Material handling sensor device and method

Claim 2

A material handling sensor device, comprising: a vacuum cup having a material engaging end defining an aperture therethrough; means for applying a vacuum to said vacuum cup; a proximity sensor having a detecting end with means for sensing the presence of an object proximate thereto, said proximity sensor detecting end disposed within said vacuum cup; and means for maintaining proper registry and spacing said proximity sensor detecting end from an object in contact with said vacuum cup engaging end when a vacuum is applied to said vacuum cup.

Claim 3

The sensor device of claim 1, wherein: said registry and spacing maintaining means is a raised surface inside of said vacuum cup positioned to abut an object in contact with said vacuum cup engaging end when said vacuum is activated.

Claim 4

The sensor device of claim 2, wherein: said proximity sensor is a counting proximity sensor having means for sensing if more than one object is held proximate said proximity sensor detecting end.

Claim 5

The sensor device of claim 3, wherein: said raised surface is a generally circular ring extending about said proximity sensor detecting end.

Claim 6

The sensor of claim 2, wherein said vacuum cup has resiliently deformable sides, whereby when said vacuum is applied said vacuum cup sides deform until said object engages said raised surface.

Claim 7

The sensor device of claim 1, wherein: said vacuum cup is secured to a mounting block, said proximity sensor extending through said mounting block; and a seal disposed between said mounting block and said vacuum cup, said seal forming a vacuum seal about said proximity sensor.

Claim 8

The sensor device of claim 6, wherein said seal is formed integrally with said vacuum cup.

Claim 9

The sensor device of claim 7, wherein: said registry maintaining means is a raised surface inside of said vacuum cup positioned to abut an object in contact with said vacuum cup engaging end.

Claim 10

The sensor device of claim 1, further comprising: a mounting block; and said vacuum cup and said mounting block each have a vacuum channel therethrough, one of said mounting block and said vacuum cup having a circular recess on a surface contacting the other of said mounting block and said vacuum cup, said vacuum channels both being in air flow communication with said circular recess when said vacuum cup is secured to said mounting block.

Claim 11

A material handling sensor device, comprising: a vacuum boot having an inner surface and means for applying a vacuum therein; a proximity sensor having a detecting end secured to and exposed to the inside of said vacuum boot, said detecting end being a fixed distance from said inner surface; and a spacing surface on said vacuum boot and spaced from said detecting end, said spacing surface providing a stop for the material being handled when said vacuum is applied to provide a contact distance for said material being handled relative said detecting end.

Claim 12

A material handling sensor device, comprising: a vacuum boot having an inner surface and means for applying a vacuum therein; a proximity sensor having a detecting end secured to and exposed to the inside of said vacuum boot, said detecting end being a fixed distance from said inner surface; and a spacing surface on said vacuum boot and spaced from said detecting end, said spacing surface providing a stop for the material being handled when said vacuum is applied to provide a contact distance for said material being handled relative said detecting end.

Claim 13

The proximity sensor of claim 10, wherein: said spacing surface is a raised, generally circular ring extending about said proximity sensor detecting end.

Claim 14

The sensor device of claim 10, wherein: said vacuum boot is secured to a mounting block, said proximity sensor extending through said mounting block; and an air impermeable seal member about said proximity sensor.

Claim 15

The sensor device of claim 12, wherein: said seal is integrally formed with said vacuum cup.

Claim 16

The sensor device of claim 10, wherein: said vacuum boot is resiliently collapsible, whereby when said vacuum is applied said vacuum boot collapses until the handled material contacts said spacing surface.

Claim 17

The sensor device of claim 10, further comprising: a mounting block; and said vacuum cup and said mounting block each have a vacuum channel therethrough, one of said mounting block and said vacuum cup having a circular recess on a surface contacting the other of said mounting block and said vacuum cup, said vacuum channels both being in air flow communication with said circular recess when said vacuum cup is secured to said mounting block.

Claim 18

A material handling sensor device, comprising: a vacuum cup having a material engaging end defining an aperture therethrough; means for applying a vacuum to said vacuum cup; a proximity sensor having a detecting end with means for sensing the presence of an object proximate thereto, said proximity sensor detecting end disposed within said vacuum cup, said proximity sensor being a counting proximity sensor having means for sensing if more than one object is held proximate said proximity sensor detecting end; and means for maintaining proper registry between said proximity sensor detecting end and an object in contact with said vacuum cup engaging end when a vacuum is applied to said vacuum cup.

Claim 19

A material handling sensor device, comprising: a vacuum cup having a material engaging end defining an aperture therethrough; means for applying a vacuum to said vacuum cup; a proximity sensor having a detecting end with means for sensing the presence of an object proximate thereto, said proximity sensor detecting end disposed within said vacuum cup, said proximity sensor being a counting proximity sensor having means for sensing if more than one object is held proximate said proximity sensor detecting end; and means for maintaining proper registry between said proximity sensor detecting end and an object in contact with said vacuum cup engaging end when a vacuum is applied to said vacuum cup.

Claim 20

The sensor device of claim 16, wherein: said registry maintaining means is a raised surface inside of said vacuum cup positioned to abut an object in contact with said vacuum cup engaging end when said vacuum is activated.

Claim 21

The sensor device of claim 16, further comprising: a mounting block; and said vacuum cup and said mounting block each have a vacuum channel therethrough, one of said mounting block and said vacuum cup having a circular recess on a surface contacting the other of said mounting block and said vacuum cup, said vacuum channels both being in air flow communication with said circular recess when said vacuum cup is secured to said mounting block.

Claim 24

The method of claim 19, further comprising: spacing said field generating proximity sensor from the handled object.

Claim 25

The method of claim 20, wherein: said spacing step includes providing a raised spacing surface within said vacuum cup so as to abut the handled object when said field generating proximity sensor is selectively secured thereto.

Claim 26

The method of claim 19, further comprising: counting the number of objects proximate said vacuum cup.

Claim 27

A material handling sensor device, comprising: a vacuum cup having a material engaging end defining an aperture therethrough; means for applying a vacuum to said vacuum cup; a field generating proximity sensor having a detecting end with means for sensing the presence of an object proximate thereto by use of said field, said proximity sensor detecting end disposed within said vacuum cup; and means for maintaining proper field sensing registry between said proximity sensor detecting end and an object in contact with said vacuum cup engaging end when a vacuum is applied to said vacuum cup.

Claim 28

A material handling sensor device, comprising: a vacuum cup having a material engaging end defining an aperture therethrough; means for applying a vacuum to said vacuum cup; a field generating proximity sensor having a detecting end with means for sensing the presence of an object proximate thereto by use of said field, said proximity sensor detecting end disposed within said vacuum cup; and means for maintaining proper field sensing registry between said proximity sensor detecting end and an object in contact with said vacuum cup engaging end when a vacuum is applied to said vacuum cup.

Claim 29

The sensor device of claim 23, wherein: said field generating proximity sensor is a counting proximity sensor having means for sensing if more than one object is held proximate said proximity sensor detecting end.

Claim 30

The sensor device of claim 23, wherein: said vacuum cup is secured to a mounting block, said field generating proximity sensor extending through said mounting block; and a seal disposed between said mounting block and said vacuum cup, said seal forming a vacuum seal about said field generating proximity sensor.

Claim 31

The sensor device of claim 23, further comprising: a mounting block; and said vacuum cup and said mounting block each have a vacuum channel therethrough, one of said mounting block and said vacuum cup having a circular recess on a surface contacting the other of said mounting block and said vacuum cup, said vacuum channels both being in air flow communication with said circular recess when said vacuum cup is secured to said mounting block.

Claim 32

The sensor device of claim 26, wherein: said registry maintaining means is a raised surface inside of said vacuum cup positioned to abut an object in contact with said vacuum cup engaging end when said vacuum is activated.

Claim 33

The sensor device of claim 23, wherein: said registry maintaining means is a raised surface inside of said vacuum cup positioned to abut an object in contact with said vacuum cup engaging end when said vacuum is activated.

Claim 34

The sensor device of claim 28, wherein: said raised surface is a generally circular ring extending about said proximity sensor detecting end.