WO2018071722A1

WO2018071722A1 - Systems and methods for aerodynamically lifting parts

Info

Publication number: WO2018071722A1
Application number: PCT/US2017/056413
Authority: WO
Inventors: Jonathan Andrew SMITH; Harsha Prahlad
Original assignee: Grabit, Inc.
Priority date: 2016-10-12
Filing date: 2017-10-12
Publication date: 2018-04-19
Also published as: WO2018071722A8

Abstract

Systems, devices, and methods for aerodynamically picking up parts are described. A plurality of air flow generators generates an air field vector to project an attractive force on one or more target parts to pick them up. The air flow generators or fans are individually controlled so the pickup surface of the plurality of air flow generators can have multiple pickup zones that can be separately activated. The parts are picked up from a surface porous to the air flow to promote the generation of the air field vector.

Description

SYSTEMS AND METHODS FOR AERODYNAMICALLY LIFTING PARTS

CROSS-REFERENCE

[0001] This application claims the benefit of U.S. Provisional Application No. 62/407,286, filed 12 October, 2016, entitled "Systems and Methods for Aerodynamically Lifting Parts" [Attorney Docket No. 42462-710.101], the entire content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] The mass production of products has led to many innovations over the years. Substantial developments have been made in the industrial handling of various materials and items, particularly in the area of robotics. For example, various types of robotics and other automated systems are now used in order to "pick and place" items during many manufacturing and other materials handling processes. Such robotics and other systems can include robot arms that, for example, grip, lift and/or place an item as part of a designated process. Of course, other manipulations and materials handling techniques can also be accomplished by way of such robotics or other automated systems.

SUMMARY OF THE INVENTION

[0003] Despite many advances over the years in this field, there are limitations as to what can be handled in such a robotic or automated manner.

[0004] Conventional robotic grippers typically use either vacuum suction or a combination of large normal and shear forces and fine control with mechanical actuation in order to grip objects. Such techniques have several drawbacks. For example, the use of suction tends to require smooth, clean, dry, non -porous, and generally flat surfaces, which limits the types and conditions of objects that are gripped. Suction also tends to require a lot of power for the pumps and is prone to leaks at any location on a vacuum or low pressure seal, with a resulting loss of suction being potentially catastrophic. The use of mechanical actuation often requires large normal or "crushing" forces against an object, and also tends to limit the ability to robotically grip flexible, deformable, fragile, or delicate objects. Producing large forces also increases the cost of mechanical actuation.

Mechanical pumps and conventional mechanical actuation with large crushing forces also often require substantial weight, which is a major disadvantage for some applications, such as the end of a robot arm where added mass must be supported. Furthermore, even when used with sturdy objects, robotic arms, mechanical claws and the like can still leave damaging marks on the surface of the object itself. [0005] Alternative techniques for handling items and materials also have drawbacks. For example, chemical adhesives can leave residues and tend to attract dust and other debris that reduce effectiveness. Chemical adhesives can also require a significant amount of added force to undo or overcome a grip or attachment to an object once such a chemical adhesive grip or attachment is applied, since the gripping interaction and force is typically not reversible in such instances.

[0006] Conventional robotic grippers often do not support gripping of more than one object at a time and thus limit the speed with which operations including a plurality of objects are completed. Conventional systems are also often constrained by a requirement that said objects be fed to the robotic gripper with precise orientations by a human operator for proper "pick and place".

Furthermore, conventional systems are typically large and require special fencing to protect operators from the hazards of working near high-speed robots.

[0007] Although many systems and techniques for handling materials in an automated fashion for the manufacture of an article have generally worked well in the past, there is a desire to provide alternative and improved ways of handling items. In particular, improved automated systems, devices, and techniques are needed to enable the picking and placing or other handling of a plurality of materials including a broad spectrum of flexible and/or porous materials of various shapes and sizes that cannot be handled reliably using conventional vacuum and mechanical methods. Such materials include but are not limited to woven and knit fabric, as used in athletic footwear and apparel manufacturing, carbon fiber sheets, as used in airframe manufacture, and flexible printed circuit boards.

[0008] Provided herein are systems, devices, and methods for aerodynamically picking up one or more parts.

[0009] Provided herein are systems for aerodynamically picking up one or more parts. An exemplary system comprises (a) one or more air flow generators having a pickup surface, the one or more air flow generators being configured to generate a vectored air field on the pickup surface, the vectored air field being configured to cause the one or more parts to be picked up by and adhere onto the pickup surface, (b) a controller coupled to and configured to selectively control each of the one or more air flow generators to generate the vectored air field, and (c) a porous placement surface over which the one or more parts to be picked up are initially placed, the porous placement surface being configured to allow air flow therethrough to facilitate the generation of the vectored air field. In some embodiments, the porous placement surface comprises a movable conveyer. In some embodiments, the one or more parts to be picked up comprise a plurality of parts to be picked up. In some embodiments, the pickup surface comprises a plurality of pickup zones, and wherein the controller is configured to individually activate the pickup zones. In some embodiments, the generated vectored air field comprises one or more pressure differentials between different sides of the pickup surface, the one or more pressure differentials being configured to exert an attractive force on the one or more parts to be picked up. In some embodiments, the one or more air flow generators comprise one or more fans. Some embodiments further comprise a movable arm coupled to the one or more air field generators, the movable arm being configured to adjust a position of the one or more air flow generators relative to the porous placement surface. Some embodiments further comprise a target surface, wherein the movable arm is configured to move the one or more air flow generators toward the target surface at acceleration equal or greater to 1 G. In some embodiments, the controller is configured to deactivate one or more of the one or more air flow generators as the movable arm moves the one or more air flow generators toward the target surface, thereby releasing the picked-up one or more parts onto the target surface while minimizing translation movement of the one or more parts relative to the part interface surface. In some embodiments, the system further comprises a plurality of electrodes coupled the pickup surface, the plurality of electrodes configured to generate electroadhesion to facilitate adhesion of the one or more parts onto the pickup surface. In some embodiments, the system further comprises a release mechanism coupled to the one or more air flow generators, the release mechanism configured to facilitate release of the one or more parts from the pickup surface.

[0010] Provided herein are methods for aerodynamically picking up one or more parts. An exemplary method comprises providing one or more parts on a porous placement surface and generating a vectored air field with a pickup tool to attract the one or more parts toward a pickup surface of the pickup tool, the pickup tool comprising one or more air flow generators to generate the vectored air field and wherein the placement surface is porous to facilitate the generation of the vectored air field at least partially passing therethrough. In some embodiments, generating the vectored air field comprises selectively activating one or more pickup zones of the pickup surface. In some embodiments, providing the one or more parts on the porous placement surface comprises moving the one or more parts through a conveyer. In some embodiments, the one or more parts to be picked up comprise a plurality of parts to be picked up. In some embodiments, generating the vectored air field comprises generating one or more pressure differentials between different sides of the pickup surface, the one or more pressure differentials being configured to exert an attractive force on the one or more parts to be picked up. In some embodiments, the one or more air flow generators comprises a plurality of fans. Some embodiments further comprise adjusting a position of the one or more air flow generators relative to the porous placement surface. The position of the one or more air flow generators is adjusted using a movable arm coupled to the one or more air flow generators. In some embodiments, adjusting the position of the one or more air flow generators comprises moving the one or more air flow generators toward a target placement surface at an acceleration greater or equal to 1 G. Some embodiments further comprise deactivating one or more pickup zones of the pickup surface as the one or more air flow generators is moved toward the target placement surface. Some embodiments, further comprise generating electroadhesion with the pickup tool to facilitate adhesion of the one or more parts onto the pickup surface. Some embodiments further comprise releasing the one or more parts from the pickup surface using a release mechanism coupled to the one or more air flow generators.

INCORPORATION BY REFERENCE

[0011] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:

[0013] FIG. 1 shows a schematic of an aerodynamic gripper cell which highlights the aerodynamic process used to capture a part;

[0014] FIG. 2A shows a schematic of the aerodynamic gripper cell;

[0015] FIG. 2B shows a perspective view of the aerodynamic gripper cell with fan attached;

[0016] FIG. 2C shows an embodiment of an aerodynamic gripper cell with a single electroadhesion zone;

[0017] FIG. 3A shows a bottom view of an embodiment of an aerodynamic gripper comprising a plurality of aerodynamic gripper cells;

[0018] FIG. 3B shows a bottom view schematic of a pickup surface of the aerodynamic gripper with a plurality of article components captured thereto;

[0019] FIG. 3C shows an exemplary embodiment of an aerodynamic gripper with multiple air flow generators and multiple electroadhesion zones;

[0020] FIG. 4A shows a side-view schematic of an embodiment of an aerodynamic pickup system wherein the first platform comprises a conveyor;

[0021] FIG. 4B shows a top view schematic of the embodiment of FIG. 4A;

[0022] FIG. 4C shows a top view schematic of an embodiment of an aerodynamic pickup system where the system comprise two first platforms; [0023] FIG. 5A shows a schematic of the aerodynamic pickup system with a first and a second article component on a first platform;

[0024] FIGS. 5B-5C show schematics of the aerodynamic gripper picking up a first article component but not yet a second article component (i.e. the aerodynamic gripper picks up the article components or parts sequentially, though the aerodynamic gripper can pick up the article components or parts simultaneously as well);

[0025] FIGS. 5D-5E show schematics of the aerodynamic gripper picking up the second article component;

[0026] FIG. 5F shows a schematic of the system after the aerodynamic gripper has been moved above the second platform;

[0027] FIG. 5G shows a schematic of the release of the first article component onto the second platform while the second article component is retained on the aerodynamic gripper;

[0028] FIG. 5H shows a schematic of the release of the second article component;

[0029] FIG. 6A shows three exemplary article components;

[0030] FIG. 6B shows a schematic of an exemplary placement pattern for the three article components of FIG. 6A on the pickup surface of the aerodynamic gripper;

[0031] FIG. 6C shows a schematic of the aerodynamic gripper positioned in alignment with the first article component;

[0032] FIG. 6D shows a schematic of the aerodynamic gripper with a first set of aerodynamic zones activated to capture the first article component;

[0033] FIG. 6E shows a schematic of the aerodynamic gripper positioned in alignment with the second article component;

[0034] FIG. 6F shows a schematic of the aerodynamic gripper with a second set of aerodynamic zones activated to capture the second article component;

[0035] FIG. 6G shows a schematic of the aerodynamic gripper positioned in alignment with the third article component;

[0036] FIG. 6H shows a schematic of the aerodynamic gripper with a third set of aerodynamic zones activated to capture the third article component;

[0037] FIG. 7A shows a schematic of an aerodynamic gripper cell above a porous conveyor;

[0038] FIG. 7B shows a schematic of an aerodynamic gripper cell above a non-porous conveyor;

[0039] FIG. 8A shows a perspective view of an embodiment of an aerodynamic gripper with multiple air flow generators wherein each air flow generator has independent vertical activation; [0040] FIG. 8B show a schematic of an embodiment of an aerodynamic gripper comprising a mechanical separation mechanism and an ultrasonic welder to facilitate capture and release of an article component;

[0041] FIG. 8C shows a perspective view of an embodiment of a mechanical separation mechanism with integrated ultrasonic welder;

[0042] FIG. 8D shows an aerodynamic gripper with captured article component and an array of retracted pins;

[0043] FIG. 8E shows the release of the article component by actuation of the pins through the pickup surface towards the second platform;

[0044] FIG. 9 shows a schematic of a base shoe part with an exaggerated outline overlaid thereon; and

[0045] FIG. 10 shows a flowchart of a method capturing and releasing a plurality of target objects.

DETAILED DESCRIPTION

[0046] In the following detailed description, reference is made to the accompanying figures, which form a part hereof. In the figures, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, figures, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

[0047] As described herein, improved automated systems, devices, and techniques are needed to enable the picking and placing or other handling of a plurality of materials including a broad spectrum of flexible and/or porous materials of various shapes and sizes that cannot be handled reliably using conventional vacuum and mechanical methods. Such materials include but are not limited to woven and knit fabric, as used in athletic footwear and apparel manufacturing, carbon fiber sheets, as used in airframe manufacture, and flexible printed circuit boards.

[0048] FIG. 1 shows an embodiment of an aerodynamic gripper cell 156 (also referred to herein as an airflow generator) which highlights the aerodynamic process by which the gripper captures and retains an article component 103 (also referred to herein as a part) on its pickup surface 152. Unlike conventional vacuum grippers that utilize static pressure differences to generate suction (i.e.

vacuum) for part pickup, the aerodynamic grippers described herein utilize aerodynamic effects to capture parts. A pressure differential between different sides of the pickup surface 152 is created by placing the article component 103 in a vectored air field 190. The vectored air field 190 for example comprises one or more pressure differentials configured to exert an attractive force on the part(s) 130 to be picked up which facilitate lifting and holding the article component 103 against the pickup surface 152 according to the drag equation:

F = ^pv²C_dA

where F is the drag force, p is the mass density of the fluid, υ is the flow velocity relative to the object, A is the reference area, and d is the drag coefficient. The vectored air field 190 is generally perpendicular (e.g. within about 10°) to the pickup surface 152. The vectored air field 190 flows through the portion of the pickup surface 152 which is unobstructed by the article component 103 but is blocked by the article component 103, thereby causing the air 192 above the article component 103 (i.e. within the plenum of the gripper cell 156 adjacent the article component 103) to stagnate, which results in a lower pressure field above the article component 103 than below the article component 103 that causes the article component 103 to lift and adhere to the pickup surface 152 of the cell 156. The use of a vectored air field 1 0 to generate aerodynamic lift results in the article component 103 maintaining planarity as well relative X-Y position during movement of the cell 156 after part capture.

[0049] The first platform 101 (also referred to herein as a placement surface) is optionally a conveyor. The placement surface 101 is optionally porous. The first platform 101 for example optionally comprises a high level of porosity (e.g. with fill less than about 30%). The article component 103 is optionally placed on a porous first platform 101 prior to capture by the gripper cell 156. The porous conveyor 101 helps to generate the vectored air field 190 by allowing air to flow therethrough after the article component 103 has been placed on the surface of the conveyor 101 by a user (also referred to herein as an operator).

[0050] In some embodiments, the first platform 101 is non-porous.

[0051] The first platform 101 optionally comprises a visually transparent, visually translucent, or visually opaque material. In some embodiments, the first platform 101 comprises a plurality of zones, each with a different level of visual transparency, visual translucency, and/or visual opacity.

[0052] Because it utilizes aerodynamic principles to pick up parts, the aerodynamic gripper described herein is well-suited to picking up parts which conventional vacuum-based grippers are unable to capture including, but not limited to, flexible and/or porous materials of varying shapes and sizes.

[0053] The article component 103 for example optionally comprises a textile piece, a shoe part, an automotive part, a machinery part, or a circuitry part, such that the article assembled on the second platform comprises, respectively, at least a portion of an article of clothing, at least a portion of a shoe, at least a portion of a machine, or at least a portion of a circuit. [0054] FIG. 2A shows a schematic of the aerodynamic gripper cell housing. The air flow generator 256 comprises a housing 254, a pickup surface 252 made up of a plurality of openings 257, and a plenum 274 therebetween. The housing 254 for example extends from the pickup surface 252 to the connection 271 to a robotic actuator and/or negative pressure source and forms a plenum 274 therebetween. The housing 254 is shaped to create a vectored air field at its intake face (i.e. the pickup surface 252). The housing 254 for example optionally comprises a tapered region 258 between the pickup surface 252 and the connection 271 which functions to funnel the air from the vectored air field towards the connection 271 and out of the aerodynamic cell 256 as shown in FIG. 1.

[0055] The pickup surface 252 is optionally circular, triangular, square, polygonal, or irregularly- shaped. One of ordinary skill in the art will understand that the pickup surface 252 and housing 254 can be configured with any shape which allows for the creation of a vectored air field at the pickup surface 252 of the air flow generator 256.

[0056] The holes 257 are optionally circular, triangular, square, polygonal, or irregularly-shaped. One of ordinary skill in the art will understand that the holes 257 can be configured with any shape which allows for the creation of a vectored air field at the pickup surface 252 of the air flow generator 256.

[0057] The contact between the pickup surface 252 and the housing 254 optionally forms one or more of a right angle and an obtuse angle. The housing 254 for example is curved and/or forms a right angle where the housing 254 contacts the connection 271 to the robotic actuator.

[0058] The air flow generator 256 is coupled to one or more negative pressure source. In some instances, one or more negative pressure source is external to the housing 254. In some instances, one or more negative pressure source is housed within the housing 254. The one or more negative pressure source (see e.g. fan 260 of FIG. 2B) is for example a fan, a pump, a turbine, a venturi, or any combination thereof. The one or more negative pressure source is optionally further configured to apply positive pressure through the pickup surface 252 in order to facilitate release of the picked up part (not shown for clarity).

[0059] The air flow generator 256 optionally comprises one or more electroadhesion surfaces. As the term is used herein, "electroadhesion" refers to the mechanical coupling of two objects using electrostatic forces. Electroadhesion as described herein uses electrical control of these

electrostatic forces to permit temporary and detachable attachment between a foreign substrate, for example an article component, and a pick-up surface of an electroadhesion-enabled capture element. This electrostatic adhesion holds the foreign substrate and the pick-up surface together via an electrostatic attraction normal to the surface and increases traction or friction between the foreign substrate and the surface of the capture element due to electrostatic forces created by an applied electric field. The surface of the capture element is placed against or nearby a surface of a foreign substrate. An electrostatic adhesion voltage is then applied to the electrodes using

(integrated) control electronics in electrical communication with the electrodes. The electrostatic adhesion voltage uses alternating positive and negative charges on neighboring electrodes. As a result of the voltage difference between electrodes, one or more electroadhesive forces are generated, which electroadhesive forces act to hold the surface of the capture element and the foreign substrate against one another. The electroadhesion surface optional comprises one or more of the electroadhesion surfaces as described in PCT US2017/013262, PCT/US2017/013264, and PCT/US2017/013262, the entire contents of which are incorporated herein by reference. For example, the pickup surface 252 of the air flow generator optionally comprises an electroadhesion pickup surface comprising a plurality of electrodes configured to generate electrostatic forces at the pickup surface.

[0060] FIG. 2C illustrates an embodiment of an electoadhesion-enabled aerodynamic gripper with a single electroadhesion zone. The contact surface 252 for example comprises an electroadhesive plate 251 for capturing one or more target objects (also referred to herein as article components) with electroadhesion, The electroadhesion plate 251 comprises a plurality of electrodes 255 and is operatively attached to the controller for electrode activation and deactivation. Alternatively or in combination, the contact surface comprises a plurality of holes 257 patterned as described herein with a plurality of electrodes coupled to the surface without overlapping or obstructing the holes 257 to allow for generation of the vectored air flow therethrough. In some instances, the electroadhesion plate 251 comprises a plurality of holes 257 to facilitate generation of the vectored air flow.

[0061] The aerodynamic gripper optionally comprises one or more air flow generators. In some embodiments, the gripper comprises one air flow generator 256. In some embodiments, the gripper comprises more than one air flow generator 256. It will be understood by one of ordinary skill in the art that the aerodynamic gripper can comprise any number of air flow generators as required for part pick up and/or as desired.

[0062] FIG. 2B shows a perspective view of the aerodynamic gripper cell 256 comprising a fan 260 located within housing 254. The fan 260 pulls air through the holes 257 in the pickup surface 252 in a vectored air field generally perpendicular to the surface 252 as described herein.

[0063] The fan 260 for example optionally comprises a high volumetric displacement fan system, for example a 3 Phase Brushless Fan. The fan 260 is for example controllable in speed and can be braked. Alternatively, the fan 260 optionally comprises a low inertia DCD motor system fan. [0064] FIG. 3A shows a bottom view of an embodiment of an aerodynamic gripper comprising a plurality of air flow generators 356. The plurality of air flow generators 356 are configured such that the pickup surfaces 352 of each air flow generator 356 are generally aligned with one another. The aligned pickup surfaces 352 for example form a linear or planar pickup surface 352 spanning the base of the aerodynamic gripper 305.

[0065] Each of the plurality of air flow generators 256 is selectively controllable to facilitate capture and release of one or more article components 303. A controller (not shown) is optionally coupled to each of the plurality of air field generators 356 and configured to selectively control each of the air flow generators 356 to generate the vectored air field. The plurality of air flow generators 356 optionally comprise a plurality of fans 360. Each fan 360 is selectively controllable, for example by the controller, to generate the vectored air field.

[0066] In some embodiments, the number of fans 360 matches the number of air flow generators 356 such that each cell 356 is connected to a dedicated negative pressure supply 360 embedded in each generator 356, with each supply 356 being individually controllable so as to control the vectored air field generated in each cell 356 independently of the other cells 356. For example, in an exemplary embodiment a first fan 360 is embedded in the first cell 356 and a second fan 360 is embedded in the second cell 356 such that the first and second fans 360 are independent and do not connect. The fans 360 are therefore wholly independent of each other and are able to provide vectored air flow in the first cell 356 independent of the air flow provided in the second cell 356.

[0067] In many embodiments, the negative pressure sources (e.g. fans) for each zone of air field generator 356 are interchangeable between cells 356. In some embodiments, each air field generator 356 is separable from each other air field generator 356 such that the pickup surface 352 has replaceable segments or cells 356. In some embodiments, each replaceable segment 356 of the aerodynamic gripper comprises an air field generator 1456 with a pickup surface 352 and a housing 354 with connection to a gripper (for example as illustrated in FIGS. 4A-4C), such that the housing 354 and cell 356 are a detachable unit (e.g. a removable cartridge).

[0068] The cells 356 are optionally positioned in close proximity to one another to avoid non- vectored air flow generation between cells 356. The cells 356 are optionally hexagonal in shape and the plurality of air flow generators 356 are optionally coupled together side-by-side in a honeycomb-like shape. One of ordinary skill in the art will understand that the shape of the pickup surface 352 of the gripper 305 may be configured as desired in order to facilitate capture of a wide range of part shapes and sizes. One of ordinary skill in the art will recognize that any number of cells 356 may be coupled together in order to create a pickup surface 352 on the gripper 305 which can capture the desired part(s). The pickup surface 352 may for example be configured with a size and shape corresponding to, or exceeding, the shape of the part to be picked up. The pickup surface 352 is generally sized with enough cells 356 to optimize segregation of parts to isolated zones of cells 356 (wherein each zone comprises one or more cells 356 activated simultaneously to capture a part) which can be independently activated from other zones (which optionally pick up other parts).

[0069] FIG. 3B shows a bottom view schematic of a pickup surface 352 of the aerodynamic gnpper 305 with a plurality of article components 303 captured thereto. As shown, the gripper 305 comprises a plurality of hexagonal air field generators 356 coupled together in a honeycomb -like lattice. The pickup surface 352 of the gripper 305 is sized and shaped to pick up at least three non- overlapping article components 303.

[0070] The pickup surface 352 of the gripper 305 optionally comprises a plurality of cells, and/or a plurality of zones comprising a plurality of cells, for selective capture and release of multiple article components. In many embodiments, this multi -cell/multi-zone implementation enables a single- pick of a plurality of article components off of the first platform followed by multiple individuated placements of each article component onto the second platform. The multi-cell/multi-zone implementation thereby reduces the number of motion segments needed to complete the assembled article when compared to accomplishing the assembly with a single-cell/single-zone gripper.

[0071] Selective control of each of the plurality of air flow generators 356 is optionally

accomplished by selectively controlling the activation status of the fan 360 and generation of the vectored air field. For example, in order to pick up a first article component 303 a first fan 360 of a first air flow generator 356 is activated to generate a vectored air field below the first cell 356 while a second fan 360 of a second air flow generator 356 is simultaneously left inactive to avoid disturbing additional parts 303 on the first platform. Similarly, after pickup of two parts 303, for example, the first part 303 is optionally released from the first cell 356 by deactivating the first fan 360 while the second fan 360 remains active to retain the second part 303 as the first part 303 is released.

[0072] Alternatively or in combination, selective control of each of the plurality of air flow generators 356 is accomplished by varying the porosity of the plurality of air flow generators 356 between cells 356 and/or zones of cells 356. By adjusting the porosity of the plurality of air flow generators 356 and/or by controlling the flow rate of the vectored air field through the pickup surface 352, the cells 356 can be selectively controlled. For example, a first air flow generator 356 optionally comprises a first porosity and a second air flow generator 356 optionally comprises a second porosity which is less porous (i.e. less permeable to fluid flow) than the first porosity. The first air flow generator 356 for example draws air through its surface 352 to generate a vectored air flow at a first air flow rate which lifts a first part 303. The air flow rate is for example controlled by the rotational speed of the fan 360. The second porosity is optionally configured such that it does not generate lift of a second part 303 below the second air flow generator when the air is flowing at the first air flow rate. Increasing the air flow of the second air flow generator 356, and optionally in the first air flow generator 356, to a second air flow rate which is above a threshold flow rate for the second porosity to generate lift, for example by increasing the fan speed, allows the second part 303 to be captured by the second air flow generator 356 while the first part 303 remains captured by the first air flow generator 356. Similarly, adjusting the flow rate(s) of the air flow generators 356 will allow the parts 303 to be independently released from the cells 356 once the air speeds have dropped below the threshold rates of the different porosities. Variable porosity for example can enable individual activation of cells and/or zones when a single fan is used to control multiple cells and/or zones, respectively.

[0073] In some embodiments, the porosity of one or more of the air flow generators 356 is adjusted by varying the size of the holes (see e.g. element 257 in FIG. 2A) between the generators. For example, a first air flow generator 356 can comprise holes with a first size (e.g. a first width, length, circumference, depth, etc.) and a second air flow generator 356 can comprise holes with a second size. In some instances, the holes are adjustable such that their size (e.g. one or more dimension) is variable before or during use. In some instances, the holes maintain a fixed size and varying the size of the holes involves replacing the pickup surface 352 and/or the cell 356 itself.

[0074] Alternatively or in combination, the porosity of one or more of the air flow generators 356 is adjusted by applying a substance to the pickup surface and/or within the plenum of the housing. The substance for example comprises a porous coating, a porous insert (for example a porous film or paper), or any combination thereof. Alternatively or in combination, non-porous material is optionally added to the pickup surface and/or within the plenum of the housing to reduce the porosity of the holes and/or the volume of the plenum.

[0075] The porosity of the one or more air flow generators 356 is optionally adjusted before and/or during part pickup. For example, a porous material is optionally added to the cell 356 prior to part pickup and the air flow rate is optionally adjusted during part pickup.

[0076] In some embodiments, the aerodynamic gripper comprises a plurality of electroadhesion zones for selective capture and release of multiple article components as shown in FIG. 3C, wherein electroadhesion in each electroadhesive zone is separately activated and a controller (as described further herein) configured to individually activate or deactivate electroadhesion in each of the electroadhesive zones. Electroadhesion in each of the zones is optionally activated at the same time as the air flow generator fan is activated or independently of fan activation. The electroadhesion zones for example comprise a plurality of electroadhesion zones in one or more electroadhesion plates as described in PCT/US2017/013262, PCT/US2017/013264, and

PCT/US2017/013262, the entire contents of which are incorporated herein by reference. The electroadhesion zones optionally comprise a plurality of independently controllable electrode pairs (or multiple electrode pairs) embedded in the pickup surface as described herein. The number of electroadhesion zones optionally corresponds to the number of cells 856, with each cell comprising an electroadhesion zone. The number of electroadhesion zones optionally corresponds to the number of aerodynamic zones (which is optionally fewer than the number of cells). It will be understood by one of ordinary skill in the art that the capture element comprises any number of electroadhesion zones depending on the manufacturing requirements of the article assembly.

[0077] FIGS. 4A-4C show embodiments of an aerodynamic pickup system comprising at least one first platform 401, a second platform 402, one or more article components 403, and a gripper 404. The gripper 404 for example optionally comprises a capture element 405 and a robotic actuator 406. The capture element 405 for example optionally comprises a pickup surface coupled to one or more aerodynamic gripper cells. The gripper 404 for example optionally comprises an aerodynamic gripper. In many embodiments the first platform 401 is moveable. For example, as shown in FIGS. 4A-4C, the first platform 101 comprises a conveyor. The robotic actuator 406 for example optionally comprises a robotic arm. The robotic actuator 406 optionally comprises a moveable arm.

[0078] FIG. 4A shows a side-view schematic of an embodiment of an aerodynamic pickup system wherein the first platform 401 comprises a conveyor. FIG. 4B shows a top view schematic of the embodiment of FIG. 4A. The first platform 401 optionally comprises a porous placement surface. A first article component 403A and a second article component 403B have been placed on the first platform (also referred to herein as an operator station or placement surface) 401 by a user (not shown). The conveyor 401 may be continuously moving or may periodically stop to facilitate part placement by the user or part pickup by the gripper 404. For example, the conveyor 401 is activated so as to convey the one or more article component 403 to the robot-side 411 for capture by the gripper 404 and release at the second platform 402 after confirmation of proper placement by the user as described herein. Additional article components 403 are optionally also placed on the first platform 401. It will be understood that any number of article components 403 are a part of any of the systems and methods described herein.

[0079] The first platform 401 for example optionally comprises a first portion, for example the operator-side 407, which is closer to the operator than the aerodynamic gripper 404. The second part 403B is shown on the operator-side 407 of the first platform 401 where the user works and the first part 403 A is shown on the gripper-side 411 of the first platform 401 , having been indexed to the gripper-side 411 from the operator-side 407 by the conveyor 401 after placement on the placement surface 401 by the user. Movement of the conveyor 401 delivers the article components 403 (A, B, etc.) to the gripper-side 411 while simultaneously delivering an unloaded platform to the operator-side 407, where the operator 108 then begins placing another group of article components 403 while the gripper 404 is in action. The gripper 404 for example captures the first article components 403A while the second article component 403B is being placed by the user. Capture occurs by activating one or more cells on the capture element 405. The gripper 404 then moves to a position over the second platform 402. The gripper 404 then releases the first article component 403A onto the second platform 402 at a pre-determined location. The gripper 404 then picks up the second article component from the placement surface 401, moves to a position over the second platform 402, and releases the second article component 403B onto the second platform 402 at another pre-determined location, thereby assembling at least a portion of an assembled article. The second article component 403B is for example stacked on top of the first article component 403 A. The second platform 402 for example is a conveyor. The assembled article for example is released onto a tray 413 residing on the second platform 402 as shown in FIGS. 4B-4C and then conveyed to a downstream manufacturing apparatus (if desired). The downstream manufacturing apparatus for example comprises an automated sewing head, a heat press, or a fusing machine.

[0080] In many embodiments the operator-side of the first platform 407 is isolated from a robot- side of the first platform 41 1 by the appliance cover or safety cage 410. In many embodiments the appliance cover 410 is used to isolate the gripper 404 from the operator to protect the operator from the hazards of working near the robotic actuator 406. Alternatively or in combination, in some embodiments the appliance cover 410 isolates the gripper 404 from external environmental factors which affect article component handling. For example, the system optionally includes lighting control, temperature control, humidity control, or any combination thereof so as to improve successful article component handling.

[0081] An imaging system, for example one or more cameras or projectors are optionally coupled to the appliance cover 410, gripper 404, controller, and/or other system component in order to provide illumination, article component placement guidance to the operator, article position recognition, article identity information, article component alignment, critical-to-quality ("CTQ") tolerances, or any combination thereof as described in PCT/US2017/013262, PCT/US2017/013264, and PCT/US2017/013262, the entire contents of which are incorporated herein by reference. The article component placement guidance ensures that the placed article components are completely within predetermined locations on the gripper 404, for example in one or more predetermined zones of the capture element 405, when the parts 403 are acquired by the gripper 404. The orientation of each article component 403 is further optionally arranged so as to minimize assembly time, for example reducing the movement of the robotic actuator 406 needed to capture each article component 403 by carefully arranging the article components 403 with respect to each other to facilitate capture in one or more rotations of the gripper 404. Article component identity and/or alignment information is optionally used to aid in part pickup and placement by allowing a controller to calculate the precise pickup location, even if the part has been mis-placed by the user, and adjust the capture element 405 accordingly so as to capture the part on the correct location on the pickup surface of the capture element 405.

[0082] The gripper system optionally further comprises a controller in communication with each of the first platform 401, second platform 402, robotic actuator 406, and capture element 405. The controller in some embodiments is in communication with one or more of a remote computer host, an upstream manufacturing apparatus, a downstream manufacturing apparatus 214, or any combination thereof.

[0083] The controller acts as a master controller for one or more of the parts of the system and provides communication between the various components of the system.

[0084] For example, the controller is in communication with one or more of the various components comprising the first platform 401. The controller for example is in communication with systems on the operator-side of the first platform 407, as well as the motion control of the first platform 401 and the optional environmental control systems. The motion control for example is used to move the first platform 401, for example a conveyor.

[0085] Alternatively or in combination, the controller is in communication with the various components of the capture element 405. The controller in some embodiments communicates with one or more of a zone control system which independently controls the activation status of the individual air flow generator cells. The zone control system for example optionally controls which cell(s) are active for part pickup. Alternatively or in combination, in some embodiments the controller communicates with one or more ultrasonic tack welder, for example a plurality of zone- specific tack welders as described herein.

[0086] Alternatively or in combination, in some embodiments the controller communicates with a release mechanism driver operatively coupled to an active-release mechanism to facilitate release of the captured article component from the aerodynamic gripper 404. The active-release mechanism for example comprises one or more of a netting, a positive pressure port, an ejector blade, an array of pins, or any combination thereof as described in PCT/US2017/013262, PCT/US2017/013264, and PCT US2017/013262, the entire contents of which are incorporated herein by reference. The release driver mechanism for example comprises a force-controlled actuator incorporated with an array of netting filaments or an array of pins which has the ability to separate an article component

403 from the pickup surface of the capture element 405.

[0087] Alternatively or in combination, the controller is in communication with various subsystems of the robotic actuator 406. The controller communicates with the motion control system of the robotic actuator 406 which optionally comprises planning and axis/motor control systems. For example, information regarding the alignment of the article components on the robot-side of the first platform 401 is used to plan and execute a set of motions to capture and precisely release the article components to the second platform 402.

[0088] The controller is optionally further in communication with an assembly vision recognition system, for example a camera located on the robotic actuator 406 or above the first platform 401. The assembly vision recognition system is optionally used to verify correct part placement and/or determine the location/position/orientation for precise calculation of how the gripper 404 should pick up and place the article component 403 on the second platform 402.

[0089] The controller is optionally further in communication with the motion control system of the second platform 402, for example a conveyor, such that the completion of article assembly steps alerts the second platform 402 to convey the assembled article to a downstream manufacturing apparatus.

[0090] The controller and system components are in wired communication, wireless

communication, or any combination thereof with each other. For example, the controller optionally communicates with the robotic actuator 406 and capture element 405 wirelessly while being in wired communication with the vision system and first and second platforms 401, 402. The wireless communication for example occurs by Bluetooth, WiFi, RFID, near-field communication (NFC), or other similar means, or any combination thereof. The wired communication is by USB, FfDMI, CSI, PWM, GPIO, Ethernet cable, or the like, or any combination thereof.

[0091] FIG. 4C shows a top view schematic of an embodiment of an aerodynamic pickup system where the system comprise two first platforms 401A, 401B in order to maximize efficiency (i.e. rate) of the gripper 404 and minimize gripper downtime due to transfer. For example, a first operator places article components 403 on a first platform 401A to be delivered to the gripper 404 for capture and then delivery to and release onto a second platform 402. The first platforms 401A, B for example optionally comprise a conveyor. Concurrent with the first operator's work, a second operator places article components 403 on a second turntable 40 IB to be delivered to the gripper

404 for capture and then delivery to and release onto the second platform 102. The throughput of completed assemblies (also referred to herein as stacks and assembled articles) onto the second platform 402 is thereby substantially doubled. The first platforms 401A, 401B, gripper 404, and second platform 402 are substantially the same as in the previous embodiment. The gripper 404 and second platform 402 are optionally isolated from the operators by an appliance cover 410.

[0092] FIGS. 5A-5H illustrate an embodiment of an aerodynamic pickup system in action. The aerodynamic system comprises a first platform 501, an aerodynamic gripper 504 comprising a robotic actuator 506 coupled to a capture element 505, and a second platform 502. The first platform 501 for example is a conveyor. The second platform 502 for example is a conveyor. The robotic actuator 506 for example optionally comprises a robotic arm. The capture element 505 for example optionally comprises one or more aerodynamic gripper cells. The capture element 505 for example comprises a pickup surface. The one or more parts are optionally picked up by and adhered onto the pickup surface. The capture element 505 optionally further comprises one or more individually actuating aerodynamic zones, for example a first aerodynamic zone and a second aerodynamic zone. The system is substantially similar to any of the embodiments described herein.

[0093] FIG. 5A shows the aerodynamic pickup system after a first 503A and a second article component 503B on a first platform 501 have been delivered to the robot-side. FIG. 5B shows the aerodynaic gripper 504 moving to capture the first article component 503 A. In some embodiments, the system for example recognizes the first and the second article components 503A, 503B with an automated visualization system. In some embodiments, the system for example recognizes one or more of the orientation and location of the first and the second article components 503 A, 503B. Alternatively or in combination, the system for example recognizes a first and a second predetermined capture location on the first platform 501 using an automated visualization system and precisely positions the gripper 504 so as to capture the first article component 503A from the first predetermined capture location. Capture of the first article component 503A optionally further comprises activating the first aerodynamic pickup zone but not the second aerodynamic zone. FIG. 5C shows the aerodynamic gripper 504 selectively picking up the first article component 503A but not the second article component 503B. FIG. 5D shows the aerodynamic gripper 504 moving to capture the second article component 503B. The system for example precisely positions the gripper 504 so as to capture the second article component 503B from the second predetermined capture location. Capture of the second article component 503B optionally further comprises activating the second aerodynamic zone while maintaining activation of the first aerodynamic zone so as to have both the first and the second article components 503 A, 503B captured by the gripper 504 simultaneously as shown in FIG. 5E. FIG. 5F shows the system after the aerodynamic gripper 504 has moved the first and second article components 503 A, 503B to a position above the second platform 502. The system for example optionally recognizes a first and a second predetermined location on the second platform 502 using an automated visualization system and positions the robotic actuator 506 so that the first article component 503A is precisely placed over the first predetermined location. The gripper 504 releases the first article component 503A by deactivating the first aerodynamic zone while maintaining activation of the second aerodynamic zone so as to selective release the first article component 503A but not the second article component 503B. FIG. 5G shows the release of the first article component 503A onto the second platform 502 while the second article component 503B is retained on the aerodynamic gripper 504. FIG. 5H shows the release of the second article component 503B onto the second platform 502. The system for example positions the robotic actuator 506 so that the second article component 503B is precisely placed over the second predetermined location. The system for example uses the position information acquired by one or more cameras on the operator-side. Alternatively or in combination, the system determines the placement of the first article component 503A at the second platform 502 using a gripper-mounted camera and adjusts the position of the robotic actuator 506 such that the second article component 503B is precisely placed at the second predetermined location relative to determined placement of the first article component 503 A. The gripper 504 optionally releases the second article component 503B by deactivating the second aerodynamic zone to form at least a portion of an assembled article.

[0094] In many embodiments, the first and second article components 503 A, 503B are placed at the first and second predetermined capture locations such that the gripper 504 simultaneously captures the first and the second article components 503 A, 503B by simultaneously activating both of the first and the second aerodynamic zones.

[0095] In some applications common in shoe and apparel manufacturing, for example those that incorporate hot melt fusing for instance, the gripper for example comprises one or more of a plurality of ultrasonic weld actuator components. Activation of the ultrasonic welder following release of the second article component onto the first article component temporarily fuses the article components together if one or more of the article components are impregnated with a hot- melt or other adhesive. In some embodiments, the ultrasonic welder is activated prior to release of the second article component onto the first article component. In some embodiments, the ultrasonic welder is activated before the capture element is moved away from the first and second article components. Said tack weld is used for example to prevent dislodging of the article components when transferred to or at a downstream manufacturing apparatus, for example when traveling through hot rollers or when in transit from one manufacturing apparatus to another. In some embodiments, an ultrasonic welder is optionally embedded in each of the aerodynamic cells such that the tack weld is accomplished without additional motion of the robotic actuator following release of the article components on the second platform. In some embodiments, one or more ultrasonic welder is for example mounted on the gripper and is used selectively by moving the gripper-attached welder to a pre-defined tack weld location.

[0096] FIG. 6A shows an exemplary first article component 603 A, an exemplary second article component 603B, and an exemplary third article component 603 C as placed on the first platform by a user. The first platform and the user are not shown for clarity.

[0097] FIG. 6B shows a schematic of an exemplary placement patterns 603 A', 603B', 603C for the three article components 603 A, 603B, 603C, respectively, on the pickup surface 652 of the aerodynamic gripper capture element 605. The placement patterns 603 A', 603B', 603C'are optionally calculated prior to pickup using Computer Aided Design (CAD) inputs of each of the parts as well as the assembled article as described in PCT/US2017/013262, PCT/US2017/013264, and PCT US2017/013262, the entire contents of which are incorporated herein by reference. The placement patterns 603 A', 603B', 603 C are optionally calculated prior to pickup using part placement location, identity, and/or orientation information gathered by the automated visualization system descried herein. Alternatively or in combination, the system for example recognizes a first and a second predetermined capture location on the first platform using an automated visualization system and precisely positions the gripper 604 so as to capture the first article component 603A from the first predetermined capture location.

[0098] The controller for example calculates the desired placement patterns 603A', 603B', 603C on the pickup surface 652 and the motion(s) required to capture the article components 603 A, 603B, 603C from the first platform. Such motions include motions in X, Y, Z, theta, or the combination thereof.

[0099] FIG. 6C shows a schematic of the aerodynamic gripper capture element 605 positioned in alignment with the first article component 603 A. One aligned, the first aerodynamic pickup zone 656A is activated to capture the first article component 603A at the desired placement location 603 A' on the pickup surface 652 as shown in FIG. 6D. Activation of the fans of the first aerodynamic pickup zone 656A generates the vectored air field comprising a pressure differential which allows the material to be picked up from the first platform as described herein. The first aerodynamic pickup zone 656A for example comprises three adjacent air flow generators 656. In some embodiments, the first part 603A is configured to overlap the edge of the pickup surface 652 such that a portion of the first part 603A does not contact the pickup surface 652 when captured. In some embodiments, the entire first part 603A contacts the pickup surface 652. The second and third article components 603B, 603C are not yet aligned with their desired placement locations 603B', 603C and the second and third aerodynamic pickup zones 656B, 656C are therefore not yet activated. The gripper therefore selectively captures the first article component 603A but not the second and third article components 603B, 603C. It will be understood by one of ordinary skill in the art that more than one aerodynamic pickup zone can be activated simultaneously if more than one part is properly aligned with their desired placement locations on the pickup surface at the same time.

[0100] FIG. 6E shows a schematic of the aerodynamic gripper capture element 605 positioned in alignment with the second article component 603B. After capturing the first article component 603 A, the system for example precisely positions the capture element 605 above the second article component 603B such that it is in alignment with the second desired placement location 603B' on the pickup surface 652. Capture of the second article component 603B optionally further comprises activating the second aerodynamic zone 656B while maintaining activation of the first aerodynamic zone 656A so as to have both the first and the second article components 603 A, 603B captured by the gripper 605 simultaneously as shown in FIG. 6F. The second aerodynamic pickup zone 656B for example comprises five adjacent air flow generators 656. In some embodiments, the second part 603B is configured to overlap the edge of the pickup surface 652 such that a portion of the second part 603B does not contact the pickup surface 652 when captured. In some embodiments, the entire second part 603B contacts the pickup surface 652.

[0101] FIG. 6G shows a schematic of the aerodynamic gripper capture element 605 positioned in alignment with the third article component 603C. Following capture of the first and second article components 603 A, 603B, the system for example precisely positions the capture element 605 above the third article component 603 C such that it is in alignment with the third desired placement location 603C on the pickup surface 652. Capture of the third article component 603C optionally further comprises activating the third aerodynamic zone 656C while maintaining activation of the first and second aerodynamic zones 656A, 656B so as to have all three article components 603 A, 603B, 603 C captured by the gripper 605 simultaneously as shown in FIG. 6H. The third aerodynamic pickup zone 656C for example comprises five adjacent air flow generators 656. In some embodiments, the third part 603C is configured to overlap the edge of the pickup surface 652 such that a portion of the third part 603C does not contact the pickup surface 652 when captured. In some embodiments, the entire third part 603C contacts the pickup surface 652.

[0102] After all three of the article components 603A, 603B, 603C have been captured, the gripper transfers the parts to the second platform, for example a tray on a conveyor, and releases the parts as described herein according to the instructions of the controller. The gripper may transfer the parts to the second platform by moving the gripper from above the first platform to a location above the second platform that is at a standoff height sufficient to prevent ground effect disturbance of any parts already located on the second platform. [0103] FIG. 7A shows a schematic of an aerodynamic gripper cell 756 above a porous target surface 702. Release of the captured article component onto the porous target surface 702 (also referred to herein as the second platform or second conveyor) for example occurs when the air flow generator 756 is deactivated and the vectored air field is removed. The use of a porous material for the conveyor reduces the potential for ground effect disturbance, the effects of which are shown in FIG. 7B when a non-porous conveyor 702 is utilized. When the part is released from the gripper cell 756, the air below the part is moved and this movement, which is often lateral to the target surface 702, can easily disturb parts (either being released from the gripper or already on the second platform 702) and cause translation movement of the parts relative to the pickup surface and/or second platform 702 as the air is drawn into the system.

[0104] In some embodiments, release of the captured article components is facilitated by one or more active release mechanisms. For example, release is facilitated by one or more of a netting (e.g. as shown in FIG. 8C), a positive pressure port (for example the holes 257 shown in FIG. 2A and/or a port incorporated into the pickup surface), an ejector blade (e.g. as shown in FIGS. 8B- 8C), an array of pins (e.g. as shown in FIGS. 8D-8E), or any combination thereof as described herein.

[0105] Alternatively or in combination, release is facilitated by rapidly moving the air flow generator or zone of generators 756 (and/or the entire pickup surface) towards the target surface 702. The gripper for example optionally executes a high-speed drop (e.g. greater than or equal to 1G acceleration) while the generator 756 while simultaneously deactivating the air flow generator 756 helps to prevent disturbance of the captured part, and any parts already on the target surface 702, by the ground effect. The high-speed drop is optionally executed by a high-speed Z mechanism, for example a SCARA robot which links both joint 4 and Z together. Alternatively or in combination, in some embodiments a precision high-speed Z parallel plate mechanism is utilized to activate the entire gripper in a Z direction (e.g. downward toward the second platform) from the robotic mount. Alternatively or in combination, a full-pickup surface ejection system is integrated in some embodiments.

[0106] FIG. 8A shows an embodiment of an aerodynamic gripper capture element 805 with multiple air flow generators 856, wherein each air flow generator 856 has independent vertical activation. The aerodynamic gripper is substantially similar to the gripper described in FIGS. 3A- 3C. The gripper comprises one or more actuators. For example, each cell 856 or zone of cells 856 optionally comprises its own actuator. Alternatively, a single actuator is optionally configured to individually extend and retract each of the cells 856 or zone of cells 856. The actuator is optionally a high-speed Z mechanism configured to rapidly extend the pickup surface 852 of the air flow generator with a velocity of 1G or higher as described herein. As desired by one of ordinary skill in the art, one or more of the cells 856 is extended forward from a retracted position to separate the extended cells 856 from the remainder of the one or more retracted cells 856.

[0107] In some instances, the entire pickup surface 852 is extendable, for example by one or more actuators.

[0108] FIG. 8B shows a cross-section of an embodiment of an aerodynamic gripper cell 856 comprising a mechanical separation mechanism 870 and an ultrasonic welder 841 with mechanical separation mechanism 870 extended. As illustrated, in some embodiments the ultrasonic welder 841 is integral with the mechanical separation mechanism 870, for example an ejector comprising ejector blades 873. When retracted, the ejector 870 is housed in the plenum 1474 formed between the pickup surface 852 and the housing 854 of the capture element 1405. The capture element 805 is connected to the robotic actuator 806 via a linkage system 853. Extension of the ejector blades 873 through the pickup surface 852 mechanically separates the capture element 805 from a captured article component, thereby facilitating the release of said article component from the capture element 805.

[0109] In some embodiments, extension of the ejector blades 873 projects the ultrasonic welder 841 into contact with the article components where it is activated to temporarily fuse the article components together. For example activation of the ultrasonic welder 841 following release of a second article component onto a first article component temporarily fuses the article components together if one or more of the article components are impregnated with a hot-melt or other adhesive. In some embodiments, the ultrasonic welder 841 is activated prior to release of the second article component onto the first article component. In some embodiments, activation of the ultrasonic welder 841 occurs prior to release from negative pressure of the second article component onto the first article component. In some embodiments, the ultrasonic welder 841 is activated prior to extension of the mechanical separation mechanism 870. In some embodiments, the ultrasonic welder 841 is activated before the capture element 805 is moved away from the first and second article components. Said tack weld is used for example to prevent dislodging of the article components when transferred to or at a downstream manufacturing apparatus, for example when traveling through hot rollers or when in transit from one manufacturing apparatus to another.

[0110] FIG. 8C shows a perspective view of an embodiment of a mechanical separation mechanism 870 with integrated ultrasonic welder 841 as used in FIG. 8B. The ultrasonic welder 841 is integrally located at the center of the mechanical separation mechanism 870. The mechanical separation mechanism 870 comprises a plurality of ejector blades 873, for example four ejector blades 873. The ej ector blades 873 for example form a cross with the ultrasonic welder 841 at the center. In some embodiments, the ejector blades 873 are coupled for a netting or filaments 865 which are in contact with the captured article component. Actuation of the ejector blades 873 through the electroadhesion plate 851 facilitates release of the article component from the contact surface 852 of the electroadhesion plate 851.

[0111] FIGS. 8D-8E illustrate an embodiment of an aerodynamic gripper comprising pins 877 to aid in release of an article component 803 from the gripper. The aerodynamic gripper comprises a capture element, for example one or more air flow generators 856. The gripper optionally further comprises an array of pins 878 extendable from the contact surface 852 of the gripper to facilitate release of one or more captured target object 803, for example an article component. In many embodiments, the plurality of pins 877 comprises a plurality of pin regions 879, wherein each pin region 879 is configured to separately actuated and complementary to each separately activated air flow generator 856 or zone of generators to facilitate release of the captured one or more captured target objects 803. FIG. 8D shows an embodiment of an air flow generator 856 with captured article component 803 and an array of retracted pins 878. The pickup surface 852 comprises an array of holes 880 (which are optionally the same as holes 257 shown in FIG. 2A or different from holes 257) through which the array of pins 878 is actuated. FIG. 8E shows the release of the article component 803 by actuation of the pins 877 through the pickup surface 852 towards the second platform 802.

[0112] In some instances, high-speed lateral movement of the robotic actuator, for example during movement from the first platform to the second platform, can cause the captured parts to slip from their desired position on the pickup surface. For examples, materials which have slick or rigid surfaces are prone to slippage if not combatted with alternate forces. In some embodiments, the pickup surface of the capture element are treated or coated with substances such as urethane or silicone to enhance friction and allow precision retention during high-speed lateral movement. Alternatively or in combination, the capture element is optionally an electroadhesion-enabled capture element such that activation of the electroadhesion pickup surface during (and optionally before and/or after) lateral movement of the robotic actuator helps retain the capture parts at their desired position on the pickup surface.

[0113] FIG. 9 shows a schematic of a base shoe part 995 (shaded) with an exaggerated outline overlaid thereon and used by the system (e.g. the controller) for correcting distortion or placement error introduced by the user during placement of the part on the first platform. The base shoe part 995 comprises a toe region 996, a lateral region 997, a lace region 998, and a medial region 999. The exaggerated outline is used by the controller to account for distortions by the user and improve part placement accuracy relative to their actual critical-to-quality features. For example, the lace region 998 and toe region 996 are shrunken inward while the medial and lateral regions 999, 997 are displaced forward and outward to account for many potential sources of distortion.

[0114] It will be understood by one of ordinary skill in the art that the aerodynamic pickup tool optionally comprises any of the pickup and/or release modalities described herein in any combination thereof. For example, the aerodynamic pickup tool for example comprises one or more of one or more electroadhesion pickup surface/zone, one or more active release mechanism, one or more friction enhancing coating, one or more ultrasound tool, or any of the other modalities described herein, or any combination thereof.

[0115] FIG. 10 shows a flowchart of a method 1000 of capturing and releasing a plurality of target objects using an aerodynamic pickup system comprising an aerodynamic gripper as described previously herein. The method may use one or more of the systems and apparatus described herein.

[0116] At step 1001, a first article component and a second article component on a first platform are recognized, for example using an image taken by a camera above the first platform.

[0117] At step 1002, the first article component is captured by one or more first aerodynamic cells and the second article component is captured by one or more second aerodynamic cells. Capture of the first and second article components for example comprises one or more of activating one or more fans (step 1002A), adjusting the fan speed of one or more fans (step 1002B), adjusting the porosity of one or more air flow generators (step 1002C), and activating an electroadhesive surface of the capture element. Capture of the first article component for example comprises activation of one or more fans in the one or more first aerodynamic cells. Capture of the second article component for example comprises activation of one or more fans in the one or more second aerodynamic cells. Capture of the first and second article components occurs simultaneously or sequentially.

[0118] At step 1003, the first article component is released from the one or more first aerodynamic cells while the second article component is retained at the one or more second aerodynamic cells. Release of the first article component from the one or more first aerodynamic cells for example comprises one or more of a high-speed drop of the one or more first aerodynamic cells (step 1003A), separation of a netting from the one or more first aerodynamic cells (step 1003B), extension of pins from the one or more first aerodynamic cells (step 1003C), cessation of the vectored air field at the one or more first aerodynamic cells (step 1003D), application of positive pressure the one or more first aerodynamic cells (step 1003E), adjustment of the fan speed of the one or more first aerodynamic cells (step 1003F), adjustment of the porosity of the one or more first aerodynamic cells (step 1003G), and deactivation of electroadhesion (step 1003H). [0119] At step 1004, the second article component is released from the one or more second aerodynamic cells. Release of the second article component from the one or more second aerodynamic cells for example comprises any one or more of the release mechanisms described previously herein.

[0120] At step 1005, the previous steps are repeated for multiple article components.

[0121] Although the steps above show a method 1000 of capturing and releasing a plurality of target objects using an aerodynamic pickup system comprising an aerodynamic gripper in accordance with embodiments, a person of ordinary skill in the art will recognize many variations based on the teaching described herein. The steps may be completed in a different order. Steps may be added or deleted. Some of the steps may comprise sub-steps. Many of the steps may be repeated as often as necessary to assemble at least a part of an article.

[0122] For example, in some embodiments Step 1001 may occur in multiple steps such that the first and second article components are detected at different times. Alternatively or in combination, Step 1002 optionally occurs such that the first and second article components are captured at different times. In many embodiments, additional article components are for example captured simultaneously with the capture of the first and second article components, respectively.

[0123] In many embodiments, one or more of the steps of the method 1000 are performed with circuitry of the various components described herein. In some embodiments, the circuitry is programmed to provide one or more of the steps of the method 1000, and the program comprises program instructions stored on a computer readable memory or programmed steps of the logic in the circuitry.

[0124] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.

Claims

CLAIMS WHAT IS CLAIMED IS:

1. A system for aerodynamically picking up one or more parts, the system comprising: one or more air flow generators having a pickup surface, the one or more air flow generators being configured to generate a vectored air field on the pickup surface, the vectored air field being configured to cause the one or more parts to be picked up by and adhere onto the pickup surface; a controller coupled to and configured to selectively control each of the one or more air flow generators to generate the vectored air field; and

a porous placement surface over which the one or more parts to be picked up are initially placed, the porous placement surface being configured to allow air flow therethrough to facilitate the generation of the vectored air field.

2. The system of claim 1, wherein the porous placement surface comprises a movable conveyer.

3. The system of claim 1, wherein the one or more parts to be picked up comprise a plurality of parts to be picked up.

4. The system of claim 1, wherein the pickup surface comprises a plurality of pickup zones, and wherein the controller is configured to individually activate the pickup zones.

5. The system of claim 1, wherein the generated vectored air field comprises one or more pressure differentials between different sides of the pickup surface, the one or more pressure differentials being configured to exert an attractive force on the one or more parts to be picked up.

6. The system of claim 1, wherein the one or more air flow generators comprises a one or more fans.

7. The system of claim 1, further comprising a movable arm coupled to the one or more air field generators, the movable arm being configured to adjust a position of the one or more air flow generators relative to the porous placement surface.

8. The system of claim 7, further comprising a target surface, and wherein the movable arm is configured to move the one or more air flow generators toward the target surface at acceleration equal or greater to 1 G.

9. The system of claim 8, wherein the controller is configured to deactivate one or more of the one or more air flow generators as the movable arm moves the one or more air flow generators toward the target surface, thereby releasing the picked-up one or more parts onto the target surface while minimizing translation movement of the one or more parts relative to the part interface surface.

10. The system of claim 1, further comprising a plurality of electrodes coupled the pickup surface and configured to generate electroadhesion to facilitate adhesion of the one or more parts onto the pickup surface.

11. The system of claim 1, further comprising a release mechanism coupled to the one or more air flow generators and configured to facilitate release of the one or more parts from the pickup surface.

12. A method for aerodynamically picking up one or more parts, the system comprising: providing one or more parts on a porous placement surface;

generating a vectored air field with a pickup tool to attract the one or more parts toward a pickup surface of the pickup tool, the pickup tool comprising one or more air flow generators to generate the vectored air field and wherein the placement surface is porous to facilitate the generation of the vectored air field at least partially passing therethrough.

13. The method of claim 12, wherein generating the vectored air field comprises selectively activating one or more pickup zones of the pickup surface.

14. The method of claim 12, wherein providing the one or more parts on the porous placement surface comprises moving the one or more parts through a conveyer.

15. The method of claim 10, wherein the one or more parts to be picked up comprise a plurality of parts to be picked up.

16. The method of claim 12, wherein generating the vectored air field comprises generating one or more pressure differentials between different sides of the pickup surface, the one or more pressure differentials being configured to exert an attractive force on the one or more parts to be picked up.

17. The method of claim 12, wherein the one or more air flow generators comprises a plurality of fans.

18. The method of claim 12, further comprising adjusting a position of the plurality of air flow generators relative to the porous placement surface, wherein the position of the plurality of air flow generators is adjusted using a movable arm coupled to the one or more air flow generators.

19. The method of claim 18, wherein adjusting the position of the plurality of air flow generators comprises moving the one or more air flow generators toward a target placement surface at an acceleration greater or equal to 1 G.

20. The method of claim 19, further comprising deactivating one or more pickup zones of the pickup surface as the one or more flow generators is moved toward the target placement surface.

21. The method of claim 12, further comprising generating electroadhesion with the pickup tool to facilitate adhesion of the one or more parts onto the pickup surface.

22. The method of claim 12, further comprising releasing the one or more parts from the pickup surface using a release mechanism coupled to the one or more air flow generators.

23. Any of the devices described herein.

24. Any of the methods described herein.

25. Any of the systems described herein.