How Does a Micro Vacuum Pump-Based Pick-and-Place System Work?

Your automated line needs to handle delicate parts, but mechanical grippers cause damage. This challenge slows down production and increases costs. A micro vacuum pump -based system offers a gentle, reliable alternative.

A pick-and-place system uses a micro vacuum pump to create suction at a gripper, allowing it to lift and move objects without clamping them. The pump evacuates air from a suction cup, and atmospheric pressure holds the object in place until the vacuum is released.

As an engineer at JSG DC PUMP for over two decades, I’ve helped countless clients implement these systems. The core idea is simple, but success lies in understanding how each part works together. Let’s explore the mechanics, from how suction is created to choosing the right components for your robotic application.

What Is a Pick-and-Place System?

You need to automate a repetitive task, like moving chips onto a circuit board. A pick-and-place system is the solution, but how does it function at its most basic level?

A pick-and-place system is a robot that picks up an object from one location and places it in another. A vacuum-based system uses a suction cup, a micro vacuum pump, and a valve to create the “pick” action, offering a gentle touch for fragile components.

Think of it as a highly precise, automated version of using a drinking straw to lift a small piece of paper. The robot provides the motion, but the vacuum does the delicate work of holding the object. This method is incredibly versatile, used for everything from handling fragile glass vials to assembling complex electronics.

The Four Steps of a Pick-and-Place Cycle

The robot’s operation can be broken down into a simple, repeating loop. Each step relies on precise control of both motion and vacuum.

1. Approach: The robotic arm moves the vacuum gripper over the target object. At this stage, the vacuum is off.
2. Pick: The gripper makes contact with the object. The micro vacuum pump turns on (or a valve opens), evacuating the air from the suction cup. This creates a pressure difference, and the higher atmospheric pressure outside the cup holds the object securely.
3. Move: The arm lifts the object and transports it to the target location. The vacuum pump ensures the suction is maintained throughout the movement.
4. Place: The arm positions the object. The vacuum is then released, usually by opening a small valve to let air rush back into the suction cup. This breaks the seal, and the object is placed gently.

System Components and Their Roles

How Does a Micro Vacuum Pump Create the Suction Force?

Your system needs a reliable “pick” function. A mechanical gripper is too harsh. Understanding how a pump generates gentle yet strong suction is key to your design’s success.

A micro vacuum pump, typically a diaphragm type, uses a motor to move a flexible diaphragm back and forth. This motion alternately expands and compresses a sealed chamber, pulling air in through one valve and pushing it out through another, creating a vacuum at the inlet.

I’ve spent years explaining this process. The magic isn’t in creating a “pulling” force but in removing air molecules. The pump empties the suction cup, and the surrounding atmospheric pressure does the actual work of holding the object. It’s an elegant principle that allows a small pump to lift surprisingly heavy objects.

The Mechanics of a Diaphragm Pump

The operation is a two-stroke cycle, happening hundreds of times per second.

1. Intake Stroke: The motor pulls the diaphragm down, increasing the volume of the pump chamber. This creates a low-pressure area. The higher pressure from the suction cup line pushes the inlet valve open and pulls air from the cup into the chamber. The outlet valve remains closed.
2. Exhaust Stroke: The motor pushes the diaphragm up, decreasing the chamber volume. This compresses the captured air, increasing its pressure. The high pressure forces the outlet valve open, expelling the air to the atmosphere. The inlet valve is forced shut, preventing air from going back into the suction cup.

This continuous cycle rapidly removes air from the sealed system, reaching the target vacuum level.

Key Performance Metrics Explained

Why Use a Miniature Vacuum Pump Instead of a Venturi Generator?

You need vacuum for your gripper, but should you use a pump or a venturi generator? Using compressed air for a venturi seems simple, but it hides significant long-term costs and inefficiencies.

A miniature vacuum pump is often superior because it is far more energy-efficient and provides stable, controllable vacuum. Venturi generators are noisy, wasteful of compressed air, and their performance can fluctuate with air supply pressure, making them less reliable for precise applications.

I frequently encounter systems where engineers are battling inconsistent performance from venturi ejectors. The issue is that venturis are passive devices that depend entirely on a massive, expensive air compressor. A dedicated micro vacuum pump, like our JSG DC PUMP models, offers a self-contained, electrically efficient, and highly controllable solution. It puts the vacuum source right where it’s needed.

Comparing the Two Technologies

The choice impacts everything from operating cost to system reliability.

• Energy Efficiency: A DC vacuum pump consumes watts of power only when needed. A venturi consumes large volumes of expensive compressed air, with a significant portion of that energy lost as heat and noise at the compressor.
• Controllability: A pump’s speed can be adjusted with PWM control to fine-tune vacuum levels. A venturi’s vacuum level is tied directly to the input air pressure, which can be inconsistent.
• System Complexity: A pump requires simple DC wiring. A venturi system requires an air compressor, dryers, filters, regulators, and pneumatic tubing throughout the facility, adding many potential points of failure.

Head-to-Head Comparison

For modern, compact, and energy-conscious robotic design, a dedicated miniature vacuum pump is almost always the superior choice.

What Parameters Matter Most for Robotic Pick-and-Place?

You’re designing a robotic gripper and need to select a pump. With so many specs, which ones truly determine success? Focusing on the wrong numbers can lead to a system that is too slow or too weak.

For pick-and-place, the two most critical parameters are the evacuation time (determined by flow rate and system volume) and the holding force (determined by vacuum level and suction cup area). A balance between these two ensures a fast and reliable cycle.

As an application engineer, I guide clients to think about the entire cycle. It’s not just about hitting a deep vacuum. If it takes too long to get there, your line’s throughput suffers. The goal is to reach a sufficient vacuum level as quickly as possible.

The evacuation time

This is the time it takes for the pump to remove enough air to securely grip the part. It’s a function of three things:

• Pump Flow Rate (L/min): Higher flow removes air faster.
• System Volume (L): This includes the volume of the suction cup and the tubing. Keeping this volume small is critical for fast response times.
• Target Vacuum Level: It takes longer to reach a deeper vacuum. You only need enough to hold the part securely.

The holding force

This is the force that holds the object to the suction cup. It’s calculated with a simple formula:
Force (N) = Vacuum Level (Pa) x Suction Cup Area (m²)

• Vacuum Level (-kPa): A deeper vacuum creates more holding force.
• Suction Cup Area: A larger suction cup provides more force, but it must fit on the object’s surface. A safety factor of 2x (for horizontal lifts) to 4x (for vertical lifts) is recommended to account for acceleration and surface irregularities.

Case Example: JSG BD-08VB-S for Compact Robotic Grippers?

You need a powerful, reliable vacuum source for a compact gripper, but space and power are limited. Your application demands continuous operation and high performance. How can you find the right component?

The JSG DC PUMP BD-08VB-S is an ideal solution. This 24V DC vacuum pump provides an exceptional -85 kPa vacuum and 45 L/min flow in a compact, durable all-aluminum alloy body designed for continuous duty cycles.

I was recently involved in a project for a client developing a high-speed sorting robot for cosmetics. They needed a pump small enough to be mounted directly on the robotic arm but powerful enough to handle rapid pick-and-place cycles. The BD-08VB-S was the perfect fit. Its high flow rate allowed for sub-second pick times, and its robust metal construction ensured reliability even with constant motion and vibration.

Why the BD-08VB-S Excels in Robotics

This model was engineered specifically for demanding applications like pick-and-place.

• High Performance: With -85 kPa, it can lift heavier objects or use smaller suction cups. The 45 L/min flow rate ensures minimal delay in evacuating the suction cup, maximizing throughput.
• Continuous Duty: Unlike many smaller pumps that can overheat, the BD-08VB-S’s aluminum alloy body acts as a heat sink. This allows it to run 24/7 without performance degradation, which is critical for production environments.
• Durability and Low Vibration: The solid metal construction provides stability and resistance to the constant acceleration and deceleration of a robotic arm.

Technical Specifications and Application Fit

This pump is a workhorse, providing the power and reliability needed to move from a prototype to a full-scale production system.

DC Vacuum Pump Integration Tips for Engineers?

You’ve selected the perfect pump. Now you have to integrate it into your system. Small mistakes in placement, plumbing, or control can undermine the performance you paid for.

To ensure success, mount the pump close to the suction cup to minimize volume, use a solenoid valve for rapid release, and protect the pump with an inlet filter. Proper electrical control with PWM can also help manage noise and power consumption.

After helping hundreds of engineers integrate our pumps, I’ve compiled a shortlist of best practices. Following these simple rules can be the difference between a prototype that works intermittently and a production machine that runs reliably for years. These are the details that separate amateur designs from professional ones.

Mechanical Integration Best Practices

• Minimize Tubing Length: The volume of your tubing is part of the system the pump must evacuate. Keep the distance between the pump, valve, and suction cup as short as possible for the fastest response.
• Use an Inlet Filter: Debris entering the pump is the #1 cause of premature failure. A simple, inexpensive filter between your application and the pump inlet is essential protection.
• Proper Mounting: Mount the pump on a stable surface, using rubber grommets if necessary to dampen vibration and noise. Ensure adequate airflow around the pump body for cooling.

Electrical and Control Integration

Conclusion

A micro vacuum pump is the heart of a modern pick-and-place system. Understanding how to select, integrate, and control it is key to building a fast, reliable, and efficient automated solution.

💡 JSG DC PUMP specializes in high-performance micro vacuum pumps for industrial automation, robotic handling, and OEM integration.
For technical consultation or OEM cooperation, contact our engineering team at admin@dc-pump.com.

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