Multi-Printhead End Effector With Adjustable Slice Assemblies
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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 with varied geometries, requiring multiple steps and masking operations.
Innovation Solution
An end effector with multiple parallel printheads and adjustable slice assemblies, each equipped with y- and z-actuators, allows for independent movement and positioning to print multiple colors in a single pass, accommodating complex surfaces with obstructions and angles.
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 steps
Solution Approach 1:
The end effector is segmented into multiple independent slice assemblies, each containing a printhead and actuator. This segmentation allows each printhead to be independently positioned and controlled, enabling parallel processing of multiple colors or regions simultaneously, thereby increasing productivity without requiring a completely complex monolithic system
Solution Approach 2:
The slice assemblies are nested within the end effector structure, with each assembly containing nested components (printhead, y-actuator, z-actuator). This nested arrangement allows compact integration of multiple functional elements within a unified tool, achieving high productivity while managing device complexity through modular nesting
2Productivity
If multiple successively applied paint layers are used to create colorful images, then the image can be applied using simple equipment, but the process requires multiple serial steps increasing time and labor
Solution Approach 1:
Multiple printheads capable of applying different colors are merged into a single end effector tool. This allows multiple paint layers to be applied simultaneously in parallel rather than sequentially, dramatically reducing the time required for multi-color image application while maintaining the simplicity of a single tool operation
Solution Approach 2:
The end effector is pre-configured with multiple printheads positioned and calibrated before operation. This preliminary setup allows the system to immediately apply multiple colors in parallel during operation, eliminating the need for sequential layering and reducing overall process time
3Manufacturing precision
If masking operations are used to apply paint on complex surfaces, then the paint application can be controlled, but the process becomes complex and time-consuming requiring serial repetition
Solution Approach 1:
The mechanical masking system is replaced with a controlled multi-printhead system that can selectively deposit different colors at precise locations. This substitution eliminates the need for physical masking operations while maintaining or improving paint application precision through electronic control of each printhead's position and operation
Solution Approach 2:
The system controls paint application precision by dynamically adjusting parameters such as printhead position (y and z coordinates), ink flow rate, and deposition speed rather than relying on fixed masking physical barriers. This parameter-based control reduces process complexity while maintaining precision
4Productivity
If conventional painting methods are used on large areas with contoured surfaces, then the process can be performed with simple equipment, but it requires significant time and resources
Solution Approach 1:
The end effector is designed as a universal tool that can handle multiple functions (applying different colors, accessing various surface contours) through its multiple slice assemblies with independent positioning capability. This multi-functionality allows a single tool to efficiently cover large areas with complex geometries without requiring multiple specialized tools or operations, maintaining ease of operation while significantly improving productivity
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.