3D Printing Robot Encoder Pattern Compensation

Solution Overview

Problem

Existing 3D printing systems face challenges in achieving high accuracy on curved surfaces due to structural vibrations and distortions in the initial encoder pattern, which propagate to the printed image, leading to inaccuracies.

Innovation Solution

Measuring and storing inertial data along with positional and orientational data during the encoder pattern capture run allows for compensation of distortions, enabling precise adjustment of the print head's position and orientation during printing to maintain image accuracy on curved surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the print head moves at high speed to improve productivity, then printing speed increases, but structural vibrations increase causing encoder pattern distortion

Engineering Contradiction:

Improveprinting speedVSAvoidencoder pattern accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs a preliminary encoder pattern capture run at low speed before the actual printing to establish a reference encoder pattern. This preliminary action allows the system to capture distortion information without the vibrations caused by high-speed printing, enabling subsequent compensation during high-speed operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses the captured encoder pattern information as feedback to adjust the print head positioning during printing. By comparing the actual encoder pattern deviations from the reference and using inertial measurement unit data, the system dynamically compensates for vibrations and maintains positioning accuracy even during high-speed printing operations.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If the print head moves at low speed to reduce vibrations, then encoder pattern accuracy improves, but printing time increases

Engineering Contradiction:

Improveencoder pattern accuracyVSAvoidprinting time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs a preliminary encoder pattern capture run at low speed before the actual printing to establish a reference encoder pattern. This preliminary action allows the system to capture distortion information without the vibrations caused by high-speed printing, enabling subsequent compensation during high-speed operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously captures encoder pattern information and inertial data throughout the printing process, using this continuous feedback to dynamically adjust positioning in real-time. This allows the system to maintain high precision during high-speed printing without requiring slow capture runs during the actual printing operation.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If the encoder pattern is applied directly without compensation, then the printing process is simple, but the printed image becomes distorted on curved surfaces

Engineering Contradiction:

Improveprinting process complexityVSAvoidprinted image accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system uses the captured encoder pattern information as feedback to adjust the print head positioning during printing. By comparing the actual encoder pattern deviations from the reference and using inertial measurement unit data, the system dynamically compensates for vibrations and maintains positioning accuracy even during high-speed printing operations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes the positioning parameters dynamically during printing based on the captured encoder pattern deviations and inertial data. By adjusting position and orientation parameters in real-time according to the measured distortions, the system compensates for the curved surface effects and maintains printing accuracy.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3927555B1System and method for high accuracy printing on a 3D surface

Publication Date: 2024.09.18 XYREC IP BV

Figure 1A
Figure 1B~1C
Figure 2A~2B

AI summary

A method and system for printing an image on a 3D surface is provided, wherein a printing robot is controlled to first carry out an encoder pattern capture run. During this run a print head of the robot is controlled to track an encoder pattern, which may be slightly distorted, on the 3D surface while inertial data from an inertial data measurement unit that is fixed to the print head is stored together with orientational and positional data derived from an image captured of a portion of the encoder pattern that is captured by a camera mounted on the printing head. Next, during a printing run, the print head is controlled such that the camera tracks the encoder pattern for a second time, while printing by the print head and/or a position of the print head is adjusted based on the inertial and orientational and positional data that were stored during the encoder pattern capture run.