Robot-Guided Inkjet Deposition for Closed-Loop Line Width Control
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Solution Overview
Problem
Current methods for inkjet deposition lack the ability to precisely regulate liquid material placement on substrates based on drop volume changes and fail to define trajectories over curved surfaces, leading to challenges in applications like printing on complex shapes and surfaces.
Innovation Solution
A dynamic model for line width control is developed, combining a model of line width as a function of parameters, a nonlinear estimator to determine uncertainties, and a nonlinear control law to regulate drop diameter, along with surface parametrization techniques to map 2D patterns onto 3D surfaces, ensuring precise ink placement and trajectory planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional inkjet deposition methods are used, then the system is simple to operate, but the line width control precision deteriorates when drop volume changes
Solution Approach 1:
The patent implements a closed-loop feedback control system where the actual line width is measured and compared to the desired line width, and the duty cycle is adjusted based on the error signal to achieve precise line width control despite variations in drop volume
Solution Approach 2:
The patent dynamically adjusts the duty cycle parameter based on measured line width feedback to compensate for drop volume variations, maintaining consistent line width control through parameter optimization
2Manufacturing precision
If position and velocity control techniques are used, then the placement regulation is improved, but the ability to adapt to drop volume changes deteriorates
Solution Approach 1:
The system uses feedback control where the actual line width measurement is fed back to adjust the duty cycle, enabling the system to adapt to drop volume changes while maintaining placement regulation accuracy
Solution Approach 2:
The control system dynamically adjusts the duty cycle in real-time based on feedback, making the system adaptable to varying drop volumes rather than relying on fixed position and velocity control parameters
3Speed
If feed-forward control is used, then the response speed is improved, but the precision under varying conditions deteriorates
Solution Approach 1:
The patent employs feedback control that measures actual line width and adjusts duty cycle accordingly, ensuring precision under varying conditions while maintaining acceptable response speed through continuous correction
4Stability of the object's composition
If meniscus control is used, then the line width stability is improved, but the adaptability to different surfaces and liquids deteriorates
Solution Approach 1:
The feedback control system measures actual line width and adjusts duty cycle to compensate for variations in liquid and surface properties, maintaining line width stability across different materials without requiring meniscus control
Solution Approach 2:
The duty cycle control approach provides a universal method that adapts to different liquids and surfaces through feedback, rather than requiring surface-specific meniscus control techniques
5Adaptability or versatility
If trajectory mapping on curved surfaces is attempted, then the application versatility is improved, but the trajectory accuracy deteriorates due to surface distortion
Solution Approach 1:
The patent applies local compensation by adjusting deposition parameters at each point along the trajectory based on local surface geometry and distortion characteristics, maintaining trajectory accuracy across curved surfaces
Solution Approach 2:
The system pre-calculates compensation factors for trajectory mapping based on surface geometry, applying corrective transformations before deposition to maintain accuracy on curved surfaces
6Measurement precision
If parameter estimation is performed, then the model accuracy is improved, but the computation time increases
Solution Approach 1:
The system estimates only the critical parameters needed for control (such as contact angle effects on line width) rather than performing complete parameter estimation, reducing computation time while maintaining sufficient accuracy for control purposes
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 solution provides robust, closed-loop regulation of printed line width and ensures accurate trajectory mapping on curved surfaces, achieving precise ink placement and pattern reproduction on complex 3D surfaces.
Implementation Method 1
Inkjet deposition (or inkjet printing) refers to multiple technologies to deposit liquids on a substrate
Implementation Method 2
the contact angle arising from chemical and physical properties of the liquid (e.g., ink) and surface (e.g., paper)
Data Source
AI summary
In an embodiment, a method for controlling a printer is provided. The method includes: receiving a set of parameters associated with a printer by a computing device, wherein the printer is depositing ink on a substrate to generate a line; measuring a width of the line by the computing device; receiving a duty cycle associated with the printer by the computing device; using the received duty cycle, the set of parameters, and a model, estimating one or more unknown parameters of the set of parameters by the computing device; receiving a desired width of the line by the computing device; and if the desired width is not the same as the measured width: adjusting the duty cycle associated with the printer based on the set of parameters and the model so that the measured width is closer to the desired width by the computing device.