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 systems such as object sortation systems.

End-effectors for robotic systems may be employed, for example, in certain applications to select and grasp an object, and then move the acquired object very quickly to a new location. End-effectors should be designed to quickly and easily select and grasp an object from a jumble of dissimilar objects, and should be designed to securely grasp an object during movement. Certain end-effectors, when used on different objects of different physical sizes, weights and materials, may have limitations regarding how securely they may grasp an acquired object, and how securely they may maintain the grasp on the object during rapid movement, particularly rapid acceleration and deceleration (both angular and linear).

Many end-effectors employ vacuum pressure for acquiring and securing objects for transport and/or subsequent operations by articulated arms. Other techniques for acquiring and securing objects involve 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.

In applications where vacuum pressure is used to acquire and secure objects, an end-effector on an articulated arm may include a vacuum cup having a compliant portion, e.g., a bellows portion, that contacts the object to be grasped. The compliant portion may be formed of a polymeric or elastomeric material that is flexible enough to allow it to change its shape to adapt to variations in object surface structures, and to varying physical relationships between the articulated arm and the object, such as for example varying angles of approaches to objects. The flexibility further allows the vacuum cup to conform to the shape of objects or to wrap around corners of objects to create an adequate seal for acquiring and securing the object.

When a good seal is not created between a flexible vacuum cup and an object however, or when the air-flow within the end-effector causes very noisy air-flow, sometimes a substantial amount of noise may result, and the noise level may be above safe limits if human personnel are close to the programmable motion device. Other types of end-effectors, however, including vacuum cups with less flexible compliant portions (in addition to those using 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), are less effective at acquiring and moving a wide variety of objects.

There remains a need therefore, for an end-effector system in a programmable motion system that may select and grasp any of a wide variety of objects, and then move the acquired objects very quickly to a new location while not producing an unacceptable level of noise.

<CIT> appears to disclose a vacuum pad capable of suctioning to a workpiece by utilizing a vacuum pressure, and includes a support member having a vacuum passage inside, a bellows secured to the support member, and a restriction member attached to an inner side of the bellows. When the bellows is contracted, the restriction member comes into the vacuum passage.

In accordance with an aspect, the invention provides an end-effector for a programmable motion device for use with a vacuum source in accordance with the appended independent claim <NUM>. Further optional features are recited in the appended dependent claims.

The invention generally relates to vacuum end-effectors on programmable motion devices. <FIG> shows a programmable motion device <NUM> that includes a base <NUM>, a base section <NUM>, and articulated arm sections <NUM> and <NUM>, as well as a vacuum attachment section <NUM>, and end-effector <NUM>. A high flow vacuum is provided via vacuum hose <NUM> from a high vacuum source <NUM>. The programmable motion device <NUM> may be used, under the control of one or more computer processing systems <NUM>, to grasp and move various objects <NUM>, <NUM> using the high flow vacuum provided at the end-effector <NUM>.

In high air-flow vacuum applications, a vacuum is provided that has a high air-flow, for example, an air-flow of at least about <NUM> cubic meters per minute (<NUM> cubic feet per minute), and a vacuum pressure at the end-effector of no more than about <NUM>,<NUM> Pascals below atmospheric, or <NUM>,<NUM> Pascals below atmospheric or <NUM>,<NUM> Pascals below atmospheric. Applicants have discovered that when such a high air-flow vacuum is provided it may cause particularly resonant high air-flow within the end-effector creating a loud (sometimes whistling) noise.

Applicants have further discovered that air moving through a suction cup and in particular, past the bellows cavity produces resonances for certain combinations of air speeds and cavity geometries. It is undesirable to change the vacuum cup assembly when the bellows, cup shape, and collar specifications are selected to work for a desired application. There is a need therefore, to address bellows resonances for certain vacuum cup assemblies and air speeds.

The high flow vacuum may be provided, for example, by a blower, having a vacuum pressure at the end-effector of no more than about <NUM>,<NUM> Pascals below atmospheric, or <NUM>,<NUM> Pascals below atmospheric or <NUM>,<NUM> Pascals below atmospheric (e.g., about <NUM>,<NUM> Pascals below atmospheric or <NUM> psi). A vacuum cup of an end-effector for example, may have an internal vacuum passage dimension (e.g., diameter if round) of about <NUM> (<NUM> inches) to about <NUM> (<NUM> inches) at a most narrow portion of the vacuum passage at the end-effector. In accordance with various aspects, the components of the end-effector need not be circular in cross-sectional shape, and may be polygonal, including square or triangular.

With reference to <FIG>, it may be seen that the internal vacuum passage <NUM> includes several components, each with potentially different inner dimensions. In particular, the end-effector <NUM> includes an attachment portion <NUM> for attaching to a programmable motion device <NUM> that includes an angled large inner dimension portion <NUM> as well as a vertical large inner dimension section <NUM>. A collar <NUM> is attached to the attachment portion <NUM>, and includes inner dimension sections <NUM>, <NUM>. A flexible bellows <NUM> that is formed, for example, of compliant elastomeric material has a varying inner dimension portion <NUM> forming the bellows, and a vertical inner dimension portion <NUM>. A vacuum cup <NUM> is attached to the bellows, and has a vertical inner dimension portion <NUM> and an expanding inner dimension that leads to the cup lip <NUM> which provides the opening at the underside <NUM> thereof for the end-effector <NUM>.

Applicants have discovered that when the smallest inner dimension portions on either side of the flexible bellows portion (e.g., <NUM>, <NUM>, <NUM> in the end-effector of <FIG>) either align or are within plus or minus <NUM> percent of the size of each other, substantial noise may result when using a high flow vacuum source. <FIG> shows a cut-away portion of one side of the internal vacuum passage <NUM> (shown in <FIG>), showing portions of the bellows <NUM> and the collar <NUM>. As the high flow vacuum is drawn (shown diagrammatically at <NUM>), some air travels will split on the trailing edge of the surface <NUM> and be directed toward the underside of the collar (shown diagrammatically at <NUM>), which air may become entrained in a circular pattern (shown diagrammatically at <NUM>) crossing the fast moving air shown at <NUM>. This may cause additional vortexes (shown diagrammatically at <NUM> and <NUM>) and may cause an oscillation to occur (shown diagrammatically at <NUM>) within the bellows <NUM>, any or all of which may result in substantial unwanted noise during high flow vacuum use.

A fundamental challenge of systems of high flow vacuum systems is that it is desirable to obtain both high volume air-flow at the contact portion of the end-effector, yet permit flexibility of the end-effector as it contacts and grasps objects without significant attendant noise. With reference to <FIG>, for example, a dimension of the vacuum channel may decrease from the contact portion <NUM> to a flexible intermediate portion <NUM> as shown at dimension A decreasing to dimension B in <FIG>. The smaller dimension B (relative dimension A) facilitates creating the high air-flow vacuum at the contact portion <NUM>. The flexible intermediate portion <NUM> (e.g., a bellows) provides flexibility in accommodating variations in object contact surfaces and contact experiences that the end-effector may undergo. An attachment portion <NUM> (e.g., an attachment collar and/or attachment unit) with a smallest internal dimension C increases in inner dimension to D as also shown in <FIG>. The flexible intermediate portion <NUM> is positioned between the smaller dimension B of the contact portion <NUM>, and the smaller dimension C of the attachment portion <NUM>. The term flexible intermediate portion may be used interchangeably with the term flexible intermediate section throughout this description.

A narrow inner dimension vacuum channel is maintained at the contact end of the flexible intermediate portion as shown at B in <FIG> to provide the high flow vacuum, which widens from dimension A at the contact surface <NUM> of the contact portion <NUM> (e.g., vacuum cup). The contact portion may additionally provide some flexibility, but the challenge exists in maintaining the high air-flow vacuum through the flexible intermediate portion without attendant high levels of noise.

In accordance with various aspects, the invention provides a bellows insert that extends into the flexible intermediate section a sufficient distance to inhibit a substantial amount of air-flow from entering the bellows portion yet does not significantly inhibit freedom of movement of the flexible intermediate section. In accordance with further specific aspects, the bellows insert extends into the flexible intermediate section, disturbing any resonance of moving air within the bellows portion. In accordance with further aspects and with reference to <FIG>, the end-effector attachment portion has a smallest internal dimension of APid, the contact end of the flexible intermediate portion has a smallest internal dimension of CEid; and the values APid and CEid are within <NUM>% or <NUM>% of each other. In accordance with further aspects, the end-effector system may produce audible noise when the end-effector attachment portion has a smallest internal dimension of APid, the bellows insert has a smallest internal dimension of BIid; and the values APid and BIid are within <NUM>% or <NUM>% of each other. For example, if BIid is within <NUM>% of APid, then bellows inserts in accordance with an aspect of the invention may be used. Surprisingly, the use of designs in accordance with various aspects of the invention reduces the noise generated by a compliant vacuum cup when used in such high air-flow application.

With reference to <FIG>, the invention provides in accordance with certain aspects, an end-effector <NUM> as well as the use of the end-effector <NUM> in the system including the programmable motion device <NUM> of <FIG> in place of the end-effector <NUM>. The end-effector <NUM> provides a vacuum channel <NUM> that is provided, in part, by attachment unit <NUM> having inner dimension portions <NUM> and <NUM>, collar <NUM> having inner dimension portions <NUM> and <NUM>, bellows <NUM> having varying inner dimension portions <NUM>, and vacuum cup <NUM>. The end-effector <NUM> further includes a bellows insert <NUM> having an inner dimension <NUM>. The presence of the bellows may not significantly inhibit movement (e.g., restrict a change in shape of at least <NUM>%, <NUM>%, <NUM>% or <NUM>%) of the flexible bellows in accordance with various aspects of the invention.

With reference to <FIG>, as the high air-flow vacuum is drawn (shown diagrammatically at <NUM>), very little air may be directed toward the underside of the collar <NUM>. While some air within the bellows may develop small vortexes (shown diagrammatically at <NUM>, <NUM>), and some air may develop small oscillations (shown diagrammatically at <NUM>), any movement of air may generally be non-uniform (shown diagrammatically at <NUM>). Most significantly, the rate of movement of air within the bellows may be greatly reduced, and large oscillations of air may be reduced or eliminated, resulting in a substantial decrease in unwanted noise during high flow vacuum use with the programmable motion device <NUM> of <FIG> where the end-effector <NUM> is substituted for the end-effector <NUM>.

<FIG> shows an exploded view of the combined attachment unit <NUM> and collar <NUM>, the flexible intermediate portion <NUM> including the vacuum cup <NUM>, and the bellows insert <NUM>. With further reference to <FIG>, the inner dimension portion <NUM> of the collar <NUM>, and the inner dimension portion <NUM> of the flexible intermediate portion <NUM> may be aligned or closely aligned. Applicants have discovered that in such arrangement, under certain conditions of high flow vacuum use, substantial unwanted noise may result absent a bellows insert <NUM>. As shown in <FIG>, the bellows insert <NUM> includes a head portion on a protruding end of the bellows insert that extends into the bellows on a bellows insert extension <NUM>, yet does not negatively affect substantial movement of the flexible intermediate portion <NUM>.

With reference to <FIG>, which shows both sides of the attachment collar <NUM> (that extends from the attachment unit <NUM> of <FIG>, <FIG>) and the flexible intermediate portion <NUM>, including the vacuum cup <NUM>, and the bellows insert <NUM>. With reference again to <FIG>, the inner dimension portion <NUM> of the collar <NUM>, and the inner dimension portion <NUM> of the flexible intermediate portion <NUM> may be aligned or closely aligned. By use of the bellows insert <NUM>, very little air will split on the trailing edge of the inner surface <NUM> of the bellows insert <NUM> and be directed toward the underside of the attachment collar <NUM>. While some air within the bellows may develop small vortexes (shown diagrammatically at <NUM>, <NUM>), any movement of air will generally be non-uniform (shown diagrammatically at <NUM>). Most significantly, the rate of movement of air within the bellows will be greatly reduced, and large oscillations of air will be reduced or eliminated, resulting in a substantial decrease in unwanted noise during high flow vacuum use as discussed above. The protrusion <NUM> (or securement feature) may be provided to facilitate holding the bellow inset in place.

As further shown in <FIG>, the attachment portion (e.g., collar <NUM>) will have a smallest internal dimension (APid), the contact end of the flexible intermediate portion will have a smallest internal dimension ((CEid), and the bellows insert will have a smallest internal dimension (BIid) as shown. The smallest internal dimension of the attachment portion (APid) and the smallest internal dimension (CEid) of the contact end of the flexible intermediate portion may vary no more than <NUM>% of each other in internal dimension, and preferably may vary no more than <NUM>%) of each other in internal dimension. Further, the end-effector system may produce audible noise when the smallest internal dimension of the attachment portion (APid) and the smallest internal dimension (BIid) of the bellows insert may vary no more than <NUM>% of each other in dimension, e.g., diameter, and preferably may vary no more than <NUM>% of each other in dimension, e.g., diameter. Again, the use of designs in accordance with an aspect of the invention may reduce the noise generated in a compliant end-effector when used in such a high air-flow application.

In accordance with further aspects of the invention and with reference to <FIG>, the contact end of the flexible intermediate portion <NUM> may be provided that has a smallest internal dimension (CEid) that is larger than the internal dimension of the attachment portion (APid) such that the smallest internal dimension (BIid) of the bellows insert is aligned or nearly aligned with the smallest internal dimension of the attachment portion (APid) (resulting in a whistle absent a bellows insert in accordance with an aspect of the invention). Again, the smallest internal dimension of the attachment portion (APid) and the smallest internal dimension (CEid) of the contact end of the flexible intermediate portion may vary no more than <NUM>% of each other in dimension (e.g., diameter), and preferably may vary no more than <NUM>% of each other in dimension (e.g., diameter). Further, the smallest internal dimension of the attachment portion (APid) and the smallest internal dimension (BIid) of the bellows insert may vary no more than <NUM>% of each other in dimension (e.g., diameter), and preferably may vary no more than <NUM>% of each other in dimension (e.g., diameter). While some air within the bellows may develop small vortexes (shown diagrammatically at <NUM>, <NUM>), any movement of air will generally be non-uniform. Most significantly, the rate of movement of air within the bellows will be greatly reduced, and large oscillations of air will be reduced or eliminated, resulting in a substantial decrease in unwanted noise during high flow vacuum use as discussed above.

In accordance with a further embodiment, the invention provides an end-effector <NUM> and a programmable motion device <NUM> (of <FIG>) including the end-effector <NUM> (of <FIG>). The end-effector <NUM> provides a vacuum channel <NUM> that is provided, in part, by an attachment section <NUM> that includes an attachment unit <NUM> having inner dimension portions <NUM> and <NUM>, and a collar <NUM> having inner dimension portions <NUM> and <NUM>. The end-effector <NUM> also includes a flexible intermediate section <NUM> including a bellows having varying inner dimension portions <NUM>, and a contact section <NUM> including a vacuum cup. The end-effector <NUM> further includes a bellows insert <NUM> having an inner dimension <NUM>. The bellows insert <NUM> includes a head portion <NUM> (optionally to facilitate retention) on a protruding end of the bellows insert that extends into the bellows on a bellow insert extension <NUM>, yet does not negatively affect substantial movement of the flexible intermediate portion <NUM>. Additionally, the bellows insert includes a shoulder engagement feature <NUM> that is secured against a shoulder <NUM> of the flexible intermediate section <NUM> as discussed below with reference to <FIG>.

<FIG> shows an exploded view of the combined attachment unit <NUM> and collar <NUM>, the flexible intermediate portion <NUM> including the vacuum cup <NUM>, and the bellows insert <NUM>. With further reference to <FIG>, the inner dimension portion <NUM> of the collar <NUM>, and the inner dimension portion <NUM> of the flexible intermediate portion <NUM> may be aligned or closely aligned. Applicants have discovered that in such arrangement, under certain conditions of high flow vacuum use, substantial unwanted noise may result absent a bellows insert <NUM>. The shoulder engagement feature <NUM> is secured against the shoulder <NUM> of the flexible intermediate section <NUM>. The shoulder <NUM> and an outer surface of the bellows insert <NUM> may additionally serve to secure the vacuum cup <NUM> to the flexible intermediate portion <NUM>.

Claim 1:
An end-effector (<NUM>, <NUM>) for a programmable motion device (<NUM>) for use with a vacuum source (<NUM>), said end-effector comprising:
an end-effector attachment portion (<NUM>, <NUM>) for attaching the end-effector to the programmable motion device, said end-effector attachment portion including a vacuum channel (<NUM>, <NUM>) coupled to the vacuum source (<NUM>);
a contact portion (<NUM>, <NUM>) of the end-effector (<NUM>, <NUM>) for contacting an object to be acquired by the contact portion (<NUM>, <NUM>) of the end-effector (<NUM>, <NUM>);
a flexible intermediate section (<NUM>, <NUM>) including a contact end proximate the contact portion (<NUM>, <NUM>) of the end-effector (<NUM>, <NUM>), said flexible intermediate section (<NUM>, <NUM>) of the end-effector (<NUM>, <NUM>) being intermediate the end-effector attachment portion (<NUM>, <NUM>) and the contact portion (<NUM>, <NUM>) of the end-effector (<NUM>, <NUM>), said flexible intermediate section (<NUM>, <NUM>) including a bellows portion that extends radially outwardly of the vacuum channel; and
characterized by further comprising a bellows insert (<NUM>, <NUM>) that extends into the flexible intermediate section (<NUM>, <NUM>) to inhibit air-flow from entering the bellows portion, and yet does not inhibit freedom of movement of the flexible intermediate section (<NUM>, <NUM>).