Multi-Printhead End Effector for Contoured Surface Printing
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Solution Overview
Problem
Conventional methods for applying colorful visual images on surfaces, such as aircraft, are time-consuming and labor-intensive, requiring multiple steps and masking operations, especially on complex surfaces with varied contours.
Innovation Solution
An end effector with multiple printheads and actuators that allow for wide-area printing on complex surfaces by adjusting printheads through multiple axes of movement, enabling a single pass over contoured surfaces while maintaining distance from the surface and avoiding collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional brush or aerosol spray methods are used to apply images, then the application process is simple in terms of equipment, but the process becomes time-consuming and labor intensive requiring multiple steps and masking operations
Solution Approach 1:
The patent replaces conventional mechanical painting methods (brushes, aerosol sprays, masking operations) with a digital printing system that uses printheads to deposit ink or paint directly onto the surface. The printing system is controlled by a computing device that processes images and controls the movement and operation of multiple printheads, eliminating the need for manual masking and multiple painting steps.
Solution Approach 2:
The patent combines multiple printheads (at least two, potentially three or more) into a single integrated printing system that can apply multiple colors or layers simultaneously in one pass. This merging of multiple printing functions into one coordinated system eliminates the need for sequential masking and repainting operations that would be required with conventional methods.
2Manufacturing precision
If masking operations are performed to apply images on complex surfaces, then the painting can be applied accurately, but the process requires serial repetition of masking and painting operations
Solution Approach 1:
The patent employs a manipulator system with multiple degrees of freedom that can dynamically adjust the position, orientation, and movement of the printheads to follow complex surface contours. The system includes movable platforms and articulated arms that can adapt in real-time to maintain optimal printing conditions on three-dimensional surfaces, replacing static masking operations with dynamic positional control.
Solution Approach 2:
The system incorporates sensors and control systems that provide feedback to the computing device about the position of the printheads relative to the surface being printed. This feedback loop allows the system to automatically adjust for surface variations and maintain precise image application without requiring manual masking, thereby improving both accuracy and productivity.
3Area of stationary object
If multiple printheads are used to cover wide areas, then the printing coverage area increases, but the device complexity increases with multiple actuators and coordination systems
Solution Approach 1:
The manipulator system and control architecture are designed to be universal and multi-functional, capable of coordinating multiple printheads through a single integrated control system. The computing device can manage the operation of multiple printheads, their positioning, and their coordination patterns, allowing the same system hardware to handle different printing configurations and surface types without requiring separate specialized systems for each function.
Data Source
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AI summary
An end effector (100) for printing ink on a surface (302) is disclosed. The end effector comprises a primary block (102) comprises a primary-block body (114). A plurality of primary-printing modules (116) are coupled to the primary-block body and translationally moveable, via a corresponding first actuator (160). Each one of the primary-printing modules includes at least one printhead (118) which is adjustable, relative to the primary-block body. The printhead may be adjusted by at least one of a second actuator (172), configured to rotate the printhead about a first axis, or a third actuator (174), configured to rotate the printhead about a second axis. In some examples, a fourth actuator (176) 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 (104) can be coupled to the primary block so that the at least one trailing block is movable relative to the primary block.