Multi-Axis Multi-Printhead End Effector for Contoured Surfaces
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Solution Overview
Problem
Conventional methods for applying colorful visual images on surfaces, such as paint or ink, are time-consuming and labor-intensive, especially on complex surfaces requiring multiple masking operations and serial application of paint layers, which is inefficient and resource-intensive.
Innovation Solution
An end effector with multiple printheads that are translationally and rotationally movable relative to a primary and trailing block, allowing for adjustable printhead positions and configurations to accommodate complex surfaces, enabling efficient wide-area printing with minimal passes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional brush or aerosol spray methods are used to apply paint or ink, then the process can be performed with simple equipment, but the operation becomes time-consuming and labor-intensive requiring multiple serial steps
Solution Approach 1:
The end effector is divided into multiple independent printhead modules (first printhead, second printhead, third printhead, fourth printhead) that can be selectively positioned and operated. Each printhead module functions as an independent unit, allowing parallel application of multiple paint layers simultaneously, thereby increasing productivity while maintaining manageable complexity through modular design
Solution Approach 2:
The patent introduces multi-axis positioning capability for the printheads, allowing movement in translational dimensions (x, y, z axes) and rotational dimensions (pitch, roll, yaw). This dimensional expansion enables the printheads to access complex surface geometries and maintain optimal printing orientation, significantly improving productivity on contoured surfaces without requiring a completely new device architecture
2Productivity
If multiple successively applied paint layers are used to create colorful visual images, then the desired visual effect can be achieved, but the process requires multiple serial steps increasing time and labor
Solution Approach 1:
The system performs preliminary positioning and orientation of multiple printhead modules before actual paint application. The end effector pre-configures the spatial arrangement and angular orientation of each printhead relative to the target surface, enabling complex multi-layer images to be applied in a single pass without requiring sequential masking and painting operations
Solution Approach 2:
Multiple printhead modules are combined into a single end effector assembly that can simultaneously apply different paint layers to different regions of the target surface. This merging of multiple painting functions into one integrated system eliminates the need for separate serial painting operations and reduces the complexity of coordinating multiple masking operations
3Productivity
If masking operations are performed on complex surfaces, then the desired image can be applied, but the process becomes difficult and time-consuming
Solution Approach 1:
The patent replaces complex mechanical masking operations with a positioning-based approach. Instead of physically masking surfaces and then painting, the system uses programmable positioning of printhead modules to selectively deposit paint only in desired locations. This substitution eliminates the time-consuming masking steps while the positioning system manages the complexity of accessing contoured surfaces
Solution Approach 2:
The end effector incorporates dynamic positioning capability where the printhead modules can be independently moved and oriented in real-time during the painting operation. This dynamic adjustment allows the system to adapt to complex surface geometries and maintain optimal printing conditions without requiring rigid pre-configured masking setups, thereby increasing surface coverage rate
Data Source
AI summary
An end effector for printing ink on a surface is disclosed. The end effector comprises a primary block comprises a primary-block body. A plurality of primary-printing modules are coupled to the primary-block body and translationally moveable, via a corresponding first actuator. Each one of the primary-printing modules includes at least one printhead which is adjustable, relative to the primary-block body. The printhead may be adjusted by at least one of a second actuator, configured to rotate the printhead about a first axis, or a third actuator, configured to rotate the printhead about a second axis. In some examples, a fourth actuator is configured to rotate at least one printhead, relative to at least one other printhead, about a third axis. Additionally, at least one trailing block can be coupled to the primary block so that the at least one trailing block is movable relative to the primary block.