End-of-arm tool having concentric suction cups, and related systems and methods

1. A suction cup tool for the end of a robotic arm, the suction cup tool comprising:

a housing;

an outer suction cup assembly that includes an outer suction cup at a distal end of the housing, wherein the outer suction cup is configured to apply a first vacuum gripping force;

an inner suction cup assembly that extends centrally through the outer suction cup assembly, the inner suction cup assembly comprising:

a lower suction tube;

an inner suction cup at a distal end of the lower suction tube and concentrically located relative to the outer suction cup, wherein the inner suction cup is configured to apply a second vacuum gripping force; and

an actuator configured to selectively 1) extend the lower suction tube with respect to the outer suction cup so as to engage a target surface of at least one item with the inner suction cup, and 2) retract the lower suction tube with respect to the outer suction cup so as to engage the target surface with the outer suction cup and the inner suction cup concurrently; and

at least one vacuum source, wherein the at least one vacuum source is configured to communicate vacuum pressure concurrently to the inner and outer suction cups for applying the first and second vacuum gripping forces concurrently to the target surface.

2. The suction cup tool of claim 1 , wherein the lower suction tube defines a central axis, the inner suction cup defines a distal end, the outer suction cup defines a distal end, and the lower suction tube is configured to extend and retract with respect to the outer suction cup along the central axis between a fully retracted position and a fully extended position such that, in the fully retracted position, the distal end of the inner suction cup does not protrude distally beyond the distal end of the outer suction cup.

3. The suction cup tool of claim 2 , wherein the outer suction cup and the inner suction cup are both configured to be in communication with the at least one vacuum source, wherein the at least one vacuum source is configured to communicate vacuum pressure to the distal ends of the inner and outer suction cups for gripping the target surface.

4. The suction cup tool of claim 3 , wherein the inner suction cup is configured to 1) grip the target surface in the fully extended position, 2) lift the at least one item, during retraction of the lower suction tube, toward the distal end of the outer suction cup, and 3) grip the target surface concurrently with the outer suction cup when in the fully retracted position.

5. An end-of-arm tool for the end of a robotic arm, the end-of-arm tool comprising:

a housing;

an outer suction cup assembly that includes an outer suction cup at a distal end of the housing;

at least one compliant member extending from the housing to the outer suction cup, wherein the at least one compliant member is configured to provide axial compliance between the outer suction cup and the housing responsive to a proximal force exerted on the outer suction cup; and

an inner suction cup assembly that extends centrally through the outer suction cup assembly, the inner suction cup assembly comprising:

a lower suction tube;

an inner suction cup at a distal end of the lower suction tube and in fluid communication with the lower suction tube, wherein the inner suction cup is concentrically located relative to the outer suction cup; and

an actuator configured to selectively extend and retract the lower suction tube with respect to the outer suction cup.

6. The end-of-arm tool of claim 5 , wherein the inner suction cup assembly further comprises an inner suction tube in fluid communication with the lower suction tube, wherein the lower suction tube is configured to telescopically translate with respect to the inner suction tube along a central axis.

7. The end-of-arm tool of claim 6 , further comprising:

a central plenum configured to communicate vacuum pressure from a vacuum source to the inner suction tube, wherein the inner suction tube communicates the vacuum pressure to the lower suction tube; and

at least one outer plenum configured to communicate vacuum pressure to the outer suction cup.

8. The end-of-arm tool of claim 7 , wherein the vacuum source is a first vacuum source, and the at least one outer plenum is configured to communicate vacuum pressure from a second vacuum source to the outer suction cup.

9. The end-of-arm tool of claim 7 , further comprising a manifold coupled to the housing, wherein the manifold includes an external port configured to be in fluid communication with the vacuum source, and the manifold defines an interior space in fluid communication with the external port and with the central plenum for communicating the vacuum pressure to the lower suction tube.

10. The end-of-arm tool of claim 9 , wherein the manifold extends circumferentially around the housing, the manifold defines an internal annular space, and the manifold is rotationally coupled to the housing in a manner sealing the internal annular space, whereby the manifold defines a rotary vacuum joint.

11. The end-of-arm tool of claim 7 , wherein the actuator comprises a drive member configured to drive translation of the lower suction tube with respect to the inner suction tube responsive to one or more actuation forces transmitted to the drive member.

12. The end-of-arm tool of claim 11 , wherein the at least one outer plenum defines at least one inlet in fluid communication with the central plenum, and the tool further comprising at least one valve member configured to move between 1) an open position in which the at least one inlet is open to the central plenum and the at least one outer plenum, and 2) a closed position in which the at least one valve member occludes the at least one inlet so as to inhibit fluid communication between the central plenum and the at least one outer plenum.

13. The end-of-arm tool of claim 12 , wherein the drive member is further configured to move the at least one valve member between one of the open and closed positions to the other of the open and closed positions.

14. The end-of-arm tool of claim 11 , wherein:

the drive member comprises a piston head rigidly coupled to the lower suction tube;

the actuator further comprises first and second actuation channels each extending within the end-of-arm tool and in pneumatic communication with the piston head, wherein,

the first actuation channel is configured to direct pneumatic fluid against the piston head so as to apply a first actuation force of the one or more actuation forces to the piston head, thereby driving the piston head distally along the central axis so as to extend the lower suction tube with respect to the outer suction cup, and

the second actuation channel is configured to direct pneumatic fluid against the piston head so as to apply a second actuation force of the one or more actuation forces to the piston head, thereby driving the piston head proximally along the central axis so as to retract the lower suction tube with respect to the outer suction cup.

15. The end-of-arm tool of claim 5 , wherein the housing comprises a distal portion having a distal surface, and the outer suction cup comprises an outer suction cup body defining a proximal surface spaced from the distal surface by a gap, wherein the at least one compliant member is configured to 1) allow reduction of the gap from a neutral gap distance to a compressed gap distance responsive to the proximal force, and 2) bias the outer suction cup body distally so as to return the gap to the neutral gap distance when the proximal force is removed.

16. A method of lifting various items with a robotic arm carrying an end-of-arm tool, the method comprising:

manipulating the robotic arm so as to position the end-of-arm tool at a first position proximate an item;

identifying a target area of the item;

advancing one or both of an outer suction cup and an inner suction cup of the end-of arm-tool into engagement with the target area, wherein the outer suction cup is located at a distal end of a housing of the end-of arm-tool, and the inner suction cup and the outer suction cup are concentric with each other;

communicating vacuum pressure to the inner suction cup, thereby gripping the item with the inner suction cup; and

communicating vacuum pressure to the outer suction cup concurrently while communicating vacuum pressure to the inner suction cup, thereby further gripping the item with the outer suction cup.

17. The method of claim 16 , further comprising:

sensing, via an automated sensor in electronic communication with a processor, when the target area engages the outer suction cup; and;

transmitting data to the processor, wherein the data indicates that the target area has engaged the outer suction cup.

18. The method of claim 17 , further comprising:

transmitting a command signal from an electronic control unit in electronic communication with the processor to the robotic arm; and

manipulating the robotic arm, responsive to the command signal, so as to position the end-of-arm tool, while gripping the item, to a second position remote from the first position.