Patent Application
20240208255
This disclosure relates generally to an end effector for printing ink on a surface, and more particularly to an end effector having multiple printheads for printing ink on a surface and associated systems and methods.
In various commercial products, it is desirable to apply colorful visual images to a surface through the application of a pigmented formulation. The image may be applied to a surface by various methods, such as applying a paint or ink material to a surface using a brush or aerosol spray. However, applying images using a brush or aerosol spray is time-consuming and labor intensive, which can require multiple steps to apply multiple successively applied paint layers. Furthermore, applying images on complex surfaces is difficult and can require a series of masking operations followed by application of the paint or coating. These masking and painting operations are serially repeated until the surface is completed. Performing these processes on large areas with a variety of contoured surfaces requires a significant amount of time and resources.
The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the problems of and needs created or not yet fully solved by conventional printing apparatuses and methods. Generally, the subject matter of the present application has been developed to provide an end effector for printing on a surface, and associated systems and methods, that overcome at least some of the above-discussed shortcomings of prior art techniques.
Disclosed herein is an end effector for printing ink on a surface. The end effector comprises a primary block, which comprises a primary-block body. The primary block also comprises a plurality of primary-printing modules, coupled to the primary-block body, so that each one of the plurality of primary-printing modules is translationally movable, parallel to a z-axis and relative to the primary-block body. The primary block further comprises a first actuator coupled to each one of the plurality of primary-printing modules. The first actuator is operable to selectively extend and retract a corresponding one of the plurality of primary-printing modules, parallel to the z-axis and relative to the primary-block body. Each one of the plurality of primary-printing modules comprises at least one primary printhead. Each one of the plurality of primary-printing modules further comprises at least one of a second actuator or a third actuator. The second actuator is configured to rotate the at least one primary printhead, relative to the primary-block body, about a first axis that is parallel to or collinear with an x-axis, which is perpendicular to the z-axis. The third actuator is configured to rotate the at least one primary printhead, relative to the primary-block body, about a second axis that is parallel to or collinear with a y-axis, which is perpendicular to the x-axis and the z-axis. The preceding subject matter of this paragraph characterizes example 1 of the present disclosure.
Each one of the plurality of primary-printing modules comprises both the second actuator and the third actuator. The preceding subject matter of this paragraph characterizes example 2 of the present disclosure, wherein example 2 also includes the subject matter according to example 1, above.
Each one of the plurality of primary-printing modules further comprises at least two primary printheads. Each one of the plurality of primary-printing modules also comprises a fourth actuator configured to rotate at least one of the at least two primary printheads, relative to at least one other of the at least two primary printheads, about a third axis that is parallel to the second axis. The preceding subject matter of this paragraph characterizes example 3 of the present disclosure, wherein example 3 also includes the subject matter according to any of examples 1-2, above.
Each one of the plurality of primary-printing modules comprises at least three primary printheads. The preceding subject matter of this paragraph characterizes example 4 of the present disclosure, wherein example 4 also includes the subject matter according to example 3, above.
Each one of the plurality of primary-printing modules is selectively movable, via actuation of the first actuator corresponding with each one of the plurality of primary-printing modules, independent of any other one of the plurality of primary-printing modules. The preceding subject matter of this paragraph characterizes example 5 of the present disclosure, wherein example 5 also includes the subject matter according to any of examples 1-4, above.
Each one of the at least one printhead comprises two ink outlets. Each one of the two ink outlets is configured to dispense ink having a color. The color of the ink dispensed by one of the two ink outlets is different than the color of the ink dispensed by any other one of the two ink outlets. The preceding subject matter of this paragraph characterizes example 6 of the present disclosure, wherein example 6 also includes the subject matter according to any of examples 1-5, above.
Each one of the plurality of primary-printing modules further comprises at least three primary printheads. The color of the ink dispensed by any one of the two ink outlets is different than the color of the ink dispensed by any other one of the two ink outlets of any other one of the at least three printheads. The preceding subject matter of this paragraph characterizes example 7 of the present disclosure, wherein example 7 also includes the subject matter according to example 6, above.
The plurality of primary-printing modules comprises at least six primary-printing modules. The preceding subject matter of this paragraph characterizes example 8 of the present disclosure, wherein example 8 also includes the subject matter according to any of examples 1-7, above.
The at least six primary-printing modules are grouped into at least three sets of two primary-printing modules. The two primary-printing modules of each one of the at least three sets of primary-printing modules are aligned in a direction parallel to the y-axis. The two primary-printing modules of each one of the at least three sets of primary-printing modules are offset, in a direction parallel to the x-axis, from the two primary-printing modules of any other one of the at least three sets of two primary-printing modules such that the at least three sets of two primary-printing modules are staggered. The preceding subject matter of this paragraph characterizes example 9 of the present disclosure, wherein example 9 also includes the subject matter according to example 8, above.
The plurality of primary-printing modules are staggered, in a direction parallel to the x-axis, from any other one of the plurality of primary-printing modules. The preceding subject matter of this paragraph characterizes example 10 of the present disclosure, wherein example 10 also includes the subject matter according to any of examples 1-9, above.
The primary block defines at least twenty-four axes of motion. The preceding subject matter of this paragraph characterizes example 11 of the present disclosure, wherein example 11 also includes the subject matter according to any of examples 1-10, above.
The end effector comprises a trailing block coupled with the primary block so that the trailing block is movable relative to the primary block. The trailing block comprises a trailing-block body. The trailing block also comprises a plurality of trailing-printing modules coupled to the trailing-block body so that each one of the plurality of trailing-printing modules is translationally movable, parallel to a second z-axis and relative to the trailing-block body. The trailing block further comprises a fifth actuator coupled to each one of the plurality of trailing-printing modules. The fifth actuator is operable to selectively extend and retract a corresponding one of the plurality of trailing-printing modules, parallel to the second z-axis and relative to the trailing-block body. Each one of the plurality of trailing-printing modules comprises at least one trailing printhead. Each one of the plurality of trailing-printing modules also comprises at least one of a sixth actuator or a seventh actuator. The sixth actuator is configured to rotate the at least one trailing printhead, relative to the trailing-block body, about a fourth axis that is parallel to or collinear with a second x-axis, which is perpendicular to the second z-axis. The seventh actuator is configured to rotate the at least one trailing printhead, relative to the trailing-block body, about a fifth axis that is parallel to or collinear with a second y-axis, which is perpendicular to the second x-axis and the second z-axis. The preceding subject matter of this paragraph characterizes example 12 of the present disclosure, wherein example 12 also includes the subject matter according to any of examples 1-11, above.
Each one of the plurality of trailing-printing modules comprises the sixth actuator and the seventh actuator. The preceding subject matter of this paragraph characterizes example 13 of the present disclosure, wherein example 13 also includes the subject matter according to example 12, above.
Each one of the plurality of trailing-printing modules comprises at least two trailing printheads. Each one of the plurality of trailing-printing modules also comprises an eighth actuator configured to rotate at least one of the two trailing printheads, relative to at least one other of the two trailing printheads, about a sixth axis that is parallel to the fifth axis. The preceding subject matter of this paragraph characterizes example 14 of the present disclosure, wherein example 14 also includes the subject matter according to any of examples 12-13, above.
Each one of the plurality of trailing-printing modules comprises at least three trailing printheads. The preceding subject matter of this paragraph characterizes example 15 of the present disclosure, wherein example 15 also includes the subject matter according to any of examples 12-14, above.
The primary block comprises one of at least one attachment rail or a carriage configured to slidably engage with the at least one attachment rail. The trailing block comprises at least the other one of the at least one attachment rail or the carriage configured to slidably engage with the at least one attachment rail. The carriage comprises a rotary bearing configured to be selectively rotatable about a seventh axis that is parallel to or collinear with the second x-axis. A ninth actuator is coupled to the carriage and operable to selectively extend and retract the trailing block, relative to the primary block, along the at least one attachment rail. A tenth actuator is coupled to the carriage and configured to rotate the trailing block, relative to the primary block, about the seventh axis. The preceding subject matter of this paragraph characterizes example 16 of the present disclosure, wherein example 16 also includes the subject matter according to any of examples 12-15, above.
The end effector comprises a plurality of trailing blocks. The plurality of trailing blocks comprises an upper trailing block coupled to a first portion of the primary block. The plurality of trailing blocks further comprises a lower trailing block coupled to a second portion of the primary block. The first portion is spaced apart from the second portion. The preceding subject matter of this paragraph characterizes example 17 of the present disclosure, wherein example 17 also includes the subject matter according to any of examples 12-16, above.
The upper trailing block and the lower trailing block are positionable in any position, between and inclusive of, a fully-expanded position and a fully-retracted position. When in the fully-expanded position the upper trailing block and the lower trailing block are expanded laterally, relative to the primary block, to form the end effector in a v-block formation. When in the fully-retracted position the upper trailing block and the lower trailing block are retracted laterally, relative to the primary block, to form the end effector in a collapsed formation. The preceding subject matter of this paragraph characterizes example 18 of the present disclosure, wherein example 18 also includes the subject matter according to example 17, above.
The end effector comprises a plurality of trailing blocks. The plurality of trailing blocks comprises a first upper trailing block, a second upper trailing block, a first lower trailing block, and a second lower trailing block. The first upper trailing block is coupled directly to the primary block so that the first upper trailing block is movable relative to the primary block. The second upper trailing block is coupled directly to the first upper trailing block so that the second upper trailing block is movable relative to the first upper trailing block. The first lower trailing block is coupled directly to the primary block so that the first lower trailing block is movable relative to primary block. The second lower trailing block is coupled directly to the first lower trailing block so that the second lower trailing block is movable relative to the first lower trailing block. The preceding subject matter of this paragraph characterizes example 19 of the present disclosure, wherein example 19 also includes the subject matter according to any of examples 12-18, above.
Each one of the plurality of trailing blocks is selectively movable, via actuation of a corresponding one of a plurality of ninth actuators or a corresponding one of a plurality of tenth actuators, independent of any other one of the plurality of trailing blocks. The preceding subject matter of this paragraph characterizes example 20 of the present disclosure, wherein example 20 also includes the subject matter according to example 19, above.
The end effector defines at least sixty-four axes of motion. The preceding subject matter of this paragraph characterizes example 21 of the present disclosure, wherein example 21 also includes the subject matter according to any of examples 12-20, above.
Each one of the plurality of trailing-printing modules is selectively movable, via actuation of the fifth actuator corresponding with each one of the plurality of trailing-printing modules, independent of any other one of the plurality of trailing-printing modules. The preceding subject matter of this paragraph characterizes example 22 of the present disclosure, wherein example 22 also includes the subject matter according to any of examples 12-20, above.
The plurality of trailing-printing modules are staggered, in a direction parallel to the second x-axis, from any other one of the plurality of trailing-printing modules. The preceding subject matter of this paragraph characterizes example 23 of the present disclosure, wherein example 23 also includes the subject matter according to any of examples 12-21, above.
Further disclosed herein is a system for printing ink on a surface. The system comprises a manipulator. The system also comprises an end effector removably attachable to the manipulator. The end effector comprises a primary block which comprises a primary-block body. The primary block also comprises a plurality of primary-printing modules coupled to the primary-block body so that each one of the plurality of primary-printing modules is translationally movable, parallel to a z-axis and relative to the primary-block body. The primary block further comprises a first actuator coupled to each one of the plurality of primary-printing modules. The first actuator is operable to selectively extend and retract a corresponding one of the plurality of primary-printing modules, parallel to the z-axis and relative to the primary-block body. Each one of the plurality of primary-printing modules comprises at least one primary printhead. Each one of the plurality of primary-printing modules also comprises at least one of a second actuator or a third actuator. The second actuator is configured to rotate the at least one primary printhead, relative to the primary-block body, about a first axis that is parallel to or collinear with an x-axis, which is perpendicular to the z-axis. The third actuator is configured to rotate the at least one printhead, relative to the primary-block body, about a second axis that is parallel to or collinear with a y-axis, which is perpendicular to the x-axis and the z-axis. The system further comprises a control system coupled to the end effector. The control system is configured to receive data corresponding to at least a location of the primary block, relative to the surface, and to control a position of the primary block, relative to the surface and via selective control of the manipulator, in response to the data. The preceding subject matter of this paragraph characterizes example 24 of the present disclosure.
The control system is configured to receive second data corresponding to a location of each one of the plurality of primary-printing modules, relative to the surface. The control system is also configured to control a position of the at least one primary printhead of the corresponding one of the primary-printing modules, relative to the surface, based at least partially on the second data. The preceding subject matter of this paragraph characterizes example 25 of the present disclosure, wherein example 25 also includes the subject matter according to example 24, above.
The end effector comprises at least one trailing block coupled to the primary block so that the at least one trailing block is movable relative to the primary block. The at least one trailing block comprises a trailing-block body. The at least one trailing block also comprises a plurality of trailing-printing modules coupled to the trailing-block body so that each one of the plurality of trailing-printing modules is translationally movable, parallel to a second z-axis and relative to the trailing-block body. The trailing block further comprises a fifth actuator coupled to each one of the plurality of trailing-printing modules. The fifth actuator is operable to selectively extend and retract a corresponding one of the plurality of trailing-printing modules, parallel to the second z-axis and relative to the trailing-block body. Each one of the plurality of trailing-printing modules comprises at least one trailing printhead. Each one of the plurality of trailing-printing modules also comprises at least one of a sixth actuator and a seventh actuator. The sixth actuator is configured to rotate the at least one trailing printhead, relative to the trailing-block body, about a fourth axis that is parallel to or collinear with a second x-axis, which is perpendicular to the second z-axis. The seventh actuator is configured to rotate the at least one trailing printhead, relative to the trailing-block body, about a fifth axis that is parallel to or collinear with a second y-axis, which is perpendicular to the second x-axis and the second z-axis. The control system of the system is further configured to receive third data corresponding to at least a location of the at least one trailing block, relative to the surface, and to control a position of the at least one trailing block, relative to the surface, via selective control of the manipulator, in response to the third data. The preceding subject matter of this paragraph characterizes example 26 of the present disclosure, wherein example 26 also includes the subject matter according to any of examples 24-25, above.
The control system is further configured to receive fourth data corresponding to a location of each one of the plurality of trailing-printing modules, relative to the surface. The control system is also configured to control a position of the corresponding at least one printhead, relative to the surface, based at least partially on the fourth data. The preceding subject matter of this paragraph characterizes example 27 of the present disclosure, wherein example 27 also includes the subject matter according to any of examples 24-26, above.
The control system is configured to receive a print path. The print path defines a path the end effector will follow along the surface. The control system is further configured to adjust the print path, in real time, based at least partially on the data corresponding to at the least the location of the primary block, relative to the surface. The preceding subject matter of this paragraph characterizes example 28 of the present disclosure, wherein example 28 also includes the subject matter according to any of examples 24-27, above.
Further disclosed herein is a method of printing ink on a surface. The method comprises the step of positioning an end effector relative to the surface. The end effector comprising a primary block comprising a primary-block body and a plurality of primary-printing modules. The plurality of primary-printing modules are coupled to the primary-block body so that each one of the plurality of primary-printing modules is translationally movable, parallel to a z-axis and relative to the primary-block body. Each one of the plurality of primary-printing modules comprises at least one primary printhead. The method also comprises the step of receiving a location data for each one of the plurality of primary-printing modules and the at least one primary printhead. At least one of adjusting a position of at least one of the plurality of primary-printing modules, in response to the location data for each one of the plurality of primary-printing modules, or adjusting a position of the at least one primary printhead, in response to the location data of the at least one primary printhead is adjusted. The plurality of primary-printing modules are adjustable, relative to the primary-block body, to extend or retract at least one of the plurality of primary-printing modules, parallel to the z-axis so that the at least one plurality of primary-printing modules is a desired distance away from the surface. The at least one primary printhead is adjustable so that the at least one primary printhead is a desired distance away from the surface by rotating the at least one primary printhead in at least one manner. The at least one primary printhead may be adjusted by rotating the at least one primary printhead, relative to the primary-block body, about a first axis that is parallel to or collinear with an x-axis, which is perpendicular to the z-axis. Additionally, or alternatively, the at least one primary printhead may be adjusted by rotating the at least one primary printhead, relative to the primary-block body, about a second axis that is parallel to or collinear with a y-axis, which is perpendicular to the x-axis and the z-axis. The method also comprises the step of moving the end effector along the surface. The method further comprises the step of painting ink, via the at least one primary printhead, on the surface as the end effector is moved along the surface. The preceding subject matter of this paragraph characterizes example 29 of the present disclosure.
The described features, structures, advantages, and/or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more examples, including embodiments and/or implementations. In the following description, numerous specific details are provided to impart a thorough understanding of examples of the subject matter of the present disclosure. One skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and/or methods of a particular example, embodiment, or implementation. In other instances, additional features and advantages may be recognized in certain examples, embodiments, and/or implementations that may not be present in all examples, embodiments, or implementations. Further, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.
In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific examples that are illustrated in the appended drawings. Understanding that these drawings depict only typical examples of the subject matter, they are not therefore to be considered to be limiting of its scope. The subject matter will be described and explained with additional specificity and detail through the use of the drawings, in which:
Reference throughout this specification to “one example,” “an example,” or similar language means that a particular feature, structure, or characteristic described in connection with the example is included in at least one example of the subject matter of the present disclosure. Appearances of the phrases “in one example,” “in an example,” and similar language throughout this specification may, but do not necessarily, all refer to the same example. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more examples of the subject matter of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more examples.
Disclosed herein are examples of an end effector, and associated systems and methods, for printing ink on a surface. The following provides some features of at least some examples of the end effector. The end effector includes a plurality of printheads configured to enable wide-area printing coverage on a surface. Additionally, the end effector is useful for wide-area printing on complex surfaces, such as a contoured surfaces or compound contoured surfaces, as each printhead is adjustable relative to at least one axis. In some cases, the end effector includes one block (i.e., a primary block) with a plurality of printheads that are adjustable through multiple axes of movement to maintain the printheads a desired distance from the surface during use of the end effector. In other cases, the end effector includes at least one additional block (i.e., trailing block) that is coupled to the primary block. Each trailing block also includes a plurality of printheads that are adjustable through multiple axes of movement. The trailing block(s) are designed to move (e.g., expand or retract) laterally, relative to the primary block, allowing the end effector to telescope narrower and wider for optimal printing coverage over a surface in a single pass. Additionally, due to the adjustability each printhead of the primary block and any additional trailing blocks, the end effector can be adjusted to accommodate printing on contoured surfaces while maintaining each printhead a desired distance from the surface during use of the end effector.
During a printing process, the end effector is enabled to cover a wide area of a surface in a single pass, and to adjust the lateral expansion or coverage of the end effector, during the single pass, to avoid collisions with any obstructions or features on the surface. The ability to change the macro-contour of the end effector enables the end effector to adjust to match a changing contour of the surface.
One non-limiting use of the end effector is for printing a decorative livery coating on the surface of an aircraft. The decorative livery coating creates a decorative design on the surface of the aircraft, which helps to identify and distinguish one aircraft from another. The surface of an aircraft is complex with various features, such as wings, stabilizers, window openings, engines, etc., that can obstruct a print path of the end effector. Additionally, the surface of an aircraft fuselage is often a complex contoured surface. In order to print the surface of an aircraft efficiently, the end effector can be used to minimize the number of print passes necessary to print the surface, as well as to reduce time and labor.
Referring to
In some examples, the primary block 102 includes at least two primary-printing modules 116. The plurality of primary-printing modules 116 can be arranged on the primary block 102 in any arrangement. In some examples, the plurality of primary-printing modules 116 are linearly aligned in a direction parallel to an x-axis, which is perpendicular to the z-axis. As used herein, the x-axis is parallel to or collinear with a print path of the end effector 100 when the end effector 100 is in use on a surface and following the print path. In other examples, as shown in
In some examples, the primary block 102 includes at least six primary-printing modules 116. The at least six primary-printing modules 116 can be arranged in any arrangement. For example, the at least six primary-printing modules 116 can be grouped into at least three sets of two primary-printing modules 116, such that the at least three sets of primary-printing modules 116 are aligned in a direction parallel to the y-axis, perpendicular to the x-axis. Each one of the sets of two primary-printing modules 116 are offset (i.e., not linearly aligned), in a direction parallel to the x-axis, from the two primary-printing modules 116 of any other one of the at least three sets of two primary-printing modules 116. Accordingly, the at least three sets of two primary-printing modules 116 are staggered, in the direction parallel to the x-axis, as shown in
Each one of the primary-printing modules 116 includes at least one primary printhead 118 configured to print ink on a surface. In some examples, the primary-printing modules 116 include at least three primary printheads 118, such as a first primary printhead 120, a second primary printhead 122, and a third primary printhead 124. In some examples, each one of the primary printheads 118 is or includes an inkjet head, which can be a piezo jet, thermal jet, continuous jet, and/or valve jet printhead. As used herein, ink can be any pigmented formulation which can be applied to a surface, such as an ink, water-based paint, oil-based paint, primer, coatings, varnish, etc. Each one of the primary printheads 118 is configured to print ink having a color (which includes white or black). Additionally, the ink may be opaque or translucent, such as a varnish or clear coat that is applied over the surface to add protection to the surface.
In some examples, at least two primary printheads 118 of a corresponding primary-printing module 116 print a color of ink having the same color. For example, a first primary printhead 120 may print a first coat of a color of ink and a second primary printhead 122 may print a second coat of the same color of ink. In other examples, each one of the primary printheads 118 of the corresponding primary-printing module 116 prints ink having a different color than ink printed by any other one of the primary printheads 118 of the primary-printing module 116. The primary printhead 118, in some examples, may have more than one ink outlet 119, each ink outlet 119 configured to dispense ink from the primary printhead 118 to a surface. For example, the primary printhead 118 may have two ink outlets 119 and the color of ink dispensed by one of the two ink outlets 119 may be different than the color of ink dispensed by the other one of the two ink outlets 119. In other examples, the color of ink dispensed by each ink outlets 119 of each one of the primary printheads 118 on a corresponding primary-printing module 116 is different than the color of the ink dispensed by any other one of the ink outlets 119 of each one of the primary printheads 118. In other words, a primary-printing module 116 with multiple ink outlets 119 may be configured to print multiple colors of ink, with each ink outlet 119 printing a distinct color. Various color and/or print systems can be used for printing on the surface. For example, CMYK (i.e., cyan, magenta, yellow, and key, as in black), RGB (i.e., red, green and blue) or expanded color systems can be used. It is possible for the end effector 100 to print single-color, multi-color images, chromatic images, grey-stage images, monochrome, binary images, etc.
The end effector 100 additionally includes, in some examples, at least one trailing block 104, which supports at least one trailing printhead 134 and is configured to be coupled to the primary block 102 so that the at least one trailing block 104 is movable relative to the primary block 102. The at least one trailing block 104, shown separately in
The at least one trailing block 104 includes at least two trailing-printing modules 132. The plurality of trailing-printing modules 132 can be arranged on the at least one trailing block 104 in any arrangement. In some examples, the plurality of trailing-printing modules 132 are linearly aligned in a direction parallel to the second x-axis, which is perpendicular to the second z-axis. In other examples, each one of the plurality of trailing-printing modules 132 are staggered, in a direction parallel to the second x-axis, from any other ones of the plurality of trailing-printing modules 132, such that no trailing-printing modules 132 are linearly aligned in the direction parallel to the second x-axis.
Similar to that described above in relation to the primary-printing modules 116, each one of the trailing-printing modules 132 includes at least one trailing printhead 134 configured to print ink on a surface. In some examples, each trailing-printing module 132 includes at least three trailing printheads 134, such as a first trailing printhead 136, a second trailing printhead 138, and a third trailing printhead 140.
The at least one trailing block 104, in some examples, can be an upper trailing block 105, configured to be movably coupled directly to a first portion 126 of the primary block 102 and/or a lower trailing block 107, configured to be movably coupled directly to a second portion 128 of the primary block 102. The first portion 126 is spaced apart from the second portion 128 along a trailing side 121 of the primary block 102. The end effector 100 can have multiple upper trailing blocks 105 (and/or multiple lower trailing blocks 107), where a first upper trailing block 106 is configured to be movably coupled to the primary block 102 and subsequent upper trailing blocks 105 are configured to be movably coupled to the immediately adjacent upper trailing block 105, such that only one upper trailing block 105 is directly coupled to the primary block 102. As shown in
One example of a system 300 for printing on a surface 302 is shown in
The surface 302 can be any surface 302 of any object that is capable of being printed. In some cases, the object to be printed has a three-dimensional body with a surface 302 having at least one obstruction, contour, bend, opening, angle, etc. For example, the object may be a vehicle such as a land-based, water-based, aircraft and/or space vehicle. Additionally, the object may be a non-vehicle commercial product such as home appliances, computers, furniture, toys, etc. As shown, the object is an aircraft having a fuselage surface 304 to be printed. The end effector 100 having a primary block 102 and four trailing blocks 104 is moving along the print path 312 on the fuselage surface 302. The aircraft may have one or more areas where it is difficult and/or time consuming to apply ink to the surface using conventional methods. Such areas, may include the contoured fuselage surface 304 and areas around wings, stabilizers, engines, etc. The end effector 100, with its ability to expand and retract laterally, as well as, the ability to adjust printhead location and angularity, allows the end effector 100 to print ink to the fuselage surface 304 in an efficient manner, continuing movement along the print path 312 while avoiding possible collisions.
The system 300 further includes a control system 308 communicatively coupled to the end effector 100. The control system 308 is configured to receive data corresponding to at least a location of the primary block 102, relative to the surface 302, and to control a position of the primary block 102, relative to the surface 302 and via selective control of the manipulator arm 306, in response to the data. Accordingly, the control system 308 is configured to receive location data and use at least the location data to control a position of the primary block 102 along the print path 312. The control system 308 can be described as being communicatively connected with various components. Communicatively connected refers to any type of communication and/or connection between the components that allows the component to pass and/or receive signals and/or information from another component. The communication may be along any signal path, whether a wired or a wireless connection. The control system 308 may include, or be part of, a computing device that may include one or more processors, memory, and one or more communication interfaces.
In some examples, the control system 308 is also configured to receive second data corresponding to a location of each one of the plurality of primary-printing modules 116, relative to the surface 302. The control system 308 is configured to control a position of the at least one primary printhead 118 of the corresponding one of the primary-printing modules 116, relative to the surface 302, based at least partially on the second data. The control system 308 employs at least one actuator coupled to the primary-printing module 116 to control the position of the at least one primary printhead 118. Additionally, in some examples, the control system 308 is configured to receive third data corresponding to at least a location of at least one trailing block 104, relative to the surface 302. The control system 308 can control a position of the at least one trailing block 104, relative to the surface 302, via selective control of the manipulator arm 306, and selective control of a ninth and ten actuators (see, e.g.,
In yet other examples, the control system 308 is further configured to receive fourth data corresponding to a location of each one of the plurality of trailing-printing modules 132, relative to the surface 302. The control system 308 is configured to control a position of the corresponding at least one trailing printhead 134, relative to the surface 302, based at least partially on the fourth data. The control system 308 employs at least one actuator coupled to the trailing-printing module 132 to control the position of the at least one trailing printhead 134. The control system receives data, such as the second data, third data, and the fourth data, through a plurality of sensors, as described below in reference to
The system 300 also includes an ink delivery system 310 configured to deliver ink, to each one of the primary printheads 118 of the primary block 102 and each one of the trailing printheads 134 of any trailing blocks 104 coupled to the primary block 102. The ink delivery system 310 may be directly coupled to the end effector 100, such as physically attached to the end effector 100 or indirectly coupled to the end effector 100, through a series of tubes that feed ink to the end effector 100 from an ink delivery system 310 that is separate from the end effector 100.
Referring to
The primary-printing module 116 may be in a neutral position, for example. The position of the primary-printing module 116 shown in
The primary-printing module 116 also includes a plurality of attachment points 164, such as fasteners, round pins, diamond pins, screws, etc., to attach the primary-printing module 116 to the primary-block body 114. The fasteners may allow the primary-printing modules 116 to be removed temporarily from the primary-block body 114 for maintenance, repair, or replacement. Furthermore, in some examples, certain ones of the plurality of primary-printing modules 116 can be removed from the end effector 100 so that certain ones of the plurality of primary-printing modules 116 are not on the end effector 100 during use of the end effector 100. This may be useful to avoid overlapping printed paths from previously aligned primary-printing modules 116.
The trailing-printing modules 132 have the same features and functionality as the primary-printing modules 116. Accordingly, a fifth actuator, similar to the first actuator 160, is movably (e.g., slidably) coupled to each trailing-printing module 132 on each trailing block 104 of the end effector 100. When actuated the fifth actuator is operable to selectively extend and retract a corresponding one of the trailing-printing modules 132, parallel to the second z-axis and relative to the trailing-block body.
Referring back to
Additionally, or alternatively, the primary block 102 has at least one camera 158, for imaging a surface on which the end effector 100 is currently printing, where the images provide location data. Real-time adjustments can be performed to the print path of the end effector 100 or to various parts of the primary block 102 based on the location data generated by the camera 158. In one example, a plurality of cameras 158, such as three cameras, are coupled to the primary-block body 114, adjacent to a leading side 117 of the primary block 102. In other examples, a plurality of cameras 158, such as three cameras, are coupled to the primary-block body 114, adjacent to a trailing side 121 of the primary block 102. In yet other examples, a plurality of camera 158 are along both the leading side 117 and the trailing side 121 of the primary-block body 114. The camera 158 may be any camera capable of imaging a surface, such as a 4 k or 8 k camera. If more than one camera 158 is employed on the primary block 102, each camera can be identical or at least two different cameras can be used, such a one 4 k camera and one 8 k camera. The camera 158 may be adjustable, such that the field of view of the camera can be adjusted. The primary block 102 may also include at least one illuminator 153 configured to provide illumination (i.e., light) to the surface the end effector 100 is imaging. The at least one illuminator 153, in some examples, is offset from the camera 158, such that the illuminator 153 is adjacent to the camera, in a direction parallel to the x-axis. In other examples, the illuminator 153 is aligned with the camera 158, such that the camera 158 and the illuminator 153 are co-planar in a direction perpendicular to the x-axis. One illuminator 153 can be shared by all of the cameras 158 adjacent to the leading side 117 (or trailing side 121), or each camera 158 may have an individually corresponding illuminator 153.
The primary block 102 may also include at least one laser distance sensor 154 configured to measure a distance from the sensor to a surface. The distance data from the laser distance sensor can be used to determine the distance various parts of the primary block 102 are from the surface. For example, at least one laser distance sensor 154 may be located adjacent to the leading side 117 of the primary block 102 and configured to measure the distance from the leading side 117 of the primary block 102 to the surface. Additionally, or alternatively, at least one laser distance sensor 154 may be located adjacent to the trailing side 121 of the primary block 102 and configured to measure the distance from the trailing side 121 of the primary block 102 to the surface. Laser distance sensors 154 may also be associated with individual primary printheads 118 or individual primary-printing modules 116. The primary block 102, in some examples, may also include at least one accelerometer 156, such as the accelerometer 156 located near the mount 115 of the primary block (see, e.g.,
As previously disclosed, each one of the primary-printing modules 116 includes at least one primary printhead 118. In some examples, the primary-printing module 116 has three primary printheads 118, such as shown in
In some examples, the primary-printing module 116 defines at least twenty-four axes of motion. As each primary-printing module 116 is movable, parallel to a z-axis and the at least one primary printhead 118 of each primary-printing module 116, in some examples, are rotatable about the first axis 146, the second axis 149 and the third axis 152, each primary-printing module 116 can have at least four axes of motion. Therefore, a primary block 102, as shown in
The first axis 146 extends through a midpoint of a width of the primary printhead 118 and parallel to or collinear with the x-axis. A second actuator 172 is configured to rotate (i.e., pivot) the at least one primary printhead 118, relative to the primary-block body 114, about the first axis 146. In some examples, the second actuator 172 is directly coupled to the at least one primary printhead 118. In other examples, the second actuator 172 is indirectly coupled to the at least one primary printhead 118, such that a first jointed-arm 173, coupled at one end to the second actuator 172, is coupled at the other end to an outer frame 178. The outer frame 178 entirely surrounds a perimeter of an inner frame 180, and the inner frame 180 entirely surrounds a perimeter of the at least one primary printhead 118. When the second actuator 172 is actuated, the first jointed-arm 173 is moved to rotate the at least one primary printhead 118. Accordingly, as the second actuator 172 is actuated, the outer frame 178, inner frame 180 and at least one primary printhead 118 co-rotate about the first axis 146. As shown in
The second axis 149 extends through a midpoint of a length of the primary printhead 118 and parallel to or collinear with the y-axis, which is perpendicular to the z-axis. A third actuator 174 is configured to rotate the at least one primary printhead 118, relative to the primary-block body 114, about the second axis 149. In some examples, the third actuator 174 is directly coupled to the at least one primary printhead 118. In other examples, the third actuator 174 is indirectly coupled to the at least one primary printhead 118, such that a second jointed-arm 175, extends between the third actuator 174 and the at least one primary printhead 118. The second jointed-arm 175 is coupled at one end to the third actuator 174 and is coupled at the other end to the inner frame 180. When the third actuator 174 is actuated, the second jointed-arm 175 is moved to rotate the at least one primary printhead 118. Accordingly, as the third actuator 174 is actuated, the inner frame 180 and at least one primary printhead 118 co-rotate, relative to the outer frame 178, about the second axis 149. As shown in
In examples where the primary-printing module 116 has at least two primary printheads 118, the third axis 152, or two parallel third axes 152, extend through the length of the primary printheads 118 and parallel to or collinear with the x-axis and the first axis 146. A fourth actuator 176 is configured to rotate at least one of the at least two primary printheads 118, relative to at least another one of the at least two primary printheads 118. In some examples, the fourth actuator 176 is directly coupled to one of the at least two primary printheads 118. In other examples, the fourth actuator 176 is indirectly coupled to one of the at least two primary printheads 118, such that a third jointed-arm 177, or set of third jointed-arms 177, extends between the fourth actuator 176 and at least one of the at least two primary printheads 118. The third jointed-arm 177 is coupled at one end to the fourth actuator 176 and is coupled at the other end to one of the at least two primary printhead 118. When the fourth actuator 176 is not actuated (i.e., the primary printheads 118 are in a neutral position) the at least two primary printheads 118 are co-planar, however once the fourth actuator 176 is actuated the at least two primary printheads 118 are not co-planar. When the fourth actuator 176 is actuated, the third jointed-arm 177 is moved to rotate one of the at least two primary printhead 118, relative to at least another one of the two primary printheads 118. Accordingly, as the fourth actuator 176 is actuated, the inner frame 180 and outer frame are stationary, while one of the at least two primary printhead 118 is rotated, relative to the inner frame 180, about the third axis 152.
As shown in
As the trailing-printing modules 132 have the same features as the primary-printing modules 116, the trailing-printing modules 132 also have at least one axis of motion. Referring to
Referring to
The at least one trailing block 104, in some examples, further includes a plurality of sensors. The plurality of sensors are configured to provide location data and measurement data for the trailing block 104, relative to a surface, or in some cases, relative to other blocks of the end effector 100. The plurality of sensors may include but are not limited to cameras 158, laser distance sensors 154, and accelerometers 156. The trailing block 104 has at least one camera 158. In one example, the at least one camera 158 is located adjacent to a second leading side 131 of the trailing block 104. Additionally, or alternatively, in other examples, the at least one camera 158 is coupled to the trailing-block body 130, adjacent to a second trailing side 133 of the trailing block 104. Furthermore, the at least one trailing block 104 has at least one laser distance sensor 154 configured to measure a distance from the sensor to a surface. The distance data from the laser distance sensor can be used to determine the distance various parts of the at least one trailing block 104 are from a surface. For example, at least one laser distance sensor 154 may be located adjacent to the second leading side 131 or adjacent to the second trailing side 133 of the at least one trailing block 104. Laser distance sensors 154 may also be associated with individual trailing printheads 134 or individual trailing-printing modules 132. The at least one trailing block 104, in some examples, may also include at least one accelerometer 156, such as the accelerometer 156 located adjacent to the second trailing side 133. The at least one accelerometer 156 is used to detect an orientation of the at least one trailing block 104, relative to the surface and/or relative to the primary block 102. Real time adjustments can be made to the location and/or orientation of the at least one trailing block 104 based on the location data generated by the plurality of sensors. Additionally, or alternatively, real time adjustments can also be made on the trailing-printing modules 132 based on the location data generated by the plurality of sensors.
The primary block 102 is coupled to the at least one trailing block 104 via an attachment system. The attachment system includes at least one attachment rail 190, that can be fixed to one of the primary block 102 or the trailing block 104. The attachment system further includes a carriage 191, that is configured to slidably engage with the corresponding at least one attachment rail 190. The carriage 191 is fixed to the other one of the primary block 102 or the trailing block 104. When slidably engaged, the trailing block 104 is movably in a direction parallel to or collinear with the second y-axis, relative to the primary block 102. For example, as shown in
The attachment system, between the primary block 102 and the first upper trailing block 106, is shown in
Referring to
In
Referring to
The method 400 also includes (block 404) receiving location data for each one of the plurality of primary-printing modules 116 and the at least one primary printhead 118. The primary block 102 includes a plurality of sensors that are configured to provide location data and measurement data for the end effector 100. The plurality of sensors may include cameras, distance sensors, accelerometers, encoders, and controllers. The plurality of sensors are configured to measure and received location data for at least one of the primary printheads 118, at least one primary-printing module 116, and/or the primary block 102. Controllers are configured to control the movement of the corresponding primary printhead 118, primary-printing module 116 or primary block 102. One of the plurality of sensors can be individually associated with one primary printhead 118 or one primary-printing modules 116 or shared between at least two primary printheads 118 or primary-printing modules 116.
The method further includes at least one adjusting the plurality of primary-printing modules 116 or adjusting the at least one primary printhead 118. Adjusting (block 406) the plurality of primary-printing modules 116 is done in response to the location data for each one of the plurality of primary-printing modules 116. The position of the plurality of primary-printing modules 116 is adjusted, relative to the primary-block body 114, to extend or retract at least one of the plurality of primary-printing modules 116, parallel to the z-axis so that the at least one plurality of primary-printing modules 116 is a desired distance away from the surface 302. Adjusting (block 408) the at least one primary printhead 118 is done in response to the location data for each one of the at least one primary printheads 118. A position of the at least one primary printhead is adjusted so that the at least one primary printhead 118 is a desired distance away from the surface 302. The desired distance can be achieved by at least one of rotating that at least one primary printhead 118, relative to the primary-block body 114, about a first axis 146 that is parallel to or collinear with an x-axis, which is perpendicular to the z-axis, or rotating the at least one primary printhead 118, relative to the primary-block body 114, about a second axis 149 that is parallel to or collinear with a y-axis, which is perpendicular to the x-axis and the z-axis. In some examples, the desired distances away from the surface 302 is the optimal distance away for printing ink on the surface. In other examples, the desired distances away is the optimal distance away for avoiding a collision on the surface.
The method 400 further includes (block 410) moving the end effector 100 along the surface 302. The end effector 100 is moved along the surface 302, parallel to the x-axis, along a print path 312. The print path 312 may be adjusted in real time using the data from the plurality of sensors.
The method 400 additionally includes (block 412) printing ink, via the at least one primary printhead 118, on the surface 302 as the end effector 100 is moved along the surface 302. In some examples, the method 400 further includes at least one trailing block 104 coupled to the primary block 102. The at least one trailing block 104 can be expanded laterally, relative to the primary block 102, to form an end effector 100 in a fully-expanded position, such as a v-block formation. The v-block formation can be formed by at least one upper trailing block 105 and one lower trailing block 107 extending laterally outward, relative to the primary block 102, together with the primary block 102 to form a V-shape. The fully-expanded position allows the end effector 100 to cover the widest swath along the surface 302 in a single pass. The at least one trailing block 104 can also be retracted laterally, relative to the primary block 102, to form the end effector 100 in a collapsed formation. The collapsed formation can be formed by the at least one trailing block 104 extending laterally inward, relative to the primary block 102, together with the primary block 102 to form an end effector 100 with aligned blocks, relative to the x-axis. The fully-retracted formation allows the end effector 100 to cover the narrowest swath along the surface 302 in a single pass. The end effector 100 can be adjusted to any position, between and inclusive of, the fully-expanded position and the fully-retracted position.
In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” “over,” “under” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Further, the term “plurality” can be defined as “at least two.”
Additionally, instances in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.
As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.
Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.
As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware which enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function.
The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one example of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.
The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described examples are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the examples herein are to be embraced within their scope.
