Patent Description:
During manufacturing of some mechanical systems, such as aircraft, some components may need to be transferred from one placed to another. To do so, a manufacturing system may pick a component at one location and move it to another location. The manufacturing system may include an end effector capable of holding the component. Such end effector may then be moved to transfer the component to another location.

<CIT>, in accordance with its abstract, states a vacuum adsorption hand and a composite hand mechanism attachable to the arm or the like of a material handling industrial robot are disclosed. The vacuum adsorption hand includes a sponge-like element on the outer surface of a perforated plate defining a vacuum chamber.

<CIT>, in accordance with its abstract, states a door regulation apparatus positions a door mounted in a freely rotatably state in a vehicle body at a reference position in a gap/step measuring process, makes a step of a preset portion of the door to zero, and includes: i) a frame installed outside of a vehicle body transfer line; ii) a moving member reciprocating in the frame through a driving unit; iii) a clamping unit installed in the moving member vacuum adsorbs a skin surface of the door; iv) a sensor installed in the clamping unit senses a vacuum pressure operating at the skin surface; v) a vision photographing unit installed in the moving member photographs a preset portion of the door; and iv) a control unit analyzes and processes a sensing signal from the sensor and vision data that acquires from the vision photographing unit to control the driving unit.

<CIT>, in accordance with its abstract, states aspects relate to systems, methods, and apparatus for a zoned vacuum tool comprised of independently operable vacuum sources provided a vacuum force to segregated zones. A vacuum force is generated in connection with a first zone independently of an activation or deactivation of vacuum force generation associated with a second zone.

<CIT>, in accordance with its abstract, states aspects of the present invention relate to systems, methods, and apparatus for a vacuum tool having a switchable plate, such that a common vacuum tool may be adapted with different plates. A switchable plate may form the entirety of the vacuum tool's material contacting surface or a switchable plate may form a portion of the material contacting surface.

<CIT>, in accordance with its abstract, states a fabric handling apparatus includes a layup table, a mold disposed adjacent to the layup table, and a fabric handling array suspended above the layup table and the mold. The fabric handling array is adapted to transfer at least one fabric shape from the layup table to the mold. The fabric handling array includes a plurality of attractors in an attractor array. An orientation of the fabric handling array is alterable with respect to at least one of the layup table and the mold so that the at least one fabric shape is positionable on the mold in a predetermined orientation.

The present disclosure describes a part transfer system and method for transferring a part, such as a stringer or another polymer composite object, from one location, such as a former, to another location, such as a kitting tray. The presently disclosed part transfer system allows parts, such as stringers, of different sizes to be transferred from one location to another location without significant changes to this system, thereby reducing manufacturing costs and time.

The part transfer system comprises a movable support, a plurality of arms, and an end effector coupled to each of the plurality of arms. The end effector includes a body and a plurality of dividers each coupled to the body. The plurality of dividers divides the body into a plurality of partitions. The end effector includes a plurality of vacuum ports each in fluid communication with one of the plurality of partitions. The part transfer system further includes a vacuum source in fluid communication with at least one of the plurality of vacuum ports. Each of the plurality of vacuum ports is configured to draw a fluid from the plurality of partitions to establish a vacuum between the end effector and a part that is engaged with the end effector, thereby securing the part to the end effector. The plurality of partitions includes at least a first partition and a second partition and the first partition and the second partition are detachably coupled to each other, and/or the vacuum source is configured to selectively draw the fluid from at least one of the plurality of partitions. Each of the plurality of arms is coupled to the movable support such that the arms can move concomitantly with the movable support. Each of the arms can move independently from the movable support and has three axes of freedom, wherein two axes are pivots, and one axis is a stroke for linear motions.

The part transfer system may further include a plurality of sensors each coupled to one of the plurality of partitions. Each of the plurality of sensors is configured to sense whether a pressure in each of the plurality of partitions is equal to or less than a predetermined pressure threshold, and the end effector is configured to be secured to the part when the pressure in at least one of the plurality of partitions is equal to or less than the predetermined pressure threshold. At least one of the plurality of sensors may be a flow sensor. At least one of the plurality of sensors may be a passive pressure sensor.

The part transfer system may further include a kitting tray configured to receive the part. The movable support may be configured to move to thereby place the part on the kitting tray. The vacuum source may be referred to as a first vacuum source, and the part transfer system may further include a second vacuum source in fluid communication with the kitting tray. The kitting tray may include a tray body and a plurality of vacuum tray ports extending through the tray body. Each of the plurality of vacuum tray ports may be in fluid communication with the second vacuum source to draw a gas from the plurality of vacuum tray ports to thereby secure the part to the kitting tray when the part is disposed on the kitting tray.

The part transfer system may further include an indexing mechanism configured to align the end effector with a former and with the kitting tray. The indexing mechanism may be a cup/cone system.

The part transfer system may further include a controller in communication with the first vacuum source. The controller may be programmed to command the first vacuum source to fluidly disconnect from the plurality of vacuum ports of the end effector when the plurality of vacuum tray ports is in fluid communication with the second vacuum source. The end effector has a maximum length, and at least two of the plurality of vacuum ports may be spaced apart from each other along the maximum length of the end effector.

There is provided a method of transferring a part, such as a stringer. The method includes: (a) activating a vacuum source, wherein the vacuum source is in fluid communication with a plurality of partitions of an end effector, wherein the end effector is coupled to each of a plurality of arms, wherein each of the plurality of arms is coupled to a movable support such that the arms can move concomitantly with the movable support. Each of the arms can move independently from the movable support and has three axes of freedom, wherein two axes are pivots, and one axis is a stroke for linear motions. The end effector includes a plurality of vacuum ports each in fluid communication with at least one of the plurality of partitions. The method further includes (b) moving the end effector toward the part until the end effector engages the part; (c) maintaining the end effector stationary after the end effector engages the part until the a pressure in at least one of the plurality of partitions is equal to or less than a predetermined pressure threshold; and (d) moving the end effector along with the part toward a kitting tray until the part is placed on the kitting tray. The method further comprises: detaching at least one of the plurality of partitions from a rest of the plurality of partitions; and/or blocking fluid flow between the vacuum source and at least one of the plurality of vacuum ports.

The method may further include sensing the pressure in each of the plurality of partitions using a plurality of sensors. Each of the plurality of sensors may be configured to sense whether the pressure in each of the plurality of partitions is equal to or less than the predetermined pressure threshold. The end effector may be configured to be secured to the part when the pressure in at least one of the plurality of partitions is equal to or less than the predetermined pressure threshold.

The vacuum source may be referred to as a first vacuum source as discussed above. The method may further include fluidly disconnecting the vacuum source from the plurality of vacuum ports of the end effector after the part is placed on the kitting tray. The kitting tray may include a tray body and a plurality of vacuum tray ports extending through the tray body. Each of the plurality of vacuum tray ports may be in fluid communication with a second vacuum source to draw a gas from the plurality of vacuum tray ports to secure the part to the kitting tray when the part is disposed on the kitting tray.

The method may further include fluidly connecting the second vacuum source to the plurality of vacuum tray ports to draw the gas from the plurality of vacuum tray ports to secure the part to the kitting tray after the part is disposed on the kitting tray. The method may further include commanding, by a controller, the second vacuum source to activate in order to draw the gas from the plurality of vacuum tray ports. The method may further include aligning, using an indexing mechanism, the part with the kitting tray while the moving the end effector along with the part toward the kitting tray.

The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate examples of the disclosure and together with the description, serve to explain the principles of the disclosure.

Moreover, unless explicitly stated to the contrary, examples "comprising" or "having" an element or a plurality of elements having a particular property may include additional elements not having that property.

With reference to <FIG> and <FIG>, the present disclosure describes a part transfer system <NUM> for transferring a part <NUM>, such as a stringer, from a former <NUM> to a kitting tray <NUM>. As used herein, the term "stringer" means a longitudinal structural piece in a framework of an aircraft. When assembled, the part <NUM> is secured to the skin of an aircraft for structural support. The part <NUM> may be wholly or partially be made of a metallic or polymeric material, such as a polymer composite. Regardless of the material employed, the part <NUM> may have difference sizes (e.g., length).

During the manufacturing process, it may be necessary to move parts <NUM> of different sizes from the former <NUM> to the kitting tray <NUM>. It is therefore desirable to use the same part transfer system <NUM> to transfer parts <NUM> of different sizes from one location to another. By using the presently disclosed part transfer system <NUM>, the manufacturing operators does not have to different transfer systems to move part <NUM> of different sizes. Rather, the manufacturing operators may simply use the presently disclosed part transfer system <NUM> to move parts <NUM> of different sizes from the former <NUM> to the kitting tray <NUM>, thereby saving time and reducing costs.

The part transfer system <NUM> includes a pick and place system <NUM> configured to pick and then move the part <NUM> from one location to another location. The pick and place system <NUM> includes a movable support <NUM> (<FIG>) and a plurality of arms <NUM> (<FIG>) coupled to the movable support <NUM>. The movable support <NUM> may be arranged horizontally and may be moved by a crane or another suitable device. As a non-limiting example, the movable support <NUM> may be configured as a strongback or beam specifically designed to rigidly support the plurality of arms <NUM>. Each of the plurality of arms <NUM> is coupled to the movable support <NUM>. As a result, the arms <NUM> can move concomitantly with the movable support <NUM>. Each of the arms <NUM> can move independently from the movable support <NUM> and have three axes of freedom. Two axes are pivots 119a, 119b, and one axis is a stroke (i.e., linear motions). Therefore, each arm <NUM> can move linearly as shown by double arrows DA.

With reference to <FIG>, the pick and place system <NUM> further includes an end effector <NUM> configured to pick and hold the part <NUM>. The end effector <NUM> may be configured as a compactor to match the inner cavity of the part material 102a (e.g., stringer material) formed on the former <NUM>. Irrespective of its specific configuration, the end effector <NUM> is attached the arms <NUM>. Because the arms <NUM> are coupled to the movable support <NUM>, the end effector <NUM> can move as the movable support <NUM> moves.

The end effector <NUM> includes a body <NUM> and a plurality of dividers <NUM> each coupled to the body <NUM>. The dividers <NUM> divide the body <NUM> into a plurality of partitions <NUM>. As a consequence, fluid cannot flow between the partitions <NUM>. In other words, the partitions <NUM> are fluidly decoupled from one another. For this reason, each of the partitions <NUM> may be referred to as gas-sealed partitions <NUM>. The dividers <NUM> may be configured, for example, as a metallic or polymeric piece inserted into a kerf of the body <NUM> of the end effector <NUM>. In this and other examples, the body <NUM> of the end effector <NUM> includes four partitions <NUM>, namely: a first partition 120a, a second partition 120b, a third partition 120c, and a fourth partition 120d. It is contemplated, however, that the body <NUM> of the end effector <NUM> may be divided into more or fewer partitions <NUM>. One or more of the partitions <NUM> may be detachably coupled to one another in order to accommodate parts <NUM> of different sizes. This is primarily contemplated to have a modular system that can be manufactured in short batches (cheaper) and then assembled based on the length of the former. Additionally, this allows for replacement of defective modules should damage occur. So, for example, if we have two parts lines of different lengths, one <NUM> feet (<NUM>) and one <NUM> feet (<NUM>), then we would use six <NUM>' (<NUM>) modules on the long line and three <NUM>' (<NUM>) modules on the second one. This allows the first line to build any length parts up to <NUM>' (<NUM>) and the second to build any length up to <NUM>' (<NUM>) while both lines use the same part for their end effector modules. For instance, the first partition 120a and the second partition 120b may be detachably coupled to each other. The second partition 120b and the third partition 120c may be detachably coupled to each other, and the third partition 120c and the fourth partition 120d may be detachably coupled to each other. By detachably coupling partitions <NUM> to one another, the pick and place system <NUM> can accommodate parts <NUM> of different sizes.

The end effector <NUM> further includes a plurality of vacuum ports <NUM>. Each vacuum port <NUM> is in fluid communication with at least one of the partitions <NUM>. The vacuum ports <NUM> may be directly attached to the body <NUM> of the end effector <NUM>. Each vacuum port <NUM> may be configured as a hole fluidly coupled to one or more of the partitions <NUM>. The part transfer system <NUM> further includes a first vacuum source <NUM> in fluid communication with the plurality of partitions <NUM> through the vacuum ports <NUM>, thereby allowing fluid to flow from the partitions <NUM> to the first vacuum source <NUM> via the vacuum ports <NUM>. Upon activation of the first vacuum source <NUM>, each of vacuum ports <NUM> is configured to draw a fluid F (<FIG>), such as air, from the plurality of partitions <NUM> to establish a vacuum between the end effector <NUM> and the part <NUM> that is engaged with the end effector <NUM> to secure the part <NUM> to the end effector <NUM>. The end effector <NUM> has a maximum length ML, and at least two of the vacuum ports <NUM> are spaced apart from each other along the maximum length ML of the end effector <NUM> to accommodate parts <NUM> of different sizes.

With reference to <FIG>, the pick and place system <NUM> further includes a plurality of sensors <NUM> each coupled to one or more of the partitions <NUM>. Each sensor <NUM> is configured to sense whether a pressure in one of the plurality of partitions <NUM> is less than a predetermined pressure threshold. When the pressure in one or more of the partitions <NUM> is equal or less than the predetermined pressure threshold, the end effector <NUM> is secured to the part <NUM>. In other words, when the pressure in one or more of the partitions <NUM> is equal to or less than the predetermined pressure threshold, the vacuum created between the end effector <NUM> and the part <NUM> causes the end effector <NUM> to securely hold the part <NUM>. As discussed above, the sensors <NUM> detect when the pressure in each of the partitions <NUM> is equal to or less than the predetermined pressure threshold. As a non-limiting example, one or more of the sensors <NUM> may be configured as a passive pressure sensor or a flow sensor. For instance, one or more of the sensors <NUM> may be configured as a check valve <NUM> (<FIG>) that only allows fluid flow in a single direction SD, but prevents fluid flow in the opposite direction. However, when the pressure in one or more of the partitions <NUM> is equal to or less than the predetermined pressure threshold, the check valve <NUM> prevents the fluid F, from flowing in both the single direction SD and its opposite direction, thereby indicating that the pressure in one or more of the partitions is equal to or less than the predetermined pressure threshold. Thus, the first vacuum source <NUM> is configured to selectively draw the fluid F (<FIG>) from one or more of the partitions <NUM> of the end effector <NUM>. The control system <NUM> (i.e., the controller) is in communication with the first vacuum source <NUM> and, as such, the control system <NUM> can control the operation of the first vacuum source <NUM>. For example, the control system <NUM> may be programmed to command the first vacuum source <NUM> to fluidly disconnect from the vacuum ports <NUM> of the end effector <NUM> when the vacuum tray ports <NUM> of the kitting tray <NUM> are in fluid communication with a second vacuum source <NUM>.

The sensors <NUM> and the vacuum ports <NUM> of the end effector <NUM> are in fluid communication with the first vacuum source <NUM>. The first vacuum source <NUM> may be configured as a vacuum pump or another device that that removes gas molecules from a sealed volume in order to leave behind a full or partial vacuum. In the present disclosure, each partition <NUM> of the body <NUM> of the end effector <NUM> defines a gas-sealed volume. Upon activation of the first vacuum source <NUM>, gas molecules are removed from the partitions <NUM> (which are gas-sealed) in order to leave a full or partial vacuum in the partitions <NUM>, thereby allowing the end effector <NUM> to secularly hold the part <NUM>. Once the pressure in the partitions <NUM> of the end effector <NUM> is equal to or less than the predetermined pressure threshold, the movable support <NUM> can be move in order to move the end effector <NUM> (which securely holds the part <NUM>) to the kitting tray <NUM>.

The part transfer system <NUM> may further include a control system <NUM> in electronic communication with the kitting tray <NUM>, the pick and place system <NUM>, and the first vacuum source <NUM>. Accordingly, the control system <NUM> is configured to receive input data <NUM> from and provide output data <NUM> to the kitting tray <NUM>, the pick and place system <NUM>, and the first vacuum source <NUM>. The control system <NUM> may also be referred to as the controller and may include hardware elements such as a processor <NUM>, circuitry including but not limited to a timer, oscillator, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, a digital signal processor, and input/output (I/O) devices and other signal conditioning and/or buffer circuitry. In addition to the processor <NUM>, the control system <NUM> may include memory <NUM> in communication with the processor <NUM>. The memory <NUM> may include tangible, non-transitory memory such as read only memory (ROM), e.g., magnetic, solid-state/flash, and/or optical memory, as well as sufficient amounts of random-access memory (RAM), electrically-erasable programmable read-only memory (EEPROM), and the like. The control system <NUM> may additionally include a user-interface <NUM> in communication with the processor <NUM>. The user-interface <NUM> may include a keyboard, a display, a touch screen, or other input or output devices that allow a user to input data and the processor to output data. Aside from the user-interface <NUM>, the control system <NUM> may be other hardware or software to control the part transfer system <NUM>.

The control system <NUM> may also be in electronic communication with the second vacuum source <NUM> that is in fluid communication with the kitting tray <NUM>. The second vacuum source <NUM> may be a vacuum pump or another device that that removes gas molecules from a sealed volume in order to leave behind a full or partial vacuum in the kitting tray <NUM> as discussed below. Although the depicted example shows the first vacuum source <NUM> for the pick and place system <NUM> and the second vacuum source <NUM> for the kitting tray <NUM>, it is envisioned that the part transfer system <NUM> may include more or fewer vacuum sources. For example, the part transfer system <NUM> may include a single vacuum source for both the pick and place system <NUM> and the kitting tray <NUM>.

With reference to <FIG>, <FIG>, as discussed above, the pick and place system <NUM> is configured to move the part <NUM> from the former <NUM> to the kitting tray <NUM>. The kitting tray <NUM> is configured to receive the part <NUM>. The kitting tray <NUM> includes a tray body <NUM> and a recess <NUM> defined in the tray body <NUM> configured, shaped, and sized to receive the part <NUM>. The kitting tray <NUM> can be either straight for generic stringers or include a net shape of a unique or semi-unique stringer. The recess <NUM> may extend along the entire length of the tray body <NUM>. Regardless of its specific shape, the kitting tray <NUM> has a plurality of vacuum tray ports <NUM> extending through the tray body <NUM>. It is contemplated that the kitting tray <NUM> may include a raised portion/plateau instead of the recess <NUM>. This raised portion may act as a male tooling surface to mate with a female part <NUM>. In this case, the end effector <NUM> may be a female tool to pick up the part <NUM> that was formed on a male tool. The part <NUM> may then be moved to a male tool tray. Each of the vacuum tray ports <NUM> is in fluid communication with the second vacuum source <NUM>. In the other words, the kitting tray <NUM> is in fluid communication with the second vacuum source <NUM> through the vacuum tray ports <NUM>. The vacuum tray ports <NUM> may be arranged along the length of the tray body <NUM> on opposite sides of the recess <NUM> to securely hold the part <NUM> when the part <NUM> is place in the recess <NUM> and the second vacuum source <NUM> is activated. The kitting tray <NUM> may include vacuum tray ports <NUM> in a stringer flange area to secure the flange from natural relaxation that tends to lift up. The flatness helps the scanners verify the shape and size of the fabricated stringer. For other configurations of trays that have male features, the vacuum features may be positioned as needed on the cross-section to assist manufacturing. The second vacuum source <NUM> is configured to draw a gas (e.g., air) from the vacuum tray ports <NUM> to secure the part <NUM> to the kitting tray <NUM> when the part <NUM> is disposed on the kitting tray <NUM>.

The kitting tray <NUM> includes a plurality of segments <NUM> that can be decoupled from each other. The kitting tray <NUM> includes a plurality of dividing walls <NUM> to divide the segments <NUM>, thereby preventing fluid from between the segments <NUM>. Due to the segments <NUM> and the dividing walls <NUM>, the kitting tray <NUM> can accommodate and the part <NUM> independently of its size when the second vacuum source <NUM> is activated. The vacuum chambers in created by the segment <NUM> can be sized appropriately to generate any needed resolution for accommodating varying incremental differences in part length. The segments <NUM> are also detachably coupled to one another. Thus, one or more segments <NUM> of the kitting tray <NUM> may be detached from the other segments <NUM> to accommodate parts <NUM> of different sizes. For example, the kitting tray <NUM> may be <NUM> (ten feet) long with a number of <NUM> (five-feet) segments <NUM>. Alternatively, we may have <NUM> (<NUM>') trays using <NUM> (<NUM>') modules to accommodate short stringers, then <NUM> (<NUM>') and <NUM> (<NUM>') and so forth and just roundup the stringer length. Also, the kitting tray <NUM> may be <NUM> (<NUM> feet) long or <NUM> (<NUM> feet) long. Alternatively, the kitting tray <NUM> may be a <NUM> (<NUM> feet) tray for all parts <NUM> regardless of part length. The kitting tray <NUM> may include an end plug <NUM> to gas-sealed an end segment 115e of the segments <NUM>. The fluid separations happen at the vacuum tray ports <NUM> points, but not necessarily throughout. The kitting tray <NUM> may have fluid continuity between the segments <NUM> to distribute shop vacuum for the vacuum tray ports <NUM>. The kitting tray <NUM> itself may not be a vacuum chamber due to weight but rather a hose is used to move the small amount of air. The kitting tray <NUM> does not act like an accumulator and, therefore, does not reduce the responsiveness of the sensors.

With reference to <FIG>, the part transfer system <NUM> further includes an indexing mechanism <NUM> configured to align the pick and place system <NUM> with the former <NUM> and/or the kitting tray <NUM>. The indexing mechanism <NUM> may be a cup-cone system, and in such case, the pick and place system <NUM> may include a pin <NUM>. Alternatively, the indexing mechanism <NUM> may be an optical, hard stop points, global positioning system (GPS), or another type of indexing mechanism. The former <NUM> may include a former cup <NUM> (or cone) shaped and sized to receive the pin <NUM> of the pick and place system <NUM> to align the pick and place system <NUM> with the former <NUM>. The kitting tray <NUM> may include a tray cup <NUM> (or cone) configured to receive the pin <NUM> to align the pick and place system <NUM> with the kitting tray <NUM>. To align the kitting tray <NUM> with the pick and place system <NUM>, the pin <NUM> is placed inside the tray cup <NUM> of the kitting tray <NUM>. The pin <NUM> is therefore shaped and sized to be disposed inside the tray cup <NUM> to align the kitting tray <NUM> with the pick and place system <NUM> and is shaped and sized to be disposed inside the former cup <NUM> to align the pick and place system <NUM> with the former <NUM>.

With reference to <FIG>, a method <NUM> can be executed to transfer the part <NUM> from one location to another location, such as from the former <NUM> to the kitting tray <NUM>. The method <NUM> begins at block <NUM>, where the part <NUM> or stringer material 102a is provided. The part <NUM> may be a generic length or may be trimmed to a desired length. The method <NUM> then proceeds to block <NUM>.

At block <NUM>, the part <NUM> is placed at a predetermined location, such as on the former <NUM> as shown in <FIG>. In other words, the part <NUM> is staged at an off-location, such as the former <NUM>. At block <NUM>, one or more of the partitions <NUM> may be detached from the rest of the partitions <NUM> to accommodate the length of the part <NUM>. Alternatively, the part <NUM> is supported with the fully covered partitions <NUM>. The partially covered partitions <NUM> on the end do not engage due to the sensors <NUM>, the stiffness of the part <NUM> is enough to keep the part <NUM> straight. The method <NUM> then proceed to block <NUM>. At block <NUM>, the end effector <NUM> is provided. As discussed above, the end effector <NUM> may function as a compactor to shape the shape of the part <NUM>. After block <NUM>, the method <NUM> continues to block <NUM>.

At block <NUM>, the end effector <NUM> is moved toward the part <NUM> until the end effector <NUM> engages the part <NUM>. For example, the end effector <NUM> may be moved toward the part <NUM> until the end effector <NUM> is in direct contact with the part <NUM>. While moving the end effector <NUM> toward the part <NUM>, the end effector <NUM> may be aligned with the former <NUM> by inserting the pin <NUM> into the former cup <NUM> of the indexing mechanism <NUM> (or by using other suitable indexing mechanism). The end effector <NUM> may apply pressure to the part <NUM> disposed on the former <NUM> to change the shape of the part <NUM>, thereby allowing the part <NUM> to be assembled onto a specific airplane. Alternatively, the former <NUM> may create the part <NUM> (e.g., stringer) and the end effector <NUM> only retrieve the part <NUM>. When the end effector <NUM> engages the part <NUM>, the partitions <NUM> of the end effector <NUM> are covered by the part <NUM>. In the method <NUM>, the first vacuum source <NUM> is also provided at block <NUM>. At this stage of the process, the first vacuum source <NUM> is ON after placing the end effector <NUM> engages the part <NUM> at block <NUM>. Hence, at block <NUM>, the first vacuum source <NUM> is activated. As discussed above, the first vacuum source <NUM> is in fluid communication with the partitions <NUM> of the end effector <NUM> through vacuum ports <NUM>. Then, the method <NUM> continues to block <NUM>.

At block <NUM>, the partitions <NUM> of the end effector <NUM> that are covered by the part <NUM> accumulate vacuum pressure due to the small flow through the sensors <NUM>. This vacuum pressure is accumulated until the vacuum pressure at each of the partitions <NUM> is equal to or less the predetermined pressure threshold. To do so, the first vacuum source <NUM> should be ON until the vacuum pressure at each of the partitions <NUM> is equal to or less the predetermined pressure threshold, and the end effector <NUM> should be maintained stationary until the vacuum pressure at each of the partitions <NUM> is equal to or less the predetermined pressure threshold. At block <NUM>, the sensors <NUM> sense whether the pressure in each of the partitions <NUM> is equal to or less than the predetermined pressure threshold. When the pressure in each of the partitions <NUM> is equal to or less than the predetermined pressure threshold, the part <NUM> is secured to the end effector <NUM>. The sensors <NUM> may be check valves that allow the fluid F to flow from the part <NUM> into the first vacuum source <NUM> while vacuum pressure in the partitions <NUM> is greater than the predetermined pressure threshold, but block the fluid flow F from flowing between the part <NUM> and the end effector when the vacuum pressure in the partitions is equal to or less than the predetermined pressure sensor. In other words, at block <NUM>, the fluid flow between the first vacuum source <NUM> and the vacuum ports <NUM> may be blocked once the vacuum pressure in the partitions <NUM> is equal to or less than the predetermined pressure threshold. In response to determining that the pressure in each of the partitions <NUM> is equal to or less than the predetermined pressure threshold by, for example, the sensors <NUM>, the method <NUM> proceeds to block <NUM>.

At block <NUM>, the control system <NUM> may command the pick and place system <NUM> to automatically lift the end effector <NUM> with the secured part <NUM> in response to determining that the pressure in each of the partitions <NUM> is equal to or less than the predetermined pressure threshold as shown in <FIG>. At this stage, the part <NUM> is secured to the end effector <NUM>. Thus, lifting the end effector <NUM> causes the part <NUM> to be lifted as well. Alternatively, the control system <NUM> may generate an alert (such as a visual alert or an auditable alert) to notify the user of the part transfer system <NUM> that the end effector <NUM> is secured to the part <NUM> and can therefore be moved to another location, such as the kitting tray <NUM>. The user may then command the pick and place system <NUM>, through the user-interface <NUM> of the control system <NUM>, to move to another location. The method <NUM> then proceeds to blocks <NUM> and <NUM>.

At block <NUM>, the kitting tray <NUM> is provided. The method <NUM> then proceeds to block <NUM>. At block <NUM>, the part <NUM> (which is secured to the end effector <NUM>) is moved toward the kitting tray <NUM> until the part <NUM> is placed on the kitting tray <NUM> as shown in <FIG> and <FIG>. To align the end effector <NUM> with the kitting tray <NUM>, the pin <NUM> of the pick and place system <NUM> may be inserted into the tray cup <NUM> of the indexing mechanism <NUM> while moving the part <NUM>. Alternatively, other suitable indexing mechanisms may be used to align the end effector <NUM> with the kitting tray <NUM>. The method <NUM> then proceeds to block <NUM>.

At block <NUM>, the second vacuum source <NUM> may be turned ON to draw a gas (e.g., air) from the vacuum tray ports <NUM> of the kitting tray <NUM>, thereby securing the part <NUM> to the kitting tray <NUM>, after the part <NUM> is placed on the kitting tray <NUM> at block <NUM>. At block <NUM>, the control system <NUM> may command to second vacuum source to activate (i.e., turn ON) in response to, for example, determining that the fluid F is no longer drawn thought vacuum ports <NUM> of the end effector <NUM>. Therefore, at this stage, the second vacuum source <NUM> is fluidly connected to the vacuum tray ports <NUM> of the kitting tray <NUM>. Once the part <NUM> is disposed on the kitting tray <NUM>, the end effector <NUM> should be maintained connected to (e.g., in direct contact with) the part <NUM> at the interface of the vacuum pressure between the kitting tray <NUM> and the part <NUM> is equal to or less than the predetermined pressure threshold in order to secure the part <NUM> to the kitting tray <NUM> before disconnecting the end effector <NUM> from the part <NUM>. The kitting tray <NUM> may include sensors, such as the sensors <NUM>, described above to measure the vacuum pressure at the interface between the kitting tray <NUM> and the part <NUM>. In response to determining that the vacuum pressure at the interface of the kitting tray <NUM> and the part <NUM> is equal to or less than the predetermined pressure threshold, the method <NUM> proceeds to block <NUM>.

At block <NUM>, the first vacuum source <NUM> may be turned OFF. As a consequence, the part <NUM> is released from the end effector <NUM>. At block <NUM>, the first vacuum source <NUM> may be fluidly disconnected from the vacuum ports <NUM> of the end effector <NUM>. Once the part <NUM> is released from the end effector <NUM>, the method <NUM> continues to block <NUM>. At block <NUM>, the end effector <NUM> is removed from the part <NUM>.

Claim 1:
A part transfer system (<NUM>), comprising:
a movable support (<NUM>);
a plurality of arms (<NUM>);
an end effector (<NUM>) coupled to each of the plurality of arms (<NUM>), wherein the end effector (<NUM>) includes a body (<NUM>) and a plurality of dividers (<NUM>) each coupled to the body (<NUM>), the plurality of dividers (<NUM>) divides the body (<NUM>) into a plurality of partitions (<NUM>), and the end effector (<NUM>) includes a plurality of vacuum ports (<NUM>) each in fluid communication with one of the plurality of partitions (<NUM>); and
a vacuum source (<NUM>) in fluid communication with at least one of the plurality of vacuum ports (<NUM>), wherein each of the plurality of vacuum ports (<NUM>) is configured to draw a fluid from the plurality of partitions (<NUM>) to establish a vacuum between the end effector (<NUM>) and a part (<NUM>) that is engaged with the end effector (<NUM>), thereby securing the part (<NUM>) to the end effector (<NUM>), wherein:
the plurality of partitions (<NUM>) includes at least a first partition (120a) and a second partition (120b), and the first partition (120a) and the second partition (120b) are detachably coupled to each other; and/or the vacuum source (<NUM>) is configured to selectively draw the fluid from at least one of the plurality of partitions (<NUM>); and
each of the plurality of arms (<NUM>) is coupled to the movable support (<NUM>) such that the arms (<NUM>) can move concomitantly with the movable support (<NUM>), wherein each of the arms (<NUM>) can move independently from the movable support (<NUM>) and has three axes of freedom, wherein two axes are pivots (119a, 119b), and one axis is a stroke for linear motions.