>) attached to the at least one traversable bridge apparatus <NUM>, and movable over the plurality of bi-stable valves <NUM>. The one or more wiping magnets <NUM> are configured to reset one or more of the plurality of bi-stable valves <NUM> to be in the valve closed state <NUM> or the valve open state <NUM>, prior to the control magnet <NUM> moving over the plurality of bi-stable valves <NUM>, to selectively switch one or more of the plurality of bi-stable valves <NUM> between the valve closed state <NUM> and the valve open state <NUM>.

Alternatively, instead of including one or more wiping magnets <NUM>, the valve switch mechanism <NUM>, in the form of the actuating control magnet assembly <NUM>, may further optionally include or comprise one of, as shown in <FIG>, an electromagnet <NUM>, a solenoid-mounted control magnet <NUM> with a polarity <NUM> that is opposite the control magnet polarity <NUM> of the control magnet <NUM> and with a polarity <NUM> that is the same as the wiping magnet polarity <NUM> of the wiping magnet <NUM>, a mechanism <NUM> to move a magnetic pole <NUM>, a mechanism <NUM> to block or decrease a magnetic strength <NUM>, or another suitable mechanism.

The step <NUM> of providing the automated bi-stable valve system <NUM> may further comprise providing the automated bi-stable valve system <NUM>, wherein the valve switch mechanism <NUM> comprises, in other examples, at least one actuating compliant mechanism assembly <NUM> (see <FIG>, <FIG>). With the actuating compliant mechanism assembly <NUM>, the control actuator <NUM> comprises an actuator 95a (see <FIG>) comprising a linear actuator 95b, a rotary actuator 95c, or another suitable actuator. The actuator 95a may further comprise an electric actuator, a pneumatic actuator, or another suitable type of actuator. In some examples, the actuator 95a is attached to one of the at least one traversable bridge apparatuses <NUM>.

The step <NUM> of providing the automated bi-stable valve system <NUM> may further comprise providing the automated bi-stable valve system <NUM>, wherein with the at least one actuating compliant mechanism assembly <NUM>, each of the plurality of bi-stable valves <NUM> of the bi-stable valve mechanism <NUM> comprises a plurality of vacuum ports <NUM> (see <FIG>) with a plurality of vacuum port covers <NUM> (see <FIG>) configured to open and close between the valve closed state <NUM> and the valve open state <NUM>, for example, the open position <NUM> (see <FIG>, <FIG>) and the closed position <NUM> (see <FIG>) of the vacuum ports <NUM>.

In some examples, the at least one actuating compliant mechanism assembly <NUM> comprises an actuator 95a (see <FIG>) attached to one of the at least one traversable bridge apparatuses 86a (see <FIG>, <FIG>). The actuating compliant mechanism assembly <NUM> comprises the actuating column structure <NUM> (see <FIG>) coupled to the actuator 95a. The actuating column structure <NUM> has a first end 242a (see <FIG>) and a second end 242b (see <FIG>), and a body <NUM> (see <FIG>) formed between the first end 242a and the second end 242b. The actuating column structure <NUM> is preferably a rigid structure.

The actuating compliant mechanism assembly <NUM> further comprises a plurality of hinged beams <NUM> (see <FIG>) connected between the actuating column structure <NUM> and one or more fixed column structures <NUM> (see <FIG>). The fixed column structures <NUM> are preferably rigid in structure. Each of the plurality of hinged beams <NUM> has compliant rotational hinged portions <NUM> (see <FIG>) at the ends of each hinged beam <NUM>. The compliant rotational hinged portions <NUM> function as rotational hinges. The plurality of hinged beams <NUM> and the actuating column structure <NUM> provide the actuating compliant mechanism assembly <NUM> with two equilibrium positions <NUM> (see <FIG>). As shown in <FIG>, the two equilibrium positions <NUM> include an up position 256a of the actuating column structure <NUM> and a down position 256b of the actuating column structure <NUM>, where the actuating column structure <NUM> is moved downwardly from the up position 256a to the down position 256b, when the downward force <NUM> is applied to the first end 242a of the actuating column structure <NUM>.

The actuating compliant mechanism assembly <NUM> further comprises a sliding connecting rod element <NUM> (see <FIG>) having a first end 254a (see <FIG>), a second end 254b (see <FIG>), and a curved body <NUM> (see <FIG>) formed between the first end 254a and the second end 254b. The first end 254a of the sliding connecting rod element <NUM> is coupled to, or connected to, the second end 242b of the actuating column structure <NUM>. The second end 254b of the sliding connecting rod element <NUM> is coupled to, or connected to, the vacuum port cover <NUM> (see <FIG>). As shown in <FIG>, the sliding connecting rod element <NUM> has compliant rotational hinged portions <NUM> at the ends. The actuating compliant mechanism assembly <NUM> further comprises a pair of guides <NUM> (see <FIG>) are configured to guide the vacuum port cover <NUM> between the open position <NUM> (see <FIG>, <FIG>) and the closed position <NUM> (see <FIG>). The actuating compliant mechanism assembly <NUM> further comprises a base plate <NUM> (see <FIG>).

The actuator 95a is configured to operably actuate the actuating column structure <NUM> in a down position 256b (see <FIG>), which, in turn, slides the sliding connecting rod element <NUM>, to push a vacuum port cover <NUM> (see <FIG>) of the plurality of vacuum port covers <NUM> over a vacuum port <NUM> (see <FIG>) of the plurality of vacuum ports <NUM>, and to switch the bi-stable valve <NUM> comprising the vacuum port <NUM> from the valve open state <NUM> to the valve closed state <NUM>, and to switch the vacuum port cover <NUM> from the open position <NUM> (see <FIG>) to the closed position <NUM> (see <FIG>). Thus, the vacuum port cover <NUM> is driven, such as pushed and pulled, by the actuation up and down of the sliding connecting rod element <NUM>.

As shown in <FIG>, the method <NUM> further comprises step <NUM> of coupling the automated bi-stable valve system <NUM> to an end effector <NUM> (see <FIG>) attached to a robot <NUM> (see <FIG>) and attached to a vacuum system <NUM> (see <FIG>). The automated material handling system <NUM> including the automated bi-stable valve system <NUM>, comprises the robot <NUM>, such as in the form of a pick-and-place operations robot 22a (see <FIG>), or another suitable robot, having an arm <NUM> (see <FIG>) with the end effector <NUM> (see <FIG>), configured to hold the automated bi-stable valve system <NUM>. The automated material handling system <NUM> (see <FIG>) further comprises the vacuum system <NUM> (see <FIG>, <FIG>) having a portion coupled to the end effector <NUM>, or another suitable part of the robot <NUM>, and having a portion coupled to the automated bi-stable valve system <NUM>. The vacuum system <NUM> comprises a vacuum manifold <NUM> (see <FIG>), one or more vacuum lines <NUM> (see <FIG>), a vacuum source <NUM> (see <FIG>), and a vacuum power supply <NUM> (see <FIG>). The vacuum source <NUM> may comprise a vacuum generator 35a (see <FIG>), a blower, or another suitable vacuum source, configured to pull air <NUM> (see <FIG>) in an air flow 38a (see <FIG>, <FIG>), or vacuum flow, through the one or more vacuum lines <NUM>, the vacuum manifold <NUM>, and the automated bi-stable valve system <NUM>. The vacuum system <NUM> may further comprise one or more control valves, shutoff valves, and/or other suitable vacuum system components.

As shown in <FIG>, the method <NUM> further comprises step <NUM> of selectively picking up and removing, with the automated bi-stable valve system <NUM>, one or more plies <NUM> (see <FIG>, <FIG>), such as one or more cut plies 42a (see <FIG>, <FIG>), from a work surface <NUM> (see <FIG>), by selectively switching, with the valve switch mechanism <NUM>, one or more of the plurality of bi-stable valves <NUM> from the valve closed state <NUM> to the valve open state <NUM>, to allow for selective control of one or more adhesion zones <NUM> (see <FIG>, <FIG>) on the bi-stable valve mechanism <NUM>, the one or more adhesion zones <NUM> corresponding to one or more adhesion areas <NUM> (see <FIG>, <FIG>) on a surface <NUM> (see <FIG>, <FIG>) of the one or more plies <NUM>, such as the one or more cut plies 42a, and to increase valve densities <NUM> (see <FIG>).

Now referring to <FIG> is an illustration of a perspective view of a vehicle <NUM>, such as an aircraft 280a, incorporating a composite part <NUM>, such as in the form of an aircraft composite part <NUM>, for example, a wing spar, made with an example of the automated material handling system <NUM> using an example of the automated bi-stable valve system <NUM> disclosed herein. As shown in <FIG>, the vehicle <NUM>, such as the aircraft 280a, includes a fuselage <NUM>, wings <NUM>, engines <NUM>, and an empennage <NUM>. As shown in <FIG>, the empennage <NUM> comprises a vertical stabilizer <NUM> and horizontal stabilizers <NUM>. The composite parts <NUM> formed using the automated material handling system <NUM> with the automated bi-stable valve system <NUM> may be used in a variety of industries and applications including, but not limited to, in connection with the manufacture of aircraft 280a and other aerospace structures and vehicles, including spacecraft, and rotorcraft, as well as vehicles such as watercraft, trains, or other suitable vehicles or structures.

Now referring to <FIG> is an illustration of a flow diagram of an exemplary aircraft manufacturing and service method <NUM>, and <FIG> is an illustration of an exemplary block diagram of an aircraft <NUM>. Referring to <FIG>, examples of the disclosure may be described in the context of the aircraft manufacturing and service method <NUM> as shown in <FIG>, and the aircraft <NUM> as shown in <FIG>.

During pre-production, exemplary aircraft manufacturing and service method <NUM> may include specification and design <NUM> of the aircraft <NUM> and material procurement <NUM>. During manufacturing, component and subassembly manufacturing <NUM> and system integration <NUM> of the aircraft <NUM> takes place. Thereafter, the aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service <NUM> by a customer, the aircraft <NUM> may be scheduled for routine maintenance and service <NUM> (which may also include modification, reconfiguration, refurbishment, and other suitable services).

Each of the processes of the aircraft manufacturing and service method <NUM> may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors. A third party may include, without limitation, any number of vendors, subcontractors, and suppliers. An operator may include an airline, leasing company, military entity, service organization, and other suitable operators.

As shown in <FIG>, the aircraft <NUM> produced by the exemplary aircraft manufacturing and service method <NUM> may include an airframe <NUM> with a plurality of systems <NUM> and an interior <NUM>. Examples of the plurality of systems <NUM> may include one or more of a propulsion system <NUM>, an electrical system <NUM>, a hydraulic system <NUM>, and an environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, the principles of the disclosure may be applied to other industries, such as the automotive industry.

Example methods and systems described herein may be employed during any one or more of the stages of the aircraft manufacturing and service method <NUM>. For example, components or subassemblies corresponding to component and subassembly manufacturing <NUM> may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft <NUM> is in service <NUM>. Also, one or more apparatus examples, method examples, or a combination thereof, may be utilized during component and subassembly manufacturing <NUM> and system integration <NUM>, for example, by expediting or substantially expediting assembly of or reducing the cost of the aircraft <NUM>. Similarly, one or more of apparatus examples, method examples, or a combination thereof, may be utilized while the aircraft <NUM> is in service <NUM>, for example and without limitation, to maintenance and service <NUM>.

Disclosed examples of the automated bi-stable valve system <NUM> (see <FIG>, <FIG>, <FIG>), the automated material handling system <NUM> (see <FIG>, <FIG>), and the method <NUM> (see <FIG>) provide for a <NUM>-to-many multiplexing valve system <NUM> (see <FIG>) using one control system <NUM> (see <FIG>), or control mechanism, to control multiple bi-stable valves <NUM> (see <FIG>), and splitting the control system <NUM> away from the individual bi-stable valves <NUM>, to enable significantly higher valve densities <NUM> (see <FIG>), and to reduce the size and mass, as compared to known valve systems and methods, while enabling a more scalable solution. Disclosed examples of the automated bi-stable valve system <NUM> (see <FIG>, <FIG>, <FIG>), the automated material handling system <NUM> (see <FIG>, <FIG>), and the method <NUM> (see <FIG>) provide for a much denser solution of bi-stable valves <NUM> by embedding the bi-stable valves <NUM> next to each other with common parts, like a common channel <NUM> (see <FIG>) and a common vacuum manifold <NUM> (see <FIG>), and not using bulky and heavy known valve blocks and valves.

With higher valve densities <NUM>, adhesion of the automated bi-stable valve system <NUM> to the plies <NUM> (see <FIG>), such as the cut plies 42a (see <FIG>), is easier to control. The closer the adhesion is to the edges <NUM> (see <FIG>) of the plies <NUM>, such as the cut plies 42a, the less chance there is of disturbing the waste material <NUM>, or skeleton material, that is not to be picked up and that is adjacent to the plies <NUM>, such as the cut plies 42a. Examples of the automated bi-stable valve system <NUM> provide for highly pixelated, discrete control for ply adhesion <NUM> (see <FIG>), and can facilitate composite structure layup, for example, high rate wing spar layup, by allowing for handling of nested unidirectional carbon fiber 50b (see <FIG>) having different shapes, sizes, and/or orientations. The bi-stable state of the bi-stable valves <NUM> is either allowing air flow 38a (see <FIG>), or vacuum flow, or blocking or denying air flow 38a, or vacuum flow.

In addition, disclosed examples of the automated bi-stable valve system <NUM> (see <FIG>, <FIG>, <FIG>), the automated material handling system <NUM> (see <FIG>, <FIG>), and the method <NUM> (see <FIG>) provide a valve switch mechanism <NUM> (see <FIG>) comprising, in some examples, an actuating control magnet assembly <NUM> (see <FIG>, <FIG>), and in other examples, an actuating compliant mechanism assembly <NUM> (see <FIG>, <FIG>). Examples of both of the actuating control magnet assembly <NUM> and the actuating compliant mechanism assembly <NUM> use the traversable bridge apparatus <NUM> that traverses, or travels over the rows 78a of bi-stable valves <NUM> to selectively set the valve closed state <NUM> or the valve open state <NUM> of each bi-stable valve <NUM>. The bi-stable valve <NUM> are selectively switched on and off without having to use a bulky and heavy valve block.

With the actuating control magnet assembly <NUM>, one or more control magnets <NUM>, one or more floating magnets <NUM>, and optionally, one or more wiping magnets <NUM>, are used for both a bi-stable state and a control of valve state. In some examples, the control magnet <NUM> is realized as a permanent magnet actuated via an actuator <NUM>, such as an electric solenoid <NUM> (see <FIG>), or another suitable actuator. However, the control magnet polarity <NUM> (see <FIG>) or relative position of the control magnet <NUM> to the bi-stable valve <NUM> may be changed in other suitable ways. The bi-stable valves <NUM> comprise floating magnets <NUM> that can move inside a non-ferrous sleeve <NUM> (see <FIG>), and comprise a magnetic shielding <NUM> (see <FIG>), or ferrous shielding, around each of the bi-stable valves <NUM>, to limit magnetic interference of adjacent bi-stable valves 78c (see <FIG>). Balancing the magnetic force <NUM> (see <FIG>) by controlling the magnetic or ferrous material, the gap areas <NUM> (see <FIG>), and the magnetic strength <NUM> of the magnets, is required to ensure bi-stable valves <NUM> that are reliable and that are able to be switch between a valve closed state <NUM> (see <FIG>) and a valve open state <NUM> (see <FIG>).

With the actuating compliant mechanism assembly <NUM>, the bi-stable valves <NUM> with floating magnets <NUM> of the automated bi-stable valve system 10a are replaced with bi-stable valves <NUM> with a plurality of vacuum ports <NUM> (see <FIG>), and the control magnets <NUM> of the automated bi-stable valve system 10a are replaced with (see <FIG>) an actuator 95a (see <FIG>), or another suitable physical contact mechanism. In this and other examples of the automated bi-stable valve system 10b, the actuating compliant mechanism assembly <NUM> provides a mechanical solution using a sliding connecting rod element <NUM> (see <FIG>) that is pushed and pulled to cover and uncover a vacuum port <NUM> (see <FIG>), as discussed in detail above.

Claim 1:
An automated bi-stable valve system (<NUM>, 10a) comprising:
a bi-stable valve mechanism (<NUM>) comprising a plurality of bi-stable valves (<NUM>), wherein each of the plurality of bi-stable valves (<NUM>) is configured to switch between a valve closed state (<NUM>) and a valve open state (<NUM>); and
a control system (<NUM>) coupled to the bi-stable valve mechanism (<NUM>) and configured to operably control the bi-stable valve mechanism (<NUM>), the control system (<NUM>) comprising:
(i) at least one traversable bridge apparatus (<NUM>, 86a); and
(ii) a valve switch mechanism (<NUM>) attached to the at least one traversable bridge apparatus (<NUM>, 86a), and movable, via the at least one traversable bridge apparatus (<NUM>, 86a), over the plurality of bi-stable valves (<NUM>),
wherein the valve switch mechanism (<NUM>):
is configured to switch one or more of the plurality of bi-stable valves (<NUM>) between the valve closed state (<NUM>) and the valve open state (<NUM>); and
comprises a plurality of control actuators (<NUM>), wherein the plurality of bi-stable valves (<NUM>) comprises a plurality of rows (78a) of bi-stable valves (<NUM>), and wherein each control actuator (<NUM>) of the plurality of control actuators (<NUM>) is configured to actuate one or more different rows (78b) of the plurality of rows (78a) of the plurality of bi-stable valves (<NUM>).