Portable vacuum gripper

Abstract

A vacuum gripper for gripping an object surface using vacuum suction is configured to be portable or operated by a hoist. Battery conservation measures are included to provide a long term vacuum generation capability, together with manually rechargeable mechanism. A manually-operated vacuum pump is also integrated to the vacuum gripper as a safeguard for the battery-operated vacuum pump failure. The vacuum gripper includes an elastic deformable vacuum seal for gripping objects with irregular surfaces, together with press rods or pin array configured to assist the vacuum seal in filling any gaps between the vacuum seal and the object surface.

What is claimed is: 
     
         1 . A vacuum gripper for gripping an object surface, the vacuum gripper comprising
 a base element,
 wherein the base element comprises openings around a periphery; 
   a flexible layer comprising a flexible portion and a compressible portion,
 wherein the flexible portion is disposed along the periphery to be accessible through the openings, 
 wherein the compressible portion is coupled to the base element; 
   a vacuum seal element coupled to the flexible layer,
 wherein the vacuum seal element comprises a deformable material, 
 wherein the vacuum seal element and the flexible layer are configured to form a cavity with the object surface contacted by the vacuum gripper, 
 wherein the openings are configured to be allow the flexible layer to be pressed toward the vacuum seal element to assist the vacuum seal element to be conformed to irregularities of the object surface; 
   an air extraction mechanism coupled to the second surface of the base element and in fluid communication with the cavity,
 wherein the air extraction mechanism is configured to extract gas from the cavity to create a suction force for coupling the object surface to the vacuum gripper. 
   
     
     
         2 . A vacuum gripper as in  claim 1 ,
 wherein the compressible portion comprises a more compressible material than the flexible portion,   wherein the compressible portion is located outside the periphery.   
     
     
         3 . A vacuum gripper as in  claim 1 ,
 wherein the compressible portion comprises a more compressible material than the flexible portion,   wherein the compressible portion is located inside the periphery.   
     
     
         4 . A vacuum gripper as in  claim 1 ,
 wherein the flexible layer is configured to be deformed with a less localized pattern than the deformable material under a point indentation, or   wherein the flexible layer is configured to be protruded more in an opposite surface than the deformable material under the point indentation, or   wherein the flexible layer comprises a higher hardness than the deformable material.   
     
     
         5 . A vacuum gripper as in  claim 1 ,
 wherein the vacuum seal element is coupled to the flexible layer along the periphery.   
     
     
         6 . A vacuum gripper as in  claim 1 ,
 wherein the vacuum seal element comprises an inner portion inside the periphery, with the inner portion comprising a thickness less than that at a peripheral portion,   wherein the vacuum seal element is coupled to the flexible layer at the inner portion.   
     
     
         7 . A vacuum gripper as in  claim 1 ,
 wherein the deformable material comprises multiple different elastic deformable materials,   wherein the multiple different elastic deformable materials are arranged in discrete layers.   
     
     
         8 . A vacuum gripper as in  claim 1 ,
 wherein the deformable material comprises multiple different elastic deformable materials,   wherein the multiple different elastic deformable materials comprise a composite layer having continuously varying levels of elastic deformation.   
     
     
         9 . A vacuum gripper as in  claim 1 ,
 wherein the deformable material comprises multiple different elastic deformable materials,   wherein the multiple different elastic deformable materials are configured to balance contact forces on the vacuum seal element when encounter the object surface that comprises a surface roughness.   
     
     
         10 . A vacuum gripper as in  claim 1 ,
 wherein the deformable material comprises a pneumatic or hydraulic element comprising a flexible and stretchable layer forming a fluid-filled cavity,   wherein the fluid-filled cavity comprises a pressure optimized for sealing the vacuum seal element on the object surface when the object surface is non-smooth.   
     
     
         11 . A vacuum gripper as in  claim 1 , further comprising
 a second flexible layer coupled to the vacuum seal element at an opposite side of the flexible layer,
 wherein the second flexible layer comprises a material more durable or more abrasion-resistant than that of the vacuum seal element. 
   
     
     
         12 . A vacuum gripper as in  claim 1 , further comprising
 hookable elements coupled to the base element,
 wherein the hookable elements are configured to be coupled to a hoist mechanism. 
   
     
     
         13 . A vacuum gripper as in  claim 1 , further comprising
 a manual air extraction mechanism coupled to the second surface of the base element and in fluid communication with the cavity,
 wherein the manual air extraction mechanism is configured to extract gas from the cavity to create a suction force for coupling the object surface to the vacuum gripper, 
 wherein the manual air extraction mechanism is configured to be operated by a person; 
   a pressure gauge coupled to the base element and in fluid communication with the cavity,
 wherein the pressure gauge is configured to provide indication of a pressure or vacuum level in the cavity; 
   an air release mechanism coupled to the base element and in fluid communication with the cavity, wherein the air release mechanism is configured to release gas from the cavity.   
     
     
         14 . A vacuum gripper as in  claim 1 , further comprising
 a power source configured to provide power to the air extraction mechanism,
 wherein the power source is housed in a handle coupled to the second surface of the base element; 
   a battery alarm coupled to the power source,
 wherein the battery alarm is configured to provide an alarm to notify a person when a power level of the battery is below a determined value; 
   a charging mechanism configured to charge the power source,
 wherein the charging mechanism is configured to charge the power source from an external power supply or manually from a person. 
   
     
     
         15 . A vacuum gripper as in  claim 1 , further comprising
 an alarm,
 wherein the alarm is configured to provide an alarm when the pressure level in the cavity is above a determined value; 
   a manual mechanism configured to maintain an operation of the vacuum gripper,
 wherein the manual mechanism is configured to extract gas from the cavity to lower the pressure level by a person when the alarm showing the pressure level is above the predetermined value. 
   
     
     
         16 . A vacuum gripper as in  claim 1 , further comprising
 a controller configured to regulate the air extraction mechanism,
 wherein the controller is configured to turn off the air extraction mechanism when a pressure level in the cavity reaches a predetermined pressure level or when a rate of pressure reduction in the cavity reaches a predetermined level, 
 wherein the controller is configured to turn on the air extraction mechanism when a pressure level in the cavity is below the predetermined pressure level. 
   
     
     
         17 . A vacuum gripper as in  claim 1 , further comprising
 a press rod,
 wherein the press rod is configured to be removably coupled to the base element, 
 wherein a size of the press rod is smaller than an openings of the openings to be used for pressing on the flexible layer through the opening. 
   
     
     
         18 . A vacuum gripper for gripping an object surface, the vacuum gripper comprising
 a base element;   an array of press rods coupled to a periphery of the base element;   a flexible layer comprising a flexible portion and a compressible portion,
 wherein the flexible portion is disposed along the periphery to be accessible through the openings, 
 wherein the compressible portion is coupled to the base element; 
   a vacuum seal element coupled to the flexible layer,
 wherein the vacuum seal element comprises a deformable material, 
 wherein the vacuum seal element and the flexible layer are configured to form a cavity with the object surface contacted by the vacuum gripper, 
 wherein the press rods are configured to be movable toward the vacuum seal element by sliding, by rotating, by screwing, or by pressing down, 
 wherein the press rods are configured to be pressed on the flexible layer toward the vacuum seal element to assist the vacuum seal element to be conformed to irregularities of the object surface; 
   an air extraction mechanism coupled to the second surface of the base element and in fluid communication with the cavity,
 wherein the air extraction mechanism is configured to extract gas from the cavity to create a suction force for coupling the object surface to the vacuum gripper. 
   
     
     
         19 . A vacuum gripper as in  claim 18 , further comprising
 a handle coupled to the second surface of the base element,
 wherein the handle is configured to house the air extraction mechanism, 
   a power source configured to provide power to the air extraction mechanism,
 wherein the power source is housed in a handle coupled to the second surface of the base element; 
   a controller configured to regulate the air extraction mechanism,
 wherein the controller is configured to turn off the air extraction mechanism when a pressure level in the cavity reaches a predetermined pressure level or when a rate of pressure reduction in the cavity reaches a predetermined level, 
 wherein the controller is configured to turn on the air extraction mechanism when a pressure level in the cavity is below the predetermined pressure level, 
   an alarm,
 wherein the alarm is configured to provide an alarm when a power level of the battery is below a first determined value or when the pressure level in the cavity is above a second determined value; 
   a manual mechanism configured to maintain an operation of the vacuum gripper,
 wherein the charging mechanism is configured
 to charge the power source from an external power supply or manually from a person when the alarm showing the power level is below the first predetermined value, or 
 to extract gas from the cavity to lower the pressure level by a person when the alarm showing the pressure level is above the second predetermined value. 
 
   
     
     
         20 . A vacuum gripper for gripping an object surface, the vacuum gripper comprising
 a base element,   a vacuum seal element coupled directly or indirectly to the base element,
 wherein the vacuum seal element comprises an elastic deformable material disposed around a periphery of the base element, 
 wherein the vacuum seal element and the base element are configured to form a cavity with the object surface contacted by the vacuum gripper, 
   an air extraction mechanism coupled to the second surface of the base element and in fluid communication with the cavity,
 wherein the air extraction mechanism is configured to extract gas from the cavity to create a suction force for coupling the object surface to the vacuum gripper, 
   a power source configured to provide power to the air extraction mechanism,
 wherein the power source is housed in a handle coupled to the second surface of the base element; 
   a controller configured to regulate the air extraction mechanism,
 wherein the controller is configured to turn off the air extraction mechanism when a pressure level in the cavity reaches a predetermined pressure level or when a rate of pressure reduction in the cavity reaches a predetermined level, 
 wherein the controller is configured to turn on the air extraction mechanism when a pressure level in the cavity is below the predetermined pressure level, 
   an alarm,
 wherein the alarm is configured to provide an alarm when a power level of the battery is below a first predetermined value or when the pressure level in the cavity is above a second predetermined value; 
   a manual mechanism configured to maintain an operation of the vacuum gripper,
 wherein the manual mechanism is configured
 to charge the power source from an external power supply or manually from a person when the alarm showing the power level is below the first predetermined value, or 
 to extract gas from the cavity to lower the pressure level by a person when the alarm showing the pressure level is above the second predetermined value.