Reconfigurable Gantry System for Complex Surface Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing industrial gantry systems are limited in their ability to achieve high print accuracy on complex surfaces with non-horizontal features and projections, as they typically restrict access to small surface areas and do not allow for precise positioning on non-flat surfaces, leading to issues with print overlap.
Innovation Solution
A multi-axis gantry system with a reconfigurable frame and vacuum attachment points, allowing the system to be mounted on different work surfaces and featuring a carriage and bridge mechanism with pucks that can be repositioned for secure vacuum attachment, enabling precise positioning and printing on complex surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If existing industrial gantry apparatus are used with tall and large structure, then they can cover large work surfaces, but they cannot access small surface print areas created by changes in elevation or surface features
Solution Approach 1:
The gantry system is divided into modular components including a bridge structure with multiple carriages that can independently position end effectors. This segmentation allows the system to access small surface areas while maintaining large work surface coverage through coordinated movement of modular units.
Solution Approach 2:
The system incorporates multi-axis movement capabilities with carriages that can position end effectors in three-dimensional space, allowing access to non-horizontal surfaces and areas with elevation changes by moving beyond the traditional planar gantry configuration.
2Stability of the object's composition
If existing gantry apparatus are designed for broad flat panel work zones, then they provide stable mounting, but they do not allow printing access to non-horizontal surfaces
Solution Approach 1:
The system employs dynamically positionable end effectors mounted on carriages that can move along the bridge structure, enabling the end effectors to reach non-horizontal surfaces while the main gantry structure remains stable and fixed during operation.
Solution Approach 2:
The system changes operational parameters by allowing end effectors to operate at varying positions and orientations along the bridge, adapting to non-horizontal surfaces while the main structure maintains its stable configuration.
3Ease of manufacture
If existing gantry apparatus are used without reconfigurable features, then they simplify manufacturing, but they cannot be repositioned for different work surface geometries
Solution Approach 1:
The system uses modular, segmented components that can be independently positioned and configured for different work surface geometries, maintaining manufacturing simplicity through standardized modular units while enabling repositioning flexibility.
4Device complexity
If existing gantry apparatus are used without precise positioning mechanisms, then they reduce system complexity, but they cause excess print overlap at borders
Solution Approach 1:
The system incorporates feedback mechanisms through controllers that monitor and adjust the position of carriages and end effectors, ensuring precise print positioning at borders while managing system complexity through automated control.
Solution Approach 2:
The system replaces complex mechanical positioning mechanisms with automated control systems that use sensors and controllers to achieve precise positioning, reducing mechanical complexity while maintaining or improving print accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides enhanced print accuracy and access to non-horizontal surfaces by allowing reconfiguration for various work surface geometries, reducing print overlap and improving positioning flexibility.
Implementation Method 1
The vacuum system includes a vacuum controller, a first vacuum source and a second vacuum source. The vacuum controller is configured to activate or deactivate the generation of vacuum by the first vacuum source and the second vacuum source.
Implementation Method 2
Each vacuum attachment point in the first plurality and in the second plurality comprise an aperture pattern. The first plurality of pucks is releasably coupled to the first rail, wherein a first puck of the first plurality of pucks is disposed on a first vacuum attachment point
Data Source
AI summary
A multi-axis gantry system comprising a multi-axis gantry apparatus and vacuum system, and method for repositioning is disclosed. The multi-axis gantry system comprises a frame. The frame includes a plurality of curved base members, a first rail, a second rail, a bridge slidably moveable along the first rail and the second rail, a carriage including an end effector, and a first plurality of pucks and a second plurality of pucks. The vacuum system comprises a vacuum controller, a first vacuum source and a second vacuum source. Each of the first and second vacuum sources is in fluid communication with one or more pucks of the first and second pluralities of pucks. The frame is reconfigurable from a first configuration mountable on a first work surface to a second configuration mountable on a second work surface that may be different from the first work surface.