Metrology-Based Inkjet Path Planning for Contoured Surfaces
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Solution Overview
Problem
The existing surface treatment processes for complex contoured surfaces, such as those found on aircraft, are time-consuming and resource-intensive due to the need for serial masking and painting operations, which are inefficient for large areas with varying geometries.
Innovation Solution
A method and system that utilize a metrology system to collect data and generate a three-dimensional point cloud model of the contoured surface, allowing for the definition of a print path for a surface treatment assembly, including discretization of the surface into regions and verification of a control plan through simulation, enabling precise and automated printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional masking and painting operations are used for coating large contoured surfaces, then complete surface coverage is achieved, but the process requires significant time and resources
Solution Approach 1:
The patent replaces traditional mechanical masking and painting operations with an inkjet printing system that deposits coating material directly onto the contoured surface. The inkjet print head assembly, guided by a robot assembly, uses computer-controlled droplet deposition to apply coating without requiring physical masks or brushes, thereby eliminating the time-consuming masking operations while maintaining complete surface coverage
Solution Approach 2:
The patent utilizes a metrology system to capture the three-dimensional geometry of the contoured surface and transforms this spatial information into a digital model. This parameter transformation enables the system to adapt print head positioning, droplet placement, and deposition parameters dynamically to match the complex surface geometry, achieving efficient coating of large contoured areas
2Manufacturing precision
If multiple serial masking and painting operations are performed to achieve decorative livery, then precise color placement is achieved, but the process becomes extremely time-consuming
Solution Approach 1:
The patent divides the decorative livery application into multiple independent inkjet print heads, with each print head equipped with nozzles for different colors. This segmentation allows simultaneous deposition of multiple colors in a single pass rather than requiring sequential masking and painting operations, dramatically reducing time while maintaining precise color placement through digital control
Solution Approach 2:
The inkjet print head assembly is designed as a multi-functional device that can deposit multiple colors and potentially different coating materials through a single integrated system. The robot assembly and control system universally manage the positioning and operation of all print heads, enabling complex multi-color decorative liveries to be applied in one continuous operation rather than multiple serial steps
3Manufacturing precision
If automated robot assembly is used to position the inkjet print head, then printing precision on contoured surfaces is improved, but system complexity increases
Solution Approach 1:
The patent introduces a computer system as an intermediary that receives three-dimensional surface data from the metrology system, processes this information to generate a digital model, and then uses this model to control the robot assembly's positioning. This intermediary computational layer translates complex spatial relationships into precise robotic motion commands, achieving high print placement accuracy while keeping the physical robot system relatively simple
Solution Approach 2:
The patent creates a digital copy or replica of the physical contoured surface through the metrology system's three-dimensional scanning. This digital model serves as a virtual template that guides the robot assembly's movements and the inkjet print head's positioning, allowing precise printing on complex surfaces without requiring physically complex positioning mechanisms
Data Source
AI summary
A method of collecting a metrology data set of a contoured surface with a metrology system and executing an automatic control plan for printing on a contoured surface is disclosed. The method includes attaching a work piece to a work piece frame and scanning a contoured surface of the work piece to obtain a metrology data set, a three-dimensional point cloud model is generated based on the metrology data set. Additionally, the method includes defining a spatial reference model of the work piece frame, and defining a print path for a print head assembly of a surface treatment assembly. Furthermore, the method includes discretizing the contoured surface into a plurality of regions and the print path is further defined into at least one independent regional print path for each region of the plurality of regions. Moreover, a computer software simulation verifies a control plan for printing on the contoured surface.