Vacuum grippers are widely used to handle objects in industry. They perform astrictive grasping or, in other words, they apply attractive forces to object surfaces through suction pressure. The uni-contact suction cup has the advantage of simple operation and enables the handling of a wide range of items, including those that are delicate, large or inaccessible by a jaw gripper [1].
One major challenge in suction grasping is how to plan a contact location among a variety of object geometries. Examples of planning methods include the heuristic search of a surface normal [2] and neural network training of grasp affordance using binary success labels [3]. Wan et al. use CAD model meshes to plan a grasp resisting gravitational wrench [4], and Dex-Net 3.0 learns the best suction contact pose from a point cloud considering both suction seal formation and gravitational wrench resistance [5]. These methods rely on RGB or depth sensors, which may not perceive fine details critical to suction sealing success, e.g., texture, rugosity, porosity, etc. Vision may also become occluded in cluttered environments.
Another challenge arises during forceful manual manipulation. In industry, robotic speed is desired for time efficiency, however the inertial force induced by motion can cause grasping failure. Pham et al. use time-optimal path generation bounded by contact stability constraints to generate critically fast arm trajectories during pick-and-place [6]. Cheng et al. demonstrate an optimal control approach with a single suction gripper to reorient an object by extrinsic dexterity, utilizing external contacts from the table [7]. Both methods utilize known inertial properties of the gripped object. These types of dynamic and forceful maneuvers could be adaptively achieved with the addition of suction cup tactile sensing, especially for objects with properties that might compromise suction seal.
The present disclosure provides novel suction cups and sensing methods. According to embodiments, a suction cup includes inner chambers, each of which connects to a pressure transducer to estimate distributed flow rates. From the distributed leakage airflow rate measures, surface properties of engaging objects and impending local suction seal breaks during a forceful robotic manipulation may be estimated or determined. For example, sensing can be incorporated into the suction mechanism to monitor local contact geometry, e.g., through haptic exploration.
The various embodiments provide a suction cup robotic gripper element configured to measure local contact state through suction flow monitoring. In an embodiment, a single-bellows suction cup includes internal wall structures separating the suction cup into multiple, e.g., four, internal chambers. Each chamber connects with its own remote pressure transducer, which enables both absolute and differential pressure measures between chambers. The distribution of pressure represents the contact states whether the vacuum seal is evenly formed or any leakage airflow exists. Using this smart suction cup, a novel haptic exploration method may be implemented that can estimate the surface texture of an object and the surface normal of a curved object by using sliding and palpation motion, respectively. The suction cup can also be used to localize breaks in the suction seal when the suction cup is about to detach from an object.
In an embodiment, a multi-chamber suction cup is provided that includes a single bellows suction cup structure; and at least one internal wall defining at least two internal chambers within the single bellows suction cup structure, each of the at least two internal chambers sharing a common port for connecting to a common vacuum source, and each of the at least two internal chambers including a port for connecting to separate pressure transducers (e.g., a dedicated pressure transducer for each chamber).
According to certain aspects, the multi-chamber suction cup includes at least two internal walls defining four internal chambers. According to certain aspects, the single bellows suction cup structure includes a symmetrical, deformable body structure including an external opening located along a central axis of the body structure, and a deformable lip surrounding the external opening and distal from the central axis. According to certain aspects, the at least one internal wall divides the external opening into at least two opening portions, each of the at least two opening portions coupled to a corresponding one of the at least two internal chambers.
According to an embodiment, a robotic arm fixture coupling to the multi-chamber suction cup is provided. According to certain aspects, the robotic arm fixture includes a common vacuum source connected to the common port, a separate pressure transducer coupled to each internal chamber, and a controller including a processor, the controller configured to receive signals representative of a pressure within a chamber from each of the separate pressure transducers. According to certain aspects, the controller is configured to control operation of the vacuum source so as to regulate the vacuum pressure applied to the internal chambers through the common port. According to certain aspects, the controller is configured to modulate the vacuum pressure with pulse width modulation at a frequency of between about 1 Hz and about 1000 Hz.
According to an embodiment, a method of measuring contact information of a surface of an object is provided. The method includes applying a vacuum pressure to an orifice of a multi-chamber suction cup and measuring a signal using a pressure transducer coupled with a bellows within the suction cup as the orifice of the suction cup is resting on the surface or actively positioned on the surface or moved along the surface or actively removed from the surface, the bellows being coupled with the orifice.
According to an embodiment, a method of measuring contact information of a surface of an object is provided. The method includes applying a vacuum pressure to an orifice of a suction cup as the orifice of the suction cup is resting on or positioned on the surface or moved along the surface, and measuring a signal representing a pressure within the bellows using at least one pressure transducer coupled with a bellows within the suction cup as the orifice of the suction cup is resting on or positioned on the surface or moved along the surface, the bellows being coupled with the orifice.
According to certain aspects, the suction cup includes a multi-chamber suction cup, comprising a single bellows suction cup structure, and at least one internal wall defining at least two internal chambers within the single bellows suction cup structure, each of the at least two internal chambers sharing a common port for connecting to a common vacuum source, and each of the at least two internal chambers including a port for connecting to separate pressure transducers. Each pressure transducer is configured to measure a signal representing a pressure within its respective internal chamber. According to certain aspects, the applying a vacuum pressure includes modulating the vacuum pressure at a frequency ranging from about 1 Hz to about 1000 Hz.
According to an embodiment, a robotic arm fixture is provided that includes a support structure, a vacuum port on or within the support structure and configured to connect to a vacuum source, a multi-chamber suction cup coupled with the support structure, the multi-chamber suction cup including a single bellows suction cup structure and at least one internal wall defining at least two internal chambers within the single bellows suction cup structure, each of the at least two internal chambers sharing the vacuum port, and at least two pressure transducers, each fluidly coupled to a respective one of the at least two internal chambers of the multi-chamber suction cup.
According to certain aspects, the multi-chamber suction cup includes at least two internal walls defining four internal chambers within the single bellows suction cup structure.
According to certain aspects, the single bellows suction cup structure includes a symmetrical, deformable body structure including an external opening located along a central axis of the body structure, and a deformable lip surrounding the external opening.
According to certain aspects, the robotic arm fixture further includes a controller including a processor and a memory, the controller configured to receive signals representative of a pressure within a corresponding internal chamber from each of the at least two pressure transducers. According to certain aspects, the controller is configured to control the vacuum source to apply a vacuum pressure and to modulate the vacuum pressure with pulse width modulation at a frequency of between about 1 Hz and about 1000 Hz.
Reference to the remaining portions of the specification, including the drawings and claims, will realize other features and advantages of the present invention. Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
The following detailed description is exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the following detailed description or the appended drawings.
According to various embodiments, novel multi-chamber suction cups and novel sensing methods using the suction cups are provided. In certain embodiments, the multi-chamber suction cups are coupled with a fixture adapted for robotic manipulation applications.
The suction cup enables localizing small breaks in the seal due to, for example, the rugosity (e.g., wrinkles, bumps, etc.) of the object surface or the application of external wrenches or torques. In certain embodiments, overall vacuum pressure may be modulated to achieve different exploratory haptic procedures, such as sliding across surfaces. From the distributed leakage air flow rate measures, the suction cup enables estimating the surface properties of engaging objects and impending local suction seal breaks during a forceful robotic manipulation.
The multi-chamber suction cup 10 utilizes airflows inside the chambers to monitor local contacts. In an embodiment, internal wall structures separate the suction cup bellows into four chambers as shown in
In another embodiment, the suction cup structure may include or define two or more bellows, with at least one wall within each bellows defining at least two internal chambers within each bellows. In yet another embodiment, the suction cup structure may include or define two or more bellows, with at least one of the two or more bellows not including an internal wall structure as described herein.
In an embodiment, the structure of suction cup 10 includes a symmetrical, deformable body structure including an external opening or orifice 15 located along a central axis 22 of the body structure. The opening or orifice 15 defines the opening to the two or more chambers. In an embodiment, the structure also include a deformable lip 20 surrounding the external opening 15 and distal from the central axis 22. As shown in
The at least one internal wall divides the external opening 15 into at least two opening portions, each of the at least two opening portions coupled to a corresponding one of the at least two internal chambers. Again, in the
Suction airflow is provided by a vacuum source coupled with a port 30 common to all chambers. A vacuum hose or line may couple the vacuum source to the common port 30. In an embodiment, the vacuum hose or line connects to the common port along the central axis 22 as shown in
In an embodiment, the wall structure is implemented inside a single-bellows suction cup, as shown in
In an embodiment, fabrication of a suction cup, including the chamber walls, may be performed in a single-step casting of silicone rubber or other material as is well known for suction cups. As an example, the casting mold may be comprised of three parts, two outer shells and one core as shown in
CFD Simulation
Using Computational Fluid Dynamics (CFD) simulation (e.g., COMSOL Multiphysics, k-E turbulence model), an evaluation was made of an embodiment of a suction cup gripper in two suction flow cases: vertical and horizontal flow, as shown in
The simulation results suggest that the suction cup gripper can locate leakage flow using differences between the four pressure transducers. Vacuum pressure (Pvac) may be defined as the difference between atmosphere air pressure (Patm) and the chamber pressure (Pchamber), or
P
vac
=P
atm
−P
chamber (1)
In the vertical leakage flow case, Pvac close to the leaking orifice shows the least vacuum pressure than the others as shown in
In certain embodiments, measurements of the pressures inside the suction cup (e.g., inside each chamber) are used for estimating vacuum seal quality, contact surface characteristics, and location of suction seal breaks. As demonstrated in [8], pressure sensors attached to a suction cup can be used to regulate the vacuum pressure if the necessary vacuum level is not achieved. In embodiments herein, the overall vacuum level inside the suction cup can be used to estimate the texture or porosity of the engaging surface and the maximum lifting weight can be estimated from it. When approaching an unknown object, the distribution of pressure in the suction cup may be used to check if the suction cup made even contact over the surface or partial contact due to misalignment. The distribution of the pressure informs the location of the leakage air flows, which may be used by a controller (e.g., feedback mechanism) to adapt to move the contact point accordingly. When manipulating an object using full vacuum power, the sensor can advantageously predict the onset of leakage flow and locate the vacuum seal breakpoint, enabling any adaptive robotic control to prevent impending grasping failure. These capabilities are particularly useful for an e-commerce warehouse where a robotic suction cup needs to handle unknown objects with various shapes and weights.
Prior tactile sensors designed for use in suction cups provide partial information about object properties and vacuum sealing state. Aoyagi et al. coat a piezoresistive polymer on a bellows suction cup to measure compression forces [9]. Doi et al. implement a capacitive proximity sensor on the base plate of a suction cup end-effector to measure the distance from the plate to the object surface [10]. These methods measure vacuum state indirectly from the deformation of the suction cup and proximity to the object. Another straight-forward approach is to monitor internal vacuum pressure of the suction cup as a discrete measure of suction sealing, as in [11]. None of these methods localize the source of a leak or measure local surface geometry as do the smart suction cups in the present embodiments. Muller et. al. developed a circular array of 16 piezoresistive force sensors that are attached to the lip of the bellows suction cup [12]. This sensor array can measure the distribution of local normal forces when grabbing a curved object, and the sensor data can estimate the curvature. Compared with this sensor, the present embodiments do not add any structures on the contact lip, and thereby do not affect the vacuum seal formation. Moreover, the present embodiments use air pressure transducers located remotely, while the prior work requires sensor connection at the suction cup lip, making the system cumbersome.
In an embodiment with four internal chambers, the spatial resolution of the suction cup can only differentiate four directions. If higher resolution is desired, other embodiments of the suction cup can include more chambers and pressure transducers, and/or a sophisticated software algorithm, such as the artificial neural network, to achieve the spatial resolution. Accordingly, various suction cup embodiments may include a bellows structure with an internal wall or walls defining two internal chambers, three internal chambers, four internal chambers, or any number of internal chambers.
Exemplary Use
A multi-chamber suction cup according to an embodiment herein may be mounted on a robotic arm via a structure/fixture, e.g., a 3D printed fixture as shown in
In an embodiment, the pressure in each chamber of a multi-chamber suction cup can be measured using separate pressure transducers, e.g., MEMS pressure transducers that have built-in Analog to Digital Converter (ADC), such as Honeywell, MPRLS 0025PA (maxi-mum sampling rate 200 Hz) dedicated to each chamber. If a faster sampling rate is desired, analog pressure transducers (e.g., NXP MPXV4115V) can be used with external ADC that samples faster.
A multi-chamber suction cup can be used to explore the surface textures and geometries of an object. For example, to seek the best suction contact location, the vacuum pressure can be lowered for gentle haptic exploration, e.g., sliding and palpating. To achieve lower vacuum pressure, a solenoid valve can regulate the pressure. For example, a vacuum generator (e.g., VacMotion, VM5-NA) converts compressed air to a vacuum source. A solenoid valve (e.g., SMC pneumatics, VQ110, On/off time=3.5/2 ms), commanded by a microcontroller, regulates the compressed air as a means of moderating vacuum intensity. During haptic exploration, the valve may be controlled with pulse width modulation (PWM) at a frequency of 30 Hz with 30% duty cycle to approximate lower vacuum pressures. Different frequencies and duty cycles can be chosen considering the on/off time of a solenoid valve, e.g., a frequency ranging from about 1 Hz to about 1000 Hz may be used.
The measured pressure from each chamber also oscillates at the PWM frequency, and the frequency response analysis, i.e., Fourier transform, at that frequency represents the surface textures and curvatures. As shown in
Another utility of a multi-chamber suction cup is to monitor detaching contact during manipulation of full vacuum mode. An example detaching sequence from a flat surface is shown in
Some embodiments further include a non-transitory computer-readable storage medium (e.g., volatile and/or non-volatile memory devices) storing instructions that, when executed by a processor or processors, perform one or more of the methods of data analysis and/or feedback and control functionality as described herein.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the embodiments (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosed embodiments and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the embodiments.
Exemplary embodiments are described herein. Variations of those exemplary embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the embodiments to be practiced otherwise than as specifically described herein. Accordingly, the scope of the disclosure includes all modifications and equivalents of the subject matter recited herein and in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
This patent application is a Continuation of International Patent Application PCTUS2022/027381, filed on May 3, 2022, which claims the benefit of U.S. Provisional Patent Application No. 63/183,338, filed May 3, 2021, both entitled, “MULTI-CHAMBER SMART SUCTION CUP FOR TACTILE SENSING.” Both of the afore-mentioned applications are incorporated by reference in their entireties for all purposes.
Number | Date | Country | |
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63183338 | May 2021 | US |
Number | Date | Country | |
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Parent | PCT/US2022/027381 | May 2022 | US |
Child | 18500341 | US |