Patent Description:
The invention generally relates to programmable motion systems and relates in particular to end effectors for programmable motion devices (e.g., robotic systems) for use in object processing such as object sortation and object distribution.

End effectors for robotic systems, for example, may be employed in certain applications to select and grasp an object, and then move the acquired object very quickly to a new location. Applications might include picking items from a tote of items, and then placing said item in another tote or other location. In many applications, and in order to increase the range of suitable applications, the robotic picking system must be able to pick a very large range of objects. It is therefore desirable to have the end-of-arm tool be able to grip as many items as is possible.

There are many kinds of end-of-arm tools for grasping items, including parallel grippers or finger-based grippers, as well as universal gripper or jamming gripper that uses a fluidized bed concept inside a bag, electro adhesive grippers, as well as vacuum grippers. Other techniques for acquiring and securing objects employ electrostatic attraction, magnetic attraction, needles for penetrating objects such as fabrics, fingers that squeeze an object, hooks that engage and lift a protruding feature of an object, and collets that expand in an opening of an object, among other techniques. Prehensile grippers, or finger-like grippers, for example, are sometimes used for grasping objects, but such systems also face challenges in certain applications. Such systems generally require two opposing surfaces in opposition to grasp an object, and finger-like grippers are mechanically complicated, typically requiring multiple parts as well as an actuation mechanism to close and open the fingers.

Vacuum grippers employ vacuum pressure for acquiring and securing objects for transport or subsequent operations by articulated arms. Vacuum grippers however, generally require having a good seal with an object, but ensuring a good seal sometimes requires that the particular suction cup be selected to correspond to the object being grasped.

Additionally, grasping certain objects, such as plastic bags, may require a specific type of end effector to ensure that the plastic bag does nor peel off of the end effector or collapse under the force of the end effector and thereby break the bag and/or the seal. Further, the lifting force may be limited by an amount proportional to the area of contact of the suction cup in a vacuum system, and the vacuum itself may damage some objects.

Many such grippers however, have considerable difficulty grasping and moving objecting having low pose authority (the ability to retain a particular pose when lifted or moved). For example, <FIG> shows at <NUM> a portion of an articulated arm <NUM> with an end effector <NUM> that may be, for example, a vacuum end effector. If the object <NUM> in the bin <NUM> has low pose authority, when the object if grasped and lifted (as shown in <FIG>), a lid <NUM> of the object <NUM> may move or rotate with respect to a base <NUM> of the object <NUM>. In an automated object processing system, this not only may cause the system to have poor control of the object (since the base <NUM> may swing or fall away), but any contents of the object may escape between the open lid <NUM> and the base <NUM>.

With further reference to <FIG>, even if the object (e.g., box) is grasped from a long side <NUM> (shown in <FIG>) or a short side <NUM> (shown in <FIG>), the contents may still escape, and the top <NUM> may swing or become separated from the base <NUM>. Any of these events may be problematic is an automated object processing system, which may operate independent of human personnel.

There remains a need therefore, for an end effector in a programmable motion system that may readily grasp an object having low pose authority, and then move the acquired object very quickly to a new location. <CIT> discloses a gripping device with pneumatic suckers for handling loads. <CIT> discloses a robot gripper for picking up packages. <CIT> discloses a robot and a robot system. <CIT> discloses a boxing device. <CIT> discloses an end effector for transferring articles. <CIT> discloses a bellowed suction cup. <CIT> discloses a suction pad. <CIT> discloses a grabbing mechanism and method. <CIT> discloses a gantry type stacking manipulator.

The invention provides an end-effector for a programmable motion device, as defined by claim <NUM>.

In accordance with an example, described is an end-effector for a programmable motion device, the end-effector including a lid containment portion for facilitating retention of a lid of an object, and a gripping portion that is adapted to engage the object, the lid containment portion being generally orthogonal to the gripping portion.

In accordance with another example, described is a programmable motion device for use in an object processing system. The programmable motion device includes an end-effector with a lid containment portion for facilitating retention of a lid of an object, and a gripping portion that is adapted to engage the object, the lid containment portion being generally orthogonal to the gripping portion.

In accordance with another example, described is an object processing system for processing objects. The object processing system includes a programmable motion device with an end-effector, a control system for identifying potentially openable portions of the object, and an end-effector with a lid containment portion for facilitating retention of a lid of an object and a gripping portion that is adapted to engage the object.

In accordance with a further aspect, the invention provides a method of processing objects, as defined by claim <NUM>.

In accordance with an aspect, the invention provides an end-effector that may be used with a programmable motion device in an object processing system for processing objects having low pose authority. <FIG> for example, shows at <NUM> a portion of an articulated arm <NUM> of a programmable motion device that includes an end-effector <NUM> in accordance with an aspect of the invention. <FIG> shows an isometric view of the end-effector <NUM>, which includes a first portion <NUM> by which a vacuum is applied to an object and that facilitates containing a lid of an object as discussed further below. The end-effector <NUM> further includes a second portion <NUM> that may engage a side of an object as also discussed in more detail below.

<FIG> shows a front view of the end-effector <NUM> with the second portion <NUM> facing forward. The end-effector <NUM> may be rotated by rotating the end-effector connection portion <NUM> (to which the end-effector <NUM> is connected) of the articulated arm <NUM>. The first portion <NUM> and the second portion <NUM> of the end-effector <NUM> may be generally mutually orthogonal. <FIG> shows a side view of the end-effector <NUM> showing the general relative positional/orientation relationship between the first portion <NUM> and the second portion <NUM> of the end-effector <NUM>. <FIG> shows a bottom view of the end-effector <NUM> with the first portion <NUM> facing downward, and <FIG> shows a rear view of the end-effector <NUM>.

<FIG> shows an enlarged view of the first portion <NUM> of the end-effector <NUM>, including a vacuum opening <NUM> coupled to a vacuum source. The vacuum source, for example, may be provided by a blower (with a vacuum pressure that is higher than a vacuum pressure provided by the ejector). The vacuum source therefore, may provide a vacuum pressure of no more than about <NUM>,<NUM> Pascals below atmospheric, with a maximum air flow rate of, for example at least about <NUM> cubic feet per minute (e.g., <NUM> - <NUM> cubic feet per minute). The first portion <NUM> further includes ridges <NUM> (some of which cross the opening <NUM> as shown at <NUM>), and the ridges facilitate distribution of the vacuum over a contact surface of the object. At least one ridge is formed as part of a closed area <NUM> over the vacuum opening <NUM>, while one or more other ridges may be open over the vacuum opening <NUM> as shown at <NUM>. In this way, a portion of the vacuum opening includes a closed area of vacuum (e.g., <NUM>), while in other areas the ridges provide vacuum flow (e.g., at <NUM>) in a first direction (along the ridges), while in further areas, the ridge(s) provide vacuum flow (e.g., at <NUM>) in a second direction (through the opening in the ridge) that is orthogonal with respect to the first direction. In this way, some portion(s) may provide more seal against the object than other portions, with the closed area providing the most seal, the ridge areas <NUM> providing less of a seal (due to vacuum flow along the ridges), and the ridge opening shown at <NUM> providing even less of a seal (due to vacuum flow along the ridges through the opening at <NUM>). Variable levels of seal and air flow may therefore be provided in different areas at the interface of the first portion <NUM> and the box being grasped, permitting lighter boxes to be held by the seal, while heavier boxes are further held by the high flow vacuum.

As also shown in <FIG>, the second portion <NUM> of the end-effector <NUM> includes non-slip surfaces <NUM> formed, for example, of rubber, cork, adhesive, or electro-static material etc. <FIG> shows an enlarged view of the first portion <NUM> of the end-effector <NUM> of <FIG>, and <FIG> shows an enlarged front view of the second portion <NUM> of the end-effector <NUM> of <FIG>. A foam or rubber seal <NUM> may encircle the ridges <NUM> and aperture <NUM> on the underside of the first portion <NUM> to facilitate the application of a vacuum to an object. The height of the foam or rubber seal <NUM> may be at least as high as the height of the ridges <NUM>.

<FIG> shows a more detailed underside view of the end-effector <NUM> showing the ridges <NUM> of the first portion <NUM>, and the non-slip surfaces <NUM> of the second portion <NUM>, as well as outer wall <NUM> of the first portion <NUM> and outer wall <NUM> of the second portion <NUM>. <FIG> shows a rear view of the end-effector <NUM> of <FIG> showing the walls <NUM>, <NUM>, as well as a coupling member <NUM> for connecting to the end-effector connection portion <NUM> discussed above. <FIG> shows a side-sectional view of the end-effector <NUM> of <FIG> taken along a center of the end-effector <NUM> shown at <NUM>-<NUM>. <FIG> shows a side view of the end-effector <NUM> of <FIG>.

The object processing system (as discussed in further detail below with reference to <FIG>) may include one or more perception units for viewing objects. The perception units are in communication (e.g., wirelessly) to one or more computer processing systems, in part, for identifying grasp locations. The system initially identifies whether the object is any of a category of objects having potentially poor pose authority. For example, objects that appear to be box-shaped or cube-shaped are analyzed for containing potentially exposed or lose flaps. <FIG> for example, shows an object <NUM> that is cube-shaped and includes three flaps <NUM> (two are shown) that are attached to a top <NUM> and that overlap a box base <NUM>. The end-effector <NUM> may be selected to grasp the object <NUM> such that the first portion of the end-effector <NUM> contacts the base <NUM> and at least a portion of one of the flaps <NUM> along a short side <NUM> of the box <NUM> as shown in <FIG>. The second portion <NUM> of the end-effector <NUM> contacts the underside of the base <NUM>.

<FIG> also shows the object <NUM> that is cube-shaped and includes three flaps <NUM> (again, two are shown) that are attached to a top <NUM> and that overlap a box base <NUM>. The end-effector <NUM> may similarly be selected to grasp the object <NUM> such that the first portion of the end-effector <NUM> contacts the base <NUM> and at least a portion of one of the flaps <NUM> along a long side <NUM> of the box <NUM> as shown in <FIG>. The second portion <NUM> of the end-effector <NUM> contacts the underside of the base <NUM>. Additionally, identifying indicia <NUM> and/or <NUM> on the box (as shown in <FIG> and <FIG>) may be identified by the object processing system. The identifying indicia may be used, in combination with a warehouse manifest, to determine a destination location for each box.

The system may therefore include one or more perception units located on or near an infeed conveyor for identifying indicia on an exterior of each of the bins, providing perception data from which the contents of the bin may be identified, and then knowing its relative position on the conveyor, track its location. It is assumed, in accordance with an aspect, that the bins of objects are marked in one or more places on their exterior with a visually distinctive mark such as a barcode (e.g., providing a UPC code), QR code, or radio-frequency identification (RFID) tag or mailing label so that they may be sufficiently identified with a scanner for processing. The type of marking depends on the type of scanning system used, but may include 1D or 2D code symbologies. Multiple symbologies or labeling approaches may be employed. The types of scanners employed are assumed to be compatible with the marking approach. The marking, e.g. by barcode, RFID tag, mailing label or other means, encodes a identifying indicia (e.g., a symbol string), which is typically a string of letters and/or numbers. The symbol string uniquely associates the vendor bin with a specific set of homogenous objects.

On the selected infeed conveyor at the object processing station, the perception system assists (using the central control system <NUM> - e.g., one or more computer processing systems) the programmable motion device including the end-effector in locating and grasping an object in the infeed bin. In accordance with further aspects, each object may also be marked with a visually distinctive mark, again such as a barcode (e.g., providing a UPC code), QR code, or radio-frequency identification (RFID) tag or mailing label so that they may be sufficiently identified with a scanner for processing. The type of marking depends on the type of scanning system used, but may include 1D or 2D code symbologies. Again, multiple symbologies or labeling approaches may be employed on each object.

With reference to <FIG>, the object processing system <NUM> may include a perception system <NUM> that looks down in the object processing station and perceives perception data from one or more objects on an infeed conveyor <NUM>. Objects to be processed may arrive on the infeed conveyor <NUM> in bins <NUM>. Objects may be processed by placing each object into a designated destination location box <NUM> that my run along either of two output conveyors <NUM>, <NUM>. A vacuum source <NUM> provides the high flow vacuum to the end-effector. The perception system <NUM> is mounted above a bin of objects to be processed, and the perception system <NUM> may include (on the underside thereof), a camera, a depth sensor and lights. A combination of 2D and 3D (depth) data may be acquired. The depth sensor may provide depth information that may be used together with the camera image data to determine depth information regarding possible flaps on the various objects in view. The lights may be used to remove shadows and to facilitate the identification of edges of objects, and may be all on during use, or may be illuminated in accordance with a desired sequence to assist in object and flap identification. The system uses this imagery and a variety of algorithms to generate a set of candidate grasp locations for the objects that include a flap in the bin as discussed in more detail below.

The system will identify candidate grasp locations that include a portion of a flap on one or more objects, and may not try to yet identify a grasp location for the object that is partially obscured by other objects. Candidate grasp locations may be indicated using a 3D model of the robot end effector placed in the location where the actual end effector would go to use as a grasp location. Grasp locations may be considered good, for example, if they are close to the center of mass of the object to provide greater stability during grasp and transport, and/or if they avoid places on an object such as caps, seams etc. where a good vacuum seal might not be available.

If an object cannot be fully perceived by the detection system, the perception system considers the object to be two different objects, and may propose more than one candidate grasps of such two different objects. If the system executes a grasp at either of these bad grasp locations, then it will either fail to acquire the object due to a bad grasp point where a vacuum seal will not occur, or it will acquire the object at a grasp location that is very far from the center of mass of the object, thereby inducing a great deal of instability during any attempted transport. Each of these results is undesirable.

If a bad grasp location is experienced, the system may remember that location for the associated object. By identifying good and bad grasp locations, a correlation is established between features in the 2D/3D images and the idea of good or bad grasp locations. Using this data and these correlations as input to machine learning algorithms, the system may eventually learn, for each image presented to it, where to best grasp an object, and where to avoid grasping an object.

With further reference to <FIG>, an object <NUM> may be removed from a bin <NUM>, and with reference to <FIG>, the object <NUM> may be placed into the appropriate box <NUM>. The conveyors <NUM>, <NUM>, <NUM> may include bi-direction sections to aid in turning, or may be provided as straight conveyors that are all within a reach of the articulated arm <NUM>. Additional sensors may be provided along the conveyors to identify bins and boxes, and to track their locations.

Again, the operations of the system described above are coordinated with a central control system <NUM> that again communicates (e.g., wirelessly) with the articulated arm, the perception units, as well as in-feed conveyor and output conveyors. This system determines from symbol strings the UPC associated with a vendor bin, as well as the outbound destination for each object. The central control system <NUM> is comprised of one or more workstations or central processing units (CPUs). For example, the correspondence between UPCs or mailing labels, and outbound destinations is maintained by a central control system in a database called a manifest. The central control system maintains the manifest by communicating with a warehouse management system (WMS). The manifest provides the outbound destination for each in-bound object.

<FIG> shows an underside view of an end-effector <NUM> in accordance with a further aspect of the invention that includes a first portion <NUM> including a vacuum opening <NUM> coupled to a vacuum source and through which a vacuum may be provided to an object. The first portion <NUM> further includes ridges <NUM> (some of which cross the opening <NUM>), and the ridges facilitate distribution of the vacuum over a contact surface of the object. As also shown in <FIG>, the second portion <NUM> of the end-effector <NUM> includes non-slip surfaces <NUM> formed, for example, of rubber, cork, adhesive, or electro-static material etc. as well as rows of angle barbs <NUM>, that are angled upward toward the first portion <NUM> to engage a side of a box. <FIG> shows an enlarged view of the first portion <NUM> of the end-effector <NUM>, and <FIG> shows an enlarged front view of the second portion <NUM> of the end-effector <NUM>. A foam or rubber seal <NUM> may encircle the ridges <NUM> and aperture <NUM> on the underside of the first portion <NUM> to facilitate the application of a vacuum to an object. The height of the foam or rubber seal <NUM> may be at least as high as the height of the ridges <NUM>.

<FIG> shows the end-effector <NUM> approaching a box such that the ridges <NUM> on the first portion <NUM> will engage a top <NUM> of the box, and both the non-slip surfaces <NUM> and the rows of barbs <NUM> will engage both a portion of a flap <NUM> as well as a side wall <NUM> of a base <NUM> of the box as further shown in <FIG>. In this way, a box having low pose authority may even be grasped with the first portion <NUM> contacting the top <NUM> of the box since the second portion <NUM> may sufficiently engage the side wall <NUM> of the base <NUM>. In accordance with certain aspects, the vacuum source may be switchable to change to a source of positive air pressure that is pushed from the source to the apertures to urge an object away from the contact surface in accordance with certain aspects of the invention.

Claim 1:
An end-effector (<NUM>) for a programmable motion device, said end effector comprising:
a body that includes a vacuum portion (<NUM>) that defines a vacuum opening (<NUM>) through which a vacuum from a vacuum source is applied to an object, and a gripping portion (<NUM>) that is adapted to engage the object, said vacuum portion being orthogonal to the gripping portion,
wherein the vacuum portion (<NUM>) includes a plurality of ridges (<NUM>), the end effector being characterized in that the plurality of ridges (<NUM>) includes a first ridge (<NUM>) that extends across the vacuum opening (<NUM>) to provide a first vacuum flow in a first direction along the first ridge (<NUM>), a second ridge (<NUM>) having an opening defined therein to provide a second vacuum flow in a second direction that is orthogonal to the first direction, and a third ridge (<NUM>) that forms a closed area over a portion of the vacuum opening (<NUM>).