An intelligent nozzle device for complex curved surface circuit robot conformal jet printing

Abstract

This invention belongs to the technical field of conformal manufacturing of curved electronic surfaces, and more specifically, relates to an intelligent printhead device for conformal printing of complex curved circuit robots. It includes a main connector, a printhead system, a vision system, a ranging system, and a controller. The printhead system, vision system, and ranging system are all electrically connected to the controller. The main connector is used to mount the printhead system, vision system, and ranging system. The ranging system acquires distance data from the end of the printhead system to an external substrate and uploads it to the controller. The vision system acquires real-time image data of the product surface on the external substrate and uploads it to the controller. The controller processes the distance data and the product surface image data and controls the distance between the end of the printhead system and the external substrate. This invention integrates the printhead system, vision system, and ranging system into one unit, realizing real-time machine vision printing observation feedback, curved surface positioning, and printing height calibration. The overall structure is compact, improving printing accuracy.

Description

Technical Field

[0001] This invention belongs to the technical field of conformal manufacturing of curved electronic surfaces, and more specifically, relates to an intelligent printhead device for conformal printing of complex curved circuits by robots. Background Technology

[0002] Curved electronics, due to their large contact area and strong spatial adaptability, better coordinate and integrate with nature, and have been widely used in many fields, from conformal curved antennas, sensing, and measurement to aerospace and artificial intelligence skin. Currently, most electronic devices and sensors are manufactured on rigid and brittle two-dimensional material surfaces, which can meet the needs of planar electronics to a certain extent, but they are incompatible with complex curved surfaces in many fields. For the manufacturing needs of large-area curved electronics, such as wing surfaces and fighter jet canopies, unfolding the curved surface into two-dimensional manufacturing requires a larger processing area, and the manufacturing process using region segmentation and splicing is complex and unreliable. For some complex non-developable curved surfaces, such as radar seekers and aerospace engine surfaces, the process of transferring from two-dimensional manufacturing to three-dimensional surfaces inevitably results in areas that are not fully conformal. Therefore, there is an urgent need to develop direct-write manufacturing processes and equipment for large-area complex curved electronics.

[0003] Currently, representative direct-write manufacturing processes for curved surfaces include laser ablation, aerosol printing, and extrusion inkjet printing. Laser ablation offers high patterning precision but involves complex and challenging curved surface coating processes. Aerosol printing offers a wide variety of materials and high printing speeds, but its resolution is difficult to improve further, and it has a limited range of applicable ink viscosities. Extrusion inkjet printing has relatively low printing precision. Curved surface electrohydraulic conformal printing uses an electric field to drive and generate an extremely fine jet from the tip of a liquid cone in a "pulling" manner. It has excellent spatial resolution and is suitable for a wide range of electrohydraulic printing materials with varying viscosities. By adjusting the driving voltage mode, it is possible to control three modes of electrohydraulic printing (point, line, and surface), enabling multilayer through-hole interconnection on complex curved surfaces, high-resolution interconnect wire fabrication, and thin-film deposition electronic packaging, respectively. Compared to planar electronics manufacturing, curved surface electronics manufacturing faces more complex printing substrates, requiring higher precision in printhead spatial positioning, printing trajectory planning, and printhead posture adjustment. For example, the planar printing systems shown in patents CN201710326311 and CN201410555068 lack printhead spatial positioning and posture adjustment functions, making them unsuitable for the complex working conditions of curved surface electronics manufacturing and unable to achieve conformal electronic manufacturing. Currently, three-axis / five-axis inkjet printing platforms are mostly used for curved surface electronics manufacturing, as shown in patents CN201710238266 and CN201710915067. These platforms can perform curved circuit integration manufacturing within a certain curvature range, but they have high curvature requirements and can only process curved surfaces within a limited angular range, making real-time printing on large-area complex curved surfaces difficult.

[0004] Therefore, there is an urgent need for an intelligent nozzle device with flexible motion control, high spatial accessibility, and high processing efficiency as a processing carrier. Summary of the Invention

[0005] To address the aforementioned deficiencies or improvement needs of existing technologies, this invention provides an intelligent printhead device for conformal printing of complex curved surface circuits by robots. By integrating the printhead system, vision system, and ranging system into one unit, and based on the electro-hydraulic inkjet printing manufacturing process, it integrates functions such as direct writing of curved surface circuits, curved surface positioning, visual feedback, and printhead replacement. This enables high-precision conformal printing of complex curved surfaces, thereby solving the technical problem of difficulties in real-time printing of large-area complex curved surfaces.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: an intelligent printhead device for conformal printing on complex curved surface circuit robots, comprising: a main connector, a printhead system, a vision system, a ranging system, and a controller. The printhead system, vision system, and ranging system are all electrically connected to the controller. The main connector includes a mounting plane and a supporting vertical plate. The mounting plane is used to fix the intelligent printhead device to the end of the robot. The horizontal ends of the supporting vertical plate are symmetrically connected with a first mounting vertical plate and a second mounting vertical plate. The first mounting vertical plate and the second mounting vertical plate are used to install the printhead system and the vision system, respectively. An arc-shaped groove for installing the ranging system is formed on the inner wall of the supporting vertical plate. The ranging system is used to acquire distance data from the end of the printhead system to the external substrate and upload the distance data to the controller. The vision system is used to acquire product surface image data on the external substrate in real time and upload the product surface image data to the controller. The controller is used to process the distance data and the product surface image data and control the distance between the end of the printhead system and the external substrate.

[0007] Furthermore, the nozzle system includes a displacement device and an injection device. The displacement device includes an XY-axis displacement stage, an XY-axis locking component, a Z-axis displacement stage, a Z-axis locking component, and a displacement stage connector. The XY-axis displacement stage is installed on the top of the first mounting vertical plate, and the Z-axis displacement stage is installed on the bottom of the first mounting vertical plate. The XY-axis displacement stage and the Z-axis displacement stage are assembled into one unit through the displacement stage connector.

[0008] Furthermore, the XY-axis locking component is a connector composed of two L-shaped fasteners. The XY-axis locking component connects the main connector and the displacement stage connector with screws through long slots at both ends. The Z-axis locking component has a long slot on one side and is connected to the displacement stage connector with screws. The Z-axis displacement stage is installed inside the first mounting vertical plate and has a slide protruding from the side wall of the first mounting vertical plate. The injection device is installed on the outer surface of the slide.

[0009] Furthermore, the injection device includes a syringe, a syringe holder, a snap fastener, an anti-backflow ink supply device, an electro-inkjet nozzle, and a plasma coaxial printhead. The Z-axis locking member is fixedly connected to the syringe holder. The syringe is placed in the slot of the syringe holder. The snap fastener is placed on the syringe holder and contacts the syringe. The anti-backflow ink supply device is connected to the inlet above the syringe. The electro-inkjet nozzle is placed at the syringe outlet. The plasma coaxial printhead is coaxially placed around the electro-inkjet nozzle and connected to the syringe holder.

[0010] Furthermore, the vision system includes an industrial camera, a lens, a lens mount, a mirror holder, and a mirror; the industrial camera is mounted on the top of the second mounting plate, the data interface of the industrial camera is connected to the controller, the top of the lens is connected to the bottom of the industrial camera, the lens is connected to the second mounting plate through the lens mount, and the mirror is mounted on the bottom of the mirror holder.

[0011] Furthermore, the vision system also includes a first magnet, a second magnet, a third magnet, a fourth magnet, a coaxial point light source, and a surface light source. The first magnet and the third magnet are mounted side by side at the bottom of the second mounting plate. The second magnet and the fourth magnet are respectively located on both sides of the bottom of the reflector placement seat. The coaxial point light source is mounted between the lens and the second mounting plate. The surface light source is mounted at the bottom of the displacement stage connector.

[0012] Furthermore, the axes of the first magnet and the second magnet are on the same straight line, and the magnetic fields of the first magnet and the second magnet are in opposite directions. The axes of the third magnet and the fourth magnet are on the same straight line, and the magnetic fields of the third magnet and the fourth magnet are in opposite directions.

[0013] Furthermore, the angle between the axis of the reflector and the axis of the lens is an acute angle, the surface light source is placed at an angle to the displacement stage connector, and the normal of the light-emitting surface of the surface light source points to the end of the nozzle system.

[0014] Furthermore, the ranging system includes a first laser sensor, a first sensor fixing block, and a second sensor fixing block. The laser sensor is connected to the outer surface of the supporting vertical plate through the first sensor fixing block and the second sensor fixing block, which are parallel to each other. The first laser sensor is used to measure the distance between the nozzle system and the external substrate in real time.

[0015] Compared with the prior art, the beneficial effects of the present invention are reflected in:

[0016] 1. This invention integrates the printhead system, vision system, and distance measurement system into one unit, realizing the integration of multiple functions such as real-time printing observation feedback, curved surface positioning, and printing height calibration by machine vision. The overall structure is compact and improves printing accuracy.

[0017] 2. The preferred nozzle system of this invention integrates curved surface electrohydrodynamic printing and plasma surface treatment into one unit. It has a compact structure but does not interfere with each other in terms of functional conversion, and is easy to use.

[0018] 3. The preferred injection device of the present invention is equipped with an anti-backflow ink supply device, which can ensure that the ink will not flow back and the ink supply pressure is uniform when the intelligent printhead device is tilted or inverted during the curved surface electro-inking process.

[0019] 4. The vision system of this invention uses a sliding table to move the position of the reflector and a magnet to fix the reflector, realizing the function switching between real-time observation of the jet state and curved surface positioning, which improves the functional integration, optimizes the printing operation process, and improves printing efficiency. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the intelligent printhead device for conformal printing on complex curved surface circuit robots according to Embodiment 1 of the present invention;

[0021] Figure 2 This is an isometric view of the nozzle system in Embodiment 1 of the present invention;

[0022] Figure 3 This is a front view of the nozzle system in Embodiment 1 of the present invention;

[0023] Figure 4 This is an isometric view of the vision system in Embodiment 1 of the present invention;

[0024] Figure 5 This is a rear view of the vision system in Embodiment 1 of the present invention;

[0025] Figure 6 This is a schematic diagram of the working state of the camera in Embodiment 1 of the present invention when it is used for observation;

[0026] Figure 7 This is a front view of the ranging system in Embodiment 1 of the present invention;

[0027] Figure 8 This is a schematic diagram of the intelligent printhead device for conformal printing on complex curved surface circuit robots according to Embodiment 2 of the present invention;

[0028] Figure 9 This is a schematic diagram of the inkjet system of Embodiment 2 of the present invention;

[0029] Figure 10 This is a schematic diagram of the vision system in Embodiment 2 of the present invention;

[0030] Figure 11 This is a schematic diagram of the working state of the vision system in Embodiment 2 of the present invention when it uses a diffuse reflection optical path for observation;

[0031] Figure 12 This is a schematic diagram of the distance measuring system of Embodiment 2 of the present invention;

[0032] Figure 13 This is a schematic diagram of the working process of the intelligent printhead device for conformal printing of complex curved surface circuit robots according to Embodiment 2 of the present invention.

[0033] In all the accompanying drawings, the same reference numerals are used to denote the same elements or structures, wherein:

[0034] 1-First main connector, 2-First printhead system, 3-First vision system, 4-First ranging system, 5-Second main connector, 6-Second printhead system, 7-Second vision system, 8-Second ranging system, 201-XY axis displacement stage, 202-XY axis locking component, 203-Z axis displacement stage, 204-Z axis locking component, 205-Displacement stage connector, 206-Instrument, 207-Instrument holder, 208-Snap fastener, 209-First anti-backflow ink supply device, 210-Electro-jet printing nozzle, 211-Plasma coaxial printhead, 301-Industrial camera, 302-Lens, 303-Lens holder, 304-Reflector holder, 305-First reflector, 306-Slide stage, 307-First magnet, 308-Second magnet, 309-Third magnet, 310-The Four magnets, 311-coaxial point light source, 312-area light source, 401-first laser sensor, 402-first sensor fixing block, 403-second sensor fixing block, 601-ink storage tube, 602-second anti-backflow ink supply device, 603-adapter, 604-nozzle tip, 605-ink storage tube slot, 611-ink supply channel, 612-air supply channel, 613-Luer connector, 701-camera, 702-telecentric lens, 703-second reflector, 704-second lens frame, 705-strip light source, 706-light source connector, 710-fifth magnet, 711-sixth magnet, 712-seventh magnet, 713-eighth magnet, 714-ninth magnet, 801-second laser sensor, 802-third sensor fixing block, 803-fourth sensor fixing block. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0036] Example 1

[0037] like Figure 1 This is a schematic diagram of the intelligent printhead device applicable to conformal printing of complex curved surface circuit robots according to the present invention. The intelligent printhead device has functions of curved surface electro-hydraulic printing, plasma surface treatment, real-time printing observation, curved surface positioning and printing height calibration. The intelligent printhead device includes: a first main connector 1, a first printhead system 2 integrating electro-hydraulic printing and plasma treatment functions, a first vision system 3 capable of switching between observation and positioning functions, and a first ranging system 4 for real-time monitoring and compensation of printing height. The first printhead system 2, the first vision system 3, and the first distance measuring system 4 are all placed on the first main connector 1. The first main connector 1 is machined with bosses, ear plates, grooves, and mounting holes, integrating the various systems into a whole. The first vision system 3 is divided into two parts and distributed on both sides of the first printhead system 2. The first printhead system 2 is the actuator of the intelligent printhead device to realize curved surface electronic manufacturing. The main function of the first vision system 3 is to realize real-time observation of the jet state during the electro-hydraulic inkjet printing process and to locate the curved surface printing position. The first distance measuring system 4 is set at the innermost end of the intelligent printhead device. The main function of the distance measuring system is to measure the distance from the intelligent printhead device to the curved substrate, i.e., the electro-ink printing height.

[0038] like Figure 2 , Figure 3In this invention, the first printhead system 2 includes an XY-axis displacement stage 201, an XY-axis locking component 202, a Z-axis displacement stage 203, a Z-axis locking component 204, a displacement stage connector 205, a syringe 206, a syringe holder 207, a snap fastener 208, a first anti-backflow ink supply device 209, an electro-inkjet nozzle 210, a plasma coaxial printhead 211, and an electro-spray sheath-assisted coaxial printhead 212. The XY-axis displacement stage 201 is placed on the first main connector 1. The XY-axis displacement stage 201 and the Z-axis displacement stage 203 are assembled together via the displacement stage connector 205. The XY-axis displacement stage 201 and the Z-axis displacement stage 203 are manually driven by a knob. Turning the knob can finely adjust the position of the electro-inkjet nozzle 210. The XY-axis locking component 202 is a three-dimensional structure composed of two L-shaped parts, with long slots at both ends. After the XY-axis displacement stage 201 is fine-tuned, screws are used to connect the XY-axis locking component 202 to the first main connecting component 1 and the displacement stage connecting component 205 through the long slots. This helps to lock the XY-axis displacement stage 201, increasing its rigidity and preventing it from shifting under load. The syringe holder 207 is installed on the slide of the Z-axis displacement stage 203. The Z-axis locking component 204 is fixedly connected to the syringe holder 207, and a long slot is opened on the other side. After the Z-axis displacement stage 203 is fine-tuned, the Z-axis locking component 204 is connected to the displacement stage connecting component 205 with screws. This helps to lock the Z-axis displacement stage 203, increasing its rigidity and preventing it from shifting under load. The syringe 206 is placed in the slot of the syringe holder 207. The syringe 206 is used to store electro-ink. The snap fastener 208 is placed on the syringe holder 207. The snap fastener 208 has a spring installed inside to provide pressure to fix the syringe 206. The first anti-backflow ink supply device 209 is connected to the syringe inlet. It contains an S-shaped flow channel to prevent ink from flowing back when the intelligent printhead is tilted or inverted. The inlet of the first anti-backflow ink supply device 209 is connected to a pressure sensor and an electro-proportional valve. The electro-proportional valve provides ink supply pressure, and the pressure sensor provides feedback on the ink supply pressure, which is then adjusted by the electro-proportional valve to ensure that the ink supply pressure remains uniform and stable. The electro-ink nozzle 210 is coaxially installed at the syringe outlet. The plasma coaxial printhead 211 is connected to the syringe holder 207. The plasma coaxial printhead 211 is coaxially placed outside the electro-ink nozzle 210. The plasma coaxial printhead 211 can work independently or synchronously with the electro-ink nozzle 210 to achieve pre- / post- / synchronous plasma processing functions. By disassembling and assembling the plasma coaxial nozzle 211 and the syringe holder 207 connector, the plasma coaxial nozzle 211 can be replaced with an electrospray sheath gas-assisted coaxial nozzle 212. The electrospray sheath gas-assisted nozzle is coaxially placed outside the electrospray nozzle 210 and works synchronously with the electrospray nozzle 210 to realize the sheath gas-assisted spraying function during the electrospraying process.

[0039] like Figure 4 , Figure 5The vision system of the present invention includes an industrial camera 301, a lens 302, a lens fixing component 303, a reflector placement seat 304, a reflector 305, a slide table 306, a first magnet 307, a second magnet 308, a third magnet 309, a fourth magnet 310, a coaxial point light source 311, and a surface light source 312. Industrial camera 301 is connected to the first main connector 1. The data interface of industrial camera 301 is connected to the controller, and its observed image signal is transmitted to the controller in real time. The controller is equipped with image processing software, which offers multiple options. The controller performs image processing and recognition on the observed image. Based on the printing resolution and the position of the printed pattern relative to the substrate reflected in the real-time observed image, and combined with the existing process parameter library, it calculates the current height and trajectory error of the printing system and generates position and height adjustment signals for several points at the next moment of the printing end. These signals are then fed back to the robot's end-effector to adjust the trajectory of several points in the printing system at the next moment. This process is repeated multiple times during printing to ensure printing accuracy and reliability. One end of lens 302 is connected to industrial camera 301, and the other end of lens 302 is connected to the first main connector 1 via a lens fixing component. The lens is fixed in place by a lens mounting bracket 303. The two mounting surfaces of the slide 306 are connected to the first main connector 1 and the reflector mount 304, respectively. The reflector 305 is mounted on the reflector mount 304. The reflector 305 is a front-coated reflector, which is used to eliminate ghosting during reflection and improve clarity. The slide 306 can move the reflector 305. The first magnet 307 and the third magnet 309 are mounted on the first main connector 1, and the second magnet 308 and the fourth magnet 310 are mounted on the reflector mount 304. The coaxial point light source 311 is connected to the lens 302. The function of the coaxial point light source 311 is to provide light to the camera when the camera is used for positioning. The surface light source 312 is connected to the displacement stage connector 205. The function of the surface light source 312 is to provide light to the camera when the camera is used for observation.

[0040] The axes of the first magnet 307 and the second magnet 308 are collinear and their magnetic fields are in opposite directions, meaning they attract each other. Similarly, the axes of the third magnet 309 and the fourth magnet 310 are collinear and their magnetic fields are in opposite directions, meaning they attract each other. When the sliding table 306 moves, and the first magnet 307 and the second magnet 308 are attracted together, the reflector 305 is positioned below the lens 302, and the camera is used for observation. Its operating state is as follows: Figure 6As shown, the surface light source 312 emits light, which is reflected by the substrate, passes through the inkjet printing nozzle 210, and is then reflected by the mirror 305 before reaching the camera for imaging, thus enabling real-time observation of the printing process. When the third magnet 309 and the fourth magnet 310 are attracted together, the mirror 305 moves away from the lens 302, allowing the camera to be positioned. The coaxial point light source 311 provides light, which is emitted from the lens 302, reflected by the substrate, and returns to the lens 302. At this time, the camera observes the substrate surface, thus achieving positioning. Furthermore, the mirror 305 is tilted, and the angle between it and the axis of the lens 302 is acute, ensuring that the position of the inkjet printing nozzle observed by the camera is below the rest of the structure, preventing interference during printing. The surface light source 312 is tilted, with the normal of its emitting surface pointing towards the foremost tip of the inkjet printing nozzle 210, ensuring sufficient light for observation.

[0041] like Figure 7 The ranging system of the present invention includes a first laser sensor 401, a first sensor fixing block 402, and a second sensor fixing block 403. The first laser sensor 401 is connected to the first main connector 1 through the first sensor fixing block 402 and the second sensor fixing block 403. The function of the first laser sensor 401 is to measure the distance between the intelligent printhead device and the curved substrate, so as to realize the feedback correction of the printing height. The first sensor fixing block 402 and the second sensor fixing block 403 are used to fix the first laser sensor 401.

[0042] Example 2

[0043] like Figure 8 This is a schematic diagram of the intelligent printhead device for conformal printing on complex curved surface circuit robots according to the present invention. This intelligent printhead device is suitable for complex curved surface electro-hydraulic printing conditions with greater curvature and stricter interference requirements. The intelligent printhead device has functions of curved surface electro-hydraulic printing, plasma surface treatment, real-time printing observation, curved surface positioning, and printing height calibration. The intelligent printhead device includes: a second main connector 5, a second printhead system 6 integrating electro-hydraulic printing and plasma treatment functions, a second vision system 7 capable of switching between observation and positioning functions, and a second ranging system 8 for real-time monitoring and compensation of printing height. The second printhead system 6, the second vision system 7, and the second ranging system 8 are all placed on the second main connector 5, which is machined with bosses, ear plates, grooves, and mounting holes, integrating the various systems into a single unit. The second printhead system 6 is located on one side, and the second vision system 7 and the second ranging system 8 are located on the other side. The ink storage tube 601, the displacement stage 602, the second laser sensor 801, and the camera 701 are arranged in a square relative position. The main purpose of this arrangement is to reduce the spatial volume of the intelligent printhead device.

[0044] like Figure 9In this embodiment 2, the second printhead system 6 adopts an integrated ink and air supply design. The ink storage tube 601 is connected to the ink supply channel 611 and the air supply channel 612 on the main connector through the second anti-backflow ink supply device 602, continuously providing ink and air pressure to the ink storage tube 601. The ink supply channel can be connected to multiple ink input tubes to provide materials required for different electro-inking processes. The air supply channel 612 is connected to the Luer connector 613 to ensure airtightness. The ink supply channel 611 and the air supply channel 612 are connected to a pressure sensor and an electro-proportional valve. The electro-proportional valve provides ink supply pressure, and the pressure sensor provides feedback on the ink supply pressure, which is then adjusted by the electro-proportional valve to ensure that the ink supply pressure and air supply pressure remain uniform and stable. The second anti-backflow ink supply device 602, ink supply channel 611, and air supply channel 612 are all designed with S-shaped channels and anti-backflow latches. The latches can only be opened in one direction, preventing ink backflow when the intelligent printhead is tilted or inverted, ensuring that liquid and gas are input to the nozzle in one direction. The ink storage tube 601 is installed on the ink storage tube slot 605. The lower part of the ink storage tube slot 605 has a protruding positioning structure for preliminary spatial positioning of the adapter 603. The end of the ink storage tube 601 is connected to the adapter 603. The adapter 603 is an S-shaped or Z-shaped adapter with an ink flow channel inside. The lower end of the adapter 603 is connected to the nozzle tip 604 to adjust the position of the nozzle tip 604, reduce the relative distance between the nozzle tip 604 and the second laser sensor 801, further reduce the overall spatial size of the intelligent printhead and reduce the spatial interference caused by the second laser sensor 801 during complex curved surface electro-hydraulic printing.

[0045] like Figure 10 , Figure 11In this embodiment 2, the second vision system 7 uses a diffuse reflection optical path for real-time observation, feedback, and control of the electro-ink printing pattern. A strip light source 705, located below the ink reservoir 601 via an adjustable-angle rigid movable connector 706, provides illumination to the printing area. The rigid movable connector 706 adjusts the illumination angle and area of ​​the strip light source 705. The light from the strip light source 705 is diffusely reflected by the processed complex curved surface to a reflector 703, and then transmitted via mirror reflection to the telecentric lens 702 and camera 701, enabling real-time observation of the electro-ink printing pattern. The reflector 703 is fixed to the frame 704, and the fifth magnet 710, sixth magnet 711, and seventh magnet 712 are fixed to the second main connector 5. The eighth magnet 713 and ninth magnet 714 are fixed to the frame 704. The eighth magnet 713 attracts the fifth magnet 710, allowing the mirror frame 704 to be fixed with a single degree of freedom. The mirror frame 704 can rotate around the mounting hole of the magnet 710. The ninth magnet 714 can attract the sixth magnet 711 and the seventh magnet 712 respectively. When the mirror frame 704 rotates to the point where the ninth magnet 714 and the sixth magnet 711 attract each other, the reflector 703 is in normal working condition, and the second vision system 7 is in real-time observation mode. When the mirror frame 704 rotates to the point where the ninth magnet 714 and the seventh magnet 712 attract each other, the reflector 703 is in a flipped state, and the second vision system 7 is in positioning mode. The purpose of this is to achieve the switching between positioning and observation states of the second vision system 7, while reducing the spatial interference caused by the reflector 703 and further compacting the spatial size of the intelligent nozzle device.

[0046] like Figure 12 In this embodiment 2, the second ranging system 8 includes a second laser sensor 801, a third sensor fixing block 802, and a fourth sensor fixing block 803. The second laser sensor 801 is connected to the second main connector 5 through the third sensor fixing block 802 and the fourth sensor fixing block 803.

[0047] The workflow of the intelligent nozzle device in this application is as follows:

[0048] like Figure 13The diagram shown is a schematic of the workflow of the intelligent printhead device used for conformal printing on complex curved surface circuit robots in this embodiment. The intelligent printhead device is applied to the curved surface electro-hydraulic printing workflow, which includes complex curved surface 3D reconstruction, planar trajectory generation, curved surface trajectory conformal, printing trajectory planning, printing path optimization, and adaptive adjustment of the printing process. The intelligent printhead device is connected to the host computer through digital I / O signals, which can realize real-time signal transmission and feedback between the intelligent printhead device and the host computer. Complex surface 3D reconstruction converts the complex surface substrate to be printed into a digital 3D model, enabling trajectory planning for the printing pattern in a host computer. Planar trajectory generation initially generates a planar printing trajectory based on the features of the printing pattern. Surface trajectory conformal mapping initially conforms the planar printing trajectory generated in the previous step onto the complex surface substrate in the host computer, resulting in a rough printing trajectory. Printing trajectory planning converts the rough printing trajectory on the complex surface substrate into an actual printing trajectory with a certain printing height, based on the resolution requirements of the printing pattern. Printing path optimization, based on a point laser ranging system, can smooth the obtained rough printing trajectory and optimize the specific printing height to achieve trajectory refinement. Adaptive adjustment during the printing process is a real-time process optimization based on real-time image observation and feedback from a visual observation feedback system, which can further improve the accuracy and resolution of fluid inkjet printing on complex surfaces.

[0049] The complex surface 3D reconstruction stage involves digitally reconstructing the complex surface substrate. For complex surfaces with unknown digital models, the point laser ranging system described in this intelligent printhead device can be used to scan and reconstruct the point cloud of the complex surface substrate to be printed. By controlling the robot, the point laser ranging system performs a rough and complete scan on the surface of the complex surface substrate. Based on the relative distance of each point measured by the laser sensor and the spatial position of the laser sensor, the spatial position of the obtained point is obtained. By statistically analyzing the spatial relative positions of several points, the digital point cloud model of the complex surface can be obtained, realizing the 3D reconstruction of the complex surface with an unknown model. For complex surfaces with known digital models, the model can be directly imported into the host computer.

[0050] The planar trajectory generation stage involves initially generating a planar printing trajectory based on the printing pattern. According to the required printed electrical function pattern, and considering the pattern resolution and overall characteristics, appropriate starting and ending points, as well as intermediate printing paths, are selected to initially generate the planar printing trajectory.

[0051] The conformal path stage involves fitting a planar printing path onto the complex curved surface substrate to achieve conformal printing path. For developable complex curved surfaces, the substrate can be unfolded into sections and matched one-to-one with the planar printing pattern, thus directly fitting the planar printing path onto the complex surface to achieve conformal printing path. For non-developable complex curved surfaces, the surface can be divided into blocks, each section approximately unfolded into a plane, and then matched one-to-one with the planar printing pattern to achieve conformal printing path.

[0052] In the printing trajectory planning stage, the printing height is initially set according to the required printing pattern resolution. The obtained conformal printing trajectory that is attached to the curved surface is then re-set on the actual printing curved surface at a certain height from the curved surface. The normal distance between the actual printing curved surface and the corresponding point of the curved surface base is not equal everywhere. It is necessary to make regional actual adjustments according to the printing resolution. At the same time, it is also necessary to reasonably set the robot end transition trajectory between adjacent points at different printing heights to obtain a relatively rough actual printing trajectory.

[0053] The print path optimization stage addresses the height and pose errors in the relatively coarse actual print trajectory obtained in the previous step by further optimizing and adjusting the printing height and trajectory of the intelligent printhead device. The point laser ranging system is used to run once according to the actual print trajectory obtained in the previous step, obtaining the actual printing height and pose of each point on the trajectory. This data is transmitted to the host computer, which compares it with the set printing height and pose and outputs a feedback control signal to the intelligent printhead device to further optimize the print trajectory, resulting in a smoother, more precise print trajectory.

[0054] The adaptive adjustment stage of the printing process involves further optimizing the printing height and trajectory based on real-time observed printing quality. The observation system monitors the resolution and positional accuracy of the printed pattern in real time. The observed images are transmitted to a host computer image processing software, which performs image segmentation and feature recognition, outputting feature points. Combined with an existing printing process parameter library, a process adjustment feedback signal is obtained and output to the intelligent printhead device. This signal adjusts the height and orientation of the intelligent printhead device in real time during the printing process, further optimizing the resolution and positional accuracy of the printed pattern.

[0055] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An intelligent printhead device for conformal printing on complex curved surface circuit robots, characterized in that, include: The system comprises a main connector, a nozzle system, a vision system, a ranging system, and a controller. The nozzle system, vision system, and ranging system are all electrically connected to the controller. The main connector includes a mounting plane and a supporting vertical plate. The mounting plane is used to fix the intelligent nozzle device to the end of the robot. The horizontal ends of the supporting vertical plate are symmetrically connected to a first mounting vertical plate and a second mounting vertical plate, which are used to mount the nozzle system and the vision system, respectively. An arc-shaped groove for mounting the ranging system is provided on the inner wall of the supporting vertical plate. The ranging system is used to acquire distance data from the end of the nozzle system to the external substrate and upload the distance data to the controller. The vision system is used to acquire product surface image data on the external substrate in real time and upload the product surface image data to the controller. The controller is used to process the distance data and the product surface image data and control the distance between the end of the nozzle system and the external substrate. The nozzle system includes a displacement device and an injection device. The displacement device includes an XY-axis displacement stage, an XY-axis locking component, a Z-axis displacement stage, a Z-axis locking component, and a displacement stage connector. The XY-axis displacement stage is installed on the top of the first mounting vertical plate, and the Z-axis displacement stage is installed on the bottom of the first mounting vertical plate. The XY-axis displacement stage and the Z-axis displacement stage are assembled into one unit through the displacement stage connector. The vision system includes an industrial camera, a lens, a lens mount, a mirror mount, and a mirror. The industrial camera is mounted on the top of the second mounting plate, the data interface of the industrial camera is connected to the controller, the top of the lens is connected to the bottom of the industrial camera, the lens is connected to the second mounting plate through the lens mount, and the mirror is mounted on the bottom of the mirror mount. The vision system also includes a first magnet, a second magnet, a third magnet, a fourth magnet, a coaxial point light source, a surface light source, and a slide. The first magnet and the third magnet are installed side by side at the bottom of the second mounting plate. The second magnet and the fourth magnet are respectively located on both sides of the bottom of the reflector placement seat. The coaxial point light source is installed between the lens and the second mounting plate. The surface light source is installed at the bottom of the displacement stage connector. The two mounting surfaces of the slide are respectively connected to the main connector and the reflector placement seat. Moving the slide translates the reflector, realizing the function switching between real-time observation of the jet state and curved surface positioning.

2. The intelligent printhead device for conformal printing on complex curved surface circuit robots according to claim 1, characterized in that, The XY-axis locking component is a connector composed of two L-shaped fasteners. The XY-axis locking component connects the main connector and the displacement stage connector with screws through long slots at both ends. The Z-axis locking component has a long slot on one side and is connected to the displacement stage connector with screws. The Z-axis displacement stage is installed inside the first mounting vertical plate and has a slide protruding from the side wall of the first mounting vertical plate. The injection device is installed on the outer surface of the slide.

3. The intelligent printhead device for conformal printing on complex curved surface circuit robots according to claim 2, characterized in that, The injection device includes a syringe, a syringe holder, a snap fastener, an anti-backflow ink supply device, an electro-inkjet nozzle, and a plasma coaxial printhead. The Z-axis locking member is fixedly connected to the syringe holder. The syringe is placed in the slot of the syringe holder. The snap fastener is placed on the syringe holder and contacts the syringe. The anti-backflow ink supply device is connected to the inlet above the syringe. The electro-inkjet nozzle is placed at the syringe outlet. The plasma coaxial printhead is coaxially placed around the electro-inkjet nozzle and connected to the syringe holder.

4. The intelligent printhead device for conformal printing on complex curved surface circuit robots according to claim 1, characterized in that, The axes of the first and second magnets are on the same straight line, and the magnetic fields of the first and second magnets are in opposite directions. The axes of the third and fourth magnets are on the same straight line, and the magnetic fields of the third and fourth magnets are in opposite directions.

5. The intelligent printhead device for conformal printing on complex curved surface circuit robots according to claim 1, characterized in that, The angle between the axis of the reflector and the axis of the lens is an acute angle. The surface light source is placed at an angle to the displacement stage connector, and the normal of the light-emitting surface of the surface light source points to the end of the nozzle system.

6. The intelligent printhead device for conformal printing on complex curved surface circuit robots according to claim 1, characterized in that, The ranging system includes a first laser sensor, a first sensor fixing block, and a second sensor fixing block. The laser sensor is connected to the outer surface of the supporting vertical plate through the first sensor fixing block and the second sensor fixing block, which are parallel to each other. The first laser sensor is used to measure the distance between the nozzle system and the external substrate in real time.

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