Multi-Printhead End Effector for Single-Pass Printing on Complex Surfaces
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Solution Overview
Problem
Conventional methods for applying colorful images to surfaces, such as paint or ink application, are time-consuming and labor-intensive, especially on complex surfaces requiring masking operations and multiple layers, which are inefficient and resource-intensive.
Innovation Solution
An end effector with multiple parallel printheads and adjustable slice assemblies, featuring y- and z-actuators, allows for simultaneous multi-color printing on complex surfaces with obstructions and varying geometries, utilizing a manipulator for precise positioning and maneuverability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional brush or aerosol spray methods are used to apply paint or ink, then the image can be applied to the surface, but the process is time-consuming and labor-intensive requiring multiple steps and masking operations
Solution Approach 1:
The end effector is divided into multiple independent slice assemblies, each with its own printhead capable of applying different colors simultaneously. This segmentation allows parallel processing of multiple color layers in a single pass, eliminating the need for sequential masking and repainting operations.
Solution Approach 2:
Multiple printheads are combined into a single end effector assembly that can apply multiple colors simultaneously to different regions of the surface. This merging of multiple printing functions into one device enables single-pass multi-color imaging, dramatically reducing the time required compared to conventional sequential methods.
2Manufacturing precision
If masking operations are performed on complex surfaces, then the image can be applied accurately, but the process requires significant time and resources
Solution Approach 1:
Each slice assembly is equipped with independent y-actuators and z-actuators that allow dynamic adjustment of the printhead position and orientation. This dynamic capability enables the system to adapt to complex surface geometries without requiring static masking operations, maintaining precision while eliminating time-consuming setup procedures.
Solution Approach 2:
The system changes the parameters of the printing process by enabling independent control of multiple printheads' positions, angles, and printing speeds. This allows precise image application on complex surfaces through computational control rather than physical masking, significantly reducing preparation time.
3Manufacturing precision
If multiple successively applied paint layers are used, then the complete image can be applied, but the process is labor intensive and time consuming
Solution Approach 1:
The end effector segments the painting task across multiple independent slice assemblies, each responsible for a specific color. This segmentation allows simultaneous execution of multiple painting operations by different operators or automated systems, reducing labor intensity while maintaining image quality.
Solution Approach 2:
The system enables continuous multi-color painting operation where multiple printheads apply their respective colors simultaneously in a single continuous pass. This eliminates the interruptions and sequential steps required in conventional methods, reducing overall labor time while maintaining precise multi-color image quality.
4Area of stationary object
If conventional painting methods are used on large areas with contoured surfaces, then the surface can be painted, but a significant amount of time and resources are required
Solution Approach 1:
Multiple slice assemblies are merged into a single end effector that can cover large surface areas in one pass. Each slice assembly contributes to covering different regions of the surface simultaneously, enabling rapid painting of large areas including contoured surfaces without the time required for conventional sequential painting methods.
Solution Approach 2:
The system adds spatial dimensionality to the painting process by deploying multiple printheads at different positions and orientations. This multi-dimensional arrangement enables simultaneous coverage of large surface areas and contoured geometries, dramatically reducing the time required compared to conventional single-point painting methods.
Data Source
AI summary
An end effector and associated systems and methods for printing ink on a surface is disclosed. The end effector comprises a main block including a back plate. The end effector also includes a plurality of slice assemblies slidably coupled to the back plate. Each one of the plurality of slice assemblies includes a printhead and a y-actuator. The y-actuator is selectively operable to extend and retract the printhead, parallel to a y-axis in first directions, and relative to the back plate. The end effector further includes a plurality of z-actuators coupled to the back plate. Each one of the plurality of z-actuators is selectively operable to extend and retract a corresponding one of the plurality of slice assemblies, parallel to a z-axis in second directions, which is perpendicular to the y-axis and relative to the back plate.