By Mike Tuohey, Sales & Marketing Communications Manager, Piab USA Inc.

Suction cups enable the vacuum to grip

Vacuum systems designed to lift, hold and move objects need to be fitted with suction
cups. These come in all shapes, forms and sizes, so it can be hard to choose one that fits a
certain application. First, you need to know how they work.

Suction cups are essential components in any vacuum system designed for materials
handling. They provide a simple and low-cost, yet reliable and proven solution. Suction cups
can lift, hold and move objects weighing anything from a few grams to hundreds of kilos.

Usually made of pliable materials such as rubber, suction cups provide a tight seal against
the handled object, ensuring a firm grip. So, how is this possible?

Low pressure under the cup

A suction cup adheres to the surface of the handled object when the pressure under the cup
is lowered. This causes the higher atmospheric pressure outside the cup to press the cup
down onto the surface. The low pressure under the cup is, of course, a result of the suction
cup being connected to a vacuum pump that pumps away the air from under the cup.

The atmosphere surrounding the cup will exert pressure on all sides of the suction cup,
making sure that the cup is firmly held against the handled object.

Use a big cup and a low vacuum

If the vacuum level is too high, the suction cup will work harder and wear out quicker.
Higher vacuum levels also use more energy. Hence, it is usually preferable to maintain a
lower vacuum and instead increase the area of the suction cup, as the lifting or holding
capacity of a suction cup is determined by:

Lifting force = pressure x area

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A simplified formula can be used to roughly estimate the cup size needed for a certain task.
Typically, the diameter (D) of the suction cup is unknown, whereas the weight of the object
being handled (m) and the vacuum level (U) are known. A safety factor also needs to be
included (n) as well as the number of suction cups used in the system (s). The equation for
working out the required suction cup diameter will end up like this:

More than size matters

Although the size plays an important part, there are other equally important considerations
when selecting an appropriate suction cup. The dimensions of the handled object as well as
the material it is made of will also affect the choice.

The texture of the objects surface is important. Seemingly flat surfaces may have small
imperfections or be grainy, which can result in leakages. Properly adjusted suction cups can
solve such issues. The surface temperature is another property worth taking into account. In
the case of extreme surface temperatures, suction cups made of a silicon material are
recommended.

The porosity of the material must also be considered. Porosity is defined as the amount of
outside atmospheric air that passes through an object under vacuum pressure. Solid sheets
of metal or glass are non-porous, but boxes of corrugated cardboard or sheets of paper are
porous and will let air through.

Tailored to fit

Although most of these considerations can be addressed by a few basic suction-cup shapes,
it is important to remember that suction cups need to be tailored to suit specific purposes.

Flat objects are best handled by flat style suction cups. Such cups can be fitted with
moulded rubber cleats inside that spread the vacuum force over the entire cup area to limit
cup movement on the handled object.

The bellows style shape is very popular as it allows the cup a degree of level adjustment,
meaning that it can compensate for irregularities in the surface and varying height of
handled objects. An oval style cup can be used in tight areas where a round shape simply
would not fit, and a deep style cup is suitable for lifting around corners or edges.

Soft lips handle with care

The cups durability, wear and oil resistance are important factors to bear in mind. As the
friction between the suction cup and the surface is of vital importance, suction cups with

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high capability to handle shear forces resulting from rapid acceleration and retardation
should be used.

Polyurethane has better abrasion and tear resistance than rubber. In addition, it has higher
load bearing capacity and exceptional elastic memory.

Suction cups in polyurethane with a soft, high friction, flexible lip and a stable body are a
good choice for many applications. For instance, these are able to keep a tight hold on bags,
and yet not damage them. The latest soft and durable lips have excellent sealing capacity
and are designed to control how the bags wrinkle.

When safety is a priority

Extra-large flat suction cups are ideal for the handling of for instance large panes of glass
with either flat or slightly concave surfaces. The cups can be equipped with a specially
designed friction pattern that is tailor-made for the vertical handling of glass or metal
sheets. The friction pattern stops sheets from slipping, even if they are slightly wet or
greasy.

A double lip design can act as an extra safety barrier. If the cups outer lip is accidentally
torn or cut, the inner lip will make sure that such damage does not have fatal consequences.
It also safeguards against the effects of overloading.

Finish off with accessories

The right accessories will enhance the performance of the materials handling system. If the
pick-up area relative to the horizontal or vertical planes changes, or if the alignment of
objects or the pick-up height vary from time to time, there are accessories that will
compensate for these variations.

For instance, a level compensator or shock-absorber accessory will automatically adjust to

different heights. A ball-joint connector can provide angle deviation to address problems
relating to objects that are not completely vertical or horizontal. This is particularly useful
on curved surfaces.

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Do you want to learn more about suction cups?

On our website we offer self-training modules on this and other subjects. Of course you are
always welcome to contact us for help.

About Piab

Established in 1951, Piab designs innovative vacuum solutions that improve the energy-
efficiency, productivity, and working environments of vacuum users around the world. As a
reliable partner to many of the world's largest manufacturers, Piab develops and
manufactures a complete line of vacuum pumps, vacuum accessories, vacuum conveyors
and suction cups for a variety of automated material handling and factory automation
processes. Piab utilizes COAX, a completely new dimension in vacuum technology, in many
of its original products and solutions. COAX cartridges are smaller, more energy efficient
and more reliable than conventional ejectors, and can be integrated directly into machinery.
This allows for the design of a flexible, modular vacuum system. Piab is a worldwide
organization with subsidiaries and distributors in almost 70 countries. Its headquarters are
in Sweden. For more information about Piab vacuum solutions for a diverse range of
applications, visit www.piab.com.