WO2020171714A1 - Système d'impression et procédé d'impression sur des surfaces tridimensionnelles - Google Patents

Système d'impression et procédé d'impression sur des surfaces tridimensionnelles Download PDF

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Publication number
WO2020171714A1
WO2020171714A1 PCT/NL2020/050116 NL2020050116W WO2020171714A1 WO 2020171714 A1 WO2020171714 A1 WO 2020171714A1 NL 2020050116 W NL2020050116 W NL 2020050116W WO 2020171714 A1 WO2020171714 A1 WO 2020171714A1
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WO
WIPO (PCT)
Prior art keywords
printhead
ink
recirculation
pressure
robot arm
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/NL2020/050116
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English (en)
Inventor
Peter BOEIJINK
Christopher L. Lewis
Glynn R. Bartlett
Carl A. BARGAINER
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Xyrec Ip Bv
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Xyrec Ip Bv
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Publication date
Application filed by Xyrec Ip Bv filed Critical Xyrec Ip Bv
Publication of WO2020171714A1 publication Critical patent/WO2020171714A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J3/00—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed
    • B41J3/407—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
    • B41J3/4073—Printing on three-dimensional objects not being in sheet or web form, e.g. spherical or cubic objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/002—Machines or plants for applying coating liquids or other fluent materials by inkjet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B05B13/04—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
    • B05B13/0431—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with spray heads moved by robots or articulated arms, e.g. for applying liquid or other fluent material to three-dimensional [3D] surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B15/00—Details of spraying plant or spraying apparatus not otherwise provided for; Accessories
    • B05B15/50—Arrangements for cleaning; Arrangements for preventing deposits, drying-out or blockage; Arrangements for detecting improper discharge caused by the presence of foreign matter
    • B05B15/58—Arrangements for cleaning; Arrangements for preventing deposits, drying-out or blockage; Arrangements for detecting improper discharge caused by the presence of foreign matter preventing deposits, drying-out or blockage by recirculating the fluid to be sprayed from upstream of the discharge opening back to the supplying means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B9/00—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour
    • B05B9/03—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material
    • B05B9/04—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material with pressurised or compressible container; with pump
    • B05B9/0403—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material with pressurised or compressible container; with pump with pumps for liquids or other fluent material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B25J11/0075—Manipulators for painting or coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J5/00—Manipulators mounted on wheels or on carriages
    • B25J5/007—Manipulators mounted on wheels or on carriages mounted on wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Program-controlled manipulators
    • B25J9/02—Program-controlled manipulators characterised by movement of the arms, e.g. cartesian coordinate type
    • B25J9/04—Program-controlled manipulators characterised by movement of the arms, e.g. cartesian coordinate type by rotating at least one arm, excluding the head movement itself, e.g. cylindrical coordinate type or polar coordinate type
    • B25J9/041—Cylindrical coordinate type
    • B25J9/042—Cylindrical coordinate type comprising an articulated arm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
    • B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
    • B41J2/01—Ink jet
    • B41J2/17—Ink jet characterised by ink handling
    • B41J2/175—Ink supply systems ; Circuit parts therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
    • B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
    • B41J2/01—Ink jet
    • B41J2/17—Ink jet characterised by ink handling
    • B41J2/18—Ink recirculation systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B9/00—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour
    • B05B9/002—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour incorporating means for heating or cooling, e.g. the material to be sprayed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B9/00—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour
    • B05B9/007—At least a part of the apparatus, e.g. a container, being provided with means, e.g. wheels, for allowing its displacement relative to the ground

Definitions

  • the invention relates to a system and method for printing on a three-dimensional print surface, in particular to using a movable robot arm mounted on a movable support, a printhead supported on the robot arm and an ink supply device that is connected to the printhead via a fluid line for supplying ink to the printhead.
  • US 2016/0355026 describes a large robot system for printing on the hull or on the wings of an aircraft.
  • a robot arm moves the printhead, that may be configured as an inkjet printer, in overlapping swaths of varying intensity across the aircraft’s complex geometry.
  • the quality of the decoration and the process speed are key factors and a freely movable system needs to support these requirements in print resolution, process quality and consistency, coverage of the colour scheme, providing support for digital presented image input, speed of finishing the decoration of the object in m 2 per hour, as well as the capability to integrate the system in an automated support system like a 7-axis degree of freedom (DoF) robot mounted on a 3-axis DoF omni-directional wheels supported platform, to provide an autonomous solution.
  • DoF degree of freedom
  • the present invention seeks to present a system that manages the integrated complexity associated with facilitating electronic drop-on-demand printing with low viscosity printing inks on complex continuously contouring surfaces regardless of their orientation with respect to gravity. It is an object of the invention to provide a more rapid, high-quality and cost effect printing system than the known application of graphics on these types of shapes/surfaces and that comprise either a flat print being applied to the surface or a manual painting process which drives both cost and time, while requiring skilled labour.
  • the invention provides a system for printing on a three-dimensional print surface comprising:
  • an ink supply device that is connected to the printhead via a fluid line for supplying ink to the printhead
  • a positioning system connected to the support, the robot arm and to the printhead for measuring the position and orientation of the printhead
  • a compensation unit connected to the printhead for mechanically positioning the printhead in a defined position
  • control unit that is operationally connected to:
  • the positioning system for positioning the printhead in a predetermined print position
  • the ink supply device for controlling the flow of ink to the printhead depending on a printhead orientation
  • the compensation unit for compensation of vibrational motions and/or positional errors of the support and of the robot arm, and maintaining the printhead in a defined position.
  • the positioning system of the robot provides a real time position control of the movable support, the robot arm and the printhead, and may include transponders on the support, a real time camera on the robot arm and/or a laser triangulation unit at or near the printhead to track stand-off of the printhead from the printing surface.
  • the pressure of the ink that is supplied by the ink supply device to the printhead from a bulk storage tank, via the ink supply line, is controlled to result in a predetermined pressure at the printhead for each printhead orientation, as the printhead moves across the three dimensional print surface.
  • a calibration step in which a test pattern is printed at those printhead orientations that occur across the printing surface, the pressure values at each printhead orientation pertaining to the specific ink viscosity are recorded, and pressure curves for generating a substantially constant ink pressure at each printhead orientation may be stored in the control unit in the form of a formula or look-up tables.
  • vibrations in the robot arm or inaccuracies inherent in the robot manipulator are compensated by the controller according to the invention in real time on the basis of the positional data of the printhead, for instance by actuating x-y or z movements of the printhead, relative to the print surface.
  • the printhead is a printhead of the recirculating type.
  • ink is continuously circulated through the printhead, and a portion of the printhead that is not ejected through nozzles of the printhead may be recirculated back to the ink supply.
  • the ink supply device is mounted on the moveable support, at a distance of at least 1 m from the printhead.
  • the moveable support is provided with wheels and/ortracks for driving across a floor.
  • the moveable support also denoted mobile support, can thus be driven around the three dimensional object onto which the ink is to be deposited.
  • the moveable support is provided with omnidirectional wheels, such as Mecanum wheels.
  • the system comprises an inflow pressure sensor at or near an ink inlet of the printhead for measuring an inflow pressure of the ink, a recirculation pressure sensor for measuring a recirculation pressure at a recirculation outlet of the printhead, and wherein the controller is adapted for controlling the flow of ink from the ink supply device to the printhead depending on the inflow pressure and the recirculation pressure in a manner ensuring that a lowest of these pressures is above a predetermined lowest ink pressure operating value for operating the printhead.
  • the system can control the flow of ink to the printhead based on the printhead orientation, as well as on the inflow pressure and the recirculation pressure.
  • a rough estimate of the pressure in the printhead can be estimated, which estimate can be combined with more fine grained measured inflow and recirculation pressure to obtain a highly more accurate indication of the actual inflow and recirculation pressure.
  • Ensuring that the lowest of the pressures remains above the predetermined lowest ink pressure operating value is typically achieved by controlling a pump that is connected between the ink supply device and the printhead.
  • the system is preferably adapted for providing data regarding the pressures to the controller at least once every 10 ms, to ensure that the ink pressure in the printhead can be kept above the predetermined lowest in pressure value for operating the printhead.
  • the predetermined lowest ink pressure operating value for operating the printhead depends on the printhead and is generally provided by the printhead manufacturer. However, this value may be dependent on the ink that is used as well.
  • the controller is adapted for controlling the flow of ink from the ink supply device to the printhead depending on the inflow pressure and the recirculation pressure in a manner ensuring that a highest of these pressures is below a predetermined highest ink pressure operating value for operating the printhead for the ink used.
  • the inflow pressure sensor is arranged directly upstream from the printhead, and the recirculation pressure sensor is arranged directly downstream from the printhead.
  • the pressure sensors are located outside of the printhead, they are arranged sufficiently close to the printhead to measure an indication of the ink pressure in the printhead.
  • both pressure sensors are arranged within 10 cm from the interior of the printhead where ink is held.
  • the inflow pressure sensor may be arranged on one side of the printhead, and the recirculation pressure sensor may be arranged on another side of the printhead, preferably on an opposite side of the printhead. By spacing the sensors apart it is ensured that they can measure different ink pressures.
  • the ink supply device comprises a main ink supply and a pump for pumping ink from the main ink supply to the printhead. The pump generally is located together with the main ink supply on the moveable support.
  • one or more ink tanks are provided on the robot arm, and one or more corresponding pumps are provided between the further tank(s) and the printhead to supply ink to the printhead.
  • the one or more ink tanks are preferably arranged within 1 m of the printhead, preferably within 10 cm thereof, but in any case closer, when seen along an ink flow path, than the main ink supply.
  • Each ink tank preferably is adapted for containing a volume of ink that is greater than the inner volume of the printhead for containing ink.
  • the system further comprises one or more ink tanks provided on the robot arm downstream of the main ink supply and pump, and one or more corresponding pumps provided on the robot arm between the one or more ink tanks and the printhead to supply ink to the printhead, preferably wherein the one or more ink tanks are preferably arranged within 3m of the printhead and closer to the printhead, when seen along an ink flow path, than the main ink supply is.
  • two or more of said corresponding pumps are provided on the robot arm, one of which is arranged for circulating ink from the ink supply through the refill channel, and another of which is arranged for circulating ink from the ink supply through the recirculation channel.
  • the printhead comprises an internal refill channel and an internal recirculation channel, and further comprises a first ink inlet and a first ink recirculation outlet, wherein the system is adapted in such a manner that, during use, ink is supplied to printhead only through the first ink inlet and ink is returned to the ink supply only through the first ink recirculation outlet.
  • the rate of flow of ink through the internal recirculation channel is at least 7 times greater than the rate of flow of ink through the internal refill channel.
  • the printhead comprises an internal refill channel and an internal recirculation channel, and the printhead further comprises:
  • system is adapted in such a manner that, during use, ink is supplied to printhead through both the first ink inlet and the second inlet, and ink is returned to the ink supply through both the first ink recirculation outlet and the second ink recirculation outlet.
  • the rate of flow of ink to the refill channel is preferably within 25% of the rate of flow of ink to the recirculation channel. For instance, if the rate of ink flow to the refill channel is 10 ml / sec, then the rate of ink flow to the recirculation channel is between 7,5 and 12,5 ml / sec.
  • the pump is arranged for circulating ink from the ink supply through the refill channel, and the system further comprises a second pump for circulating ink from the ink supply through the recirculation channel.
  • the printhead is provided with one or more dampers at an ink inlet side of the printhead, for reducing shock waves of ink in the printhead due to acceleration of the printhead relative to the print surface.
  • the printhead is of the recirculation type
  • the printhead is provided with one or more dampers at an ink recirculation outlet side of the printhead for reducing shock waves of ink in the printhead due to acceleration of the printhead relative to the print surface.
  • system further comprises a temperature sensor arranged for measuring a temperature of the ink at the printhead, and a temperature conditioning system adapted for conditioning the temperature of ink that is supplied to the printhead to a predetermined temperature range.
  • the predetermined temperature range will generally depend on the type of ink used as well as the type of printhead that is used.
  • the system is adapted for printing on a substantially stationary 3D surface while moving the printhead relative to the stationary 3D surface.
  • the surface on which a pattern is to be printed can remain stationary, e.g. relative to the floor, while the robot arm is moved relative to the floor in three dimensions.
  • the compensating system of the present invention is particularly effective on a large robot according to the invention that may be used for printing on large objects, such as vehicles, for instance airplanes.
  • a large robot may comprise a vertical arm of a height of at least 10 m, preferably about 13 m and a transverse arm that is displaceable along the vertical arm in a vertical direction and in a transverse direction, the transverse arm having a length of at least 5 m, preferably about 13 m, the printhead being situated at the end of the transverse arm.
  • the printhead comprises an array of an inkjet nozzles
  • the ink supply device comprising an inflow pressure sensor and a recirculation pressure sensor at or near the nozzles for measuring an inflow pressure at an inflow end that is situated upstream of the array of nozzles and a recirculation pressure at an outflow end that is situated downstream of the array of nozzles
  • the controller operating the ink supply device and pressurises the ink in dependence on the orientation of the printhead.
  • the ink supply system may for instance be a low flow recirculation supply system of the type LC-LFR as available from the company Megnajet, Northamptonshire, United Kingdom.
  • An embodiment of the system according to the present invention can support either 4, 6 or 7 colour schemes.
  • 6 colour scheme YMCK + Green + Orange
  • more than 90% of the Pantone colour definition can be printed on a white background.
  • the white background can be created or further improved to realize a predefined colour quality, or used for print correction of an certain area by first printing white ink on top of the print error and then reprinting this area.
  • the system according to the invention will print digitally presented images that are presented as input.
  • a standard interface is provided for input of a digital image to print by the system.
  • the input image supports the print resolution and the scaling of the image.
  • the system is optimised to handle the relatively large amount of data of large pictures, the decomposition towards each colour, and the realtime process of supplying data to the print system in relationship to the print swaths.
  • the speed of finishing the decoration of the object in m 2 per hour can be optimized for the minimum total around time for the object.
  • the system according to the invention may be provided with a bidirectional print function to limit the automation path reorientation for each printing swath and increasing the performance.
  • the present invention provides a method for printing on a stationary three dimensional surface using a mobile robot, wherein the mobile robot comprises a moveable support, a robot arm moveably mounted on said moveable support, a printhead supported on the robot arm, and an ink supply device connected to the printhead via a fluid line, the method comprising:
  • controlling the printhead to move in order to compensate for vibrational motions and/or positional errors of the support and of the robot arm, based on the measured orientations and positions;
  • the printhead is a printhead of the recirculation type and the method further comprises measuring an recirculation pressure of the ink directly downstream of the printhead, and controlling the flow of ink from the ink supply device to the printhead depending on the recirculation pressure in a manner ensuring that the recirculation pressure is below a predetermined highest ink pressure operating value for operating the printhead.
  • said controlling of the flow of ink from the ink supply to the printhead is carried out while the printhead prints a pattern on the three dimensional surface and/or while the printhead is moved relative to the three dimensional surface.
  • the method is carried out using the system of the present invention, with the moveable support, the moveable robot arm, and the ink supply device of the robot used in the method corresponding to the moveable support, the moveable robot arm, and the ink supply device of the system of the invention.
  • the mobile robot has a height of at least 10 m and a transverse arm that is displaceable along the vertical arm in a vertical direction and in a transverse direction, the transverse arm having a length of at least 5 m, the printhead being situated at the end of the transverse arm.
  • Fig. 1 shows the schematic lay-out of the printing system according to the invention
  • Fig. 2 shows a large autonomously moving robot for use in a printing system according to the invention
  • Figs 3A - 3C shows a schematic embodiment of different printheads suitable for use in the system of the invention
  • Fig. 3D shows a schematic bottom side view of these printheads
  • Figs. 4A, 4B and 4C schematically illustrate different flow circuits for ink, as may be used in the present invention.
  • Fig. 1 shows a schematic representation of a printing system 1 , comprising a movable robot 2.
  • the robot 2 has a moveable, i.e. mobile, support 3, carrying a vertical mast 4 of a height of 13 m along which a carriage 5 can travel up and down.
  • the carriage 5 supports a transverse arm 6 of a length of 13 m that is movable in a transverse direction.
  • a printhead 8 is supported.
  • the printhead 8 is mounted on an x,y,z stage 10 for displacement relative to a three-dimensional print surface, in an x,y plane that is parallel to the print surface and in a z direction that is perpendicular to the print surface.
  • a suitable robot for supporting the printhead 8 is described in US patent application nos.
  • Fig. 8 shows an inertia measurement unit (IMU) 8a that is fixed to the printhead 8, for measuring an orientation of the printhead in particular with respect to the direction of gravity.
  • the carriage 5 and mast 4 are provided with encoders 5a and 4a, respectively for keeping track of a translation and rotation of arm 6 relative to the mast 4, and for keeping track of a translation about a vertical axis of the mast relative to the support 3.
  • the printhead 8 may be formed by an ink jet printer of type Fujifilm Dimatix Part Number SG1024LA-2C.and is connected by fluid lines 1 1 to an ink supply unit 12 for supply of ink to the printhead 8.
  • the ink supply unit 12 may comprise a low flow recirculation pump system, available from Megnajet, Northamptonshire, United Kingdom.
  • a print controller 13 is connected to head drives 15 that operate the nozzles of the printhead 8 via a customised interface 9
  • the head drives 15 are shown in this embodiment to be connected to the printhead 8 via a connection 25 but can also be integrated in the printhead 8.
  • the print controller 13 decomposes the image that is to be printed and transforms the colour values of the pixels in the image into discrete voltages that are input to the printhead 8.
  • the image to be printed can be entered via a human-machine interface, such as a terminal 16, and is transmitted to the print controller 13 via Ethernet connection 14.
  • a positioning system comprises a position sensor 17 for real-life determination of the position of the printhead 8 relative to a print surface, such as by laser triangulation and/or camera’s.
  • the positioning system furthermore includes a displacement sensor 18 that may comprise an inertial measurement unit (IMU), optical sensors and/or transponders or RFID sensors for determining the robot position. It may also include transducers 19, 19’ situated on the linking segments of the movable robot parts and/or on the wheels of the support 3, for determining the position and orientation of the robot arms 4,6.
  • IMU inertial measurement unit
  • transponders 19, 19’ situated on the linking segments of the movable robot parts and/or on the wheels of the support 3, for determining the position and orientation of the robot arms 4,6.
  • a central control unit 20 comprises a robot operating system/print control unit 21 and a printhead position control unit 22, interconnected via an Ethernet connection 23.
  • the robot operating system 21 is connect to the robot 2 via an Ethernet connection 24 to communicate with the displacement sensor 18 and the transducers 19,19’ for controlling the position of the robot 1 .
  • the printhead position control unit 22 is connected to the ink supply unit 12 via a RS-485 connection 30, and is connected to the print controller 13 via a digital input/out 31 for controlling the pressures of the ink that is supplied to the printhead 8 via the ink supply unit 12.
  • the printhead position control unit 22 is connected to the position sensor 17 via signal line 32 and/or to the displacement sensor 18 (in the present embodiment shown as a wireless connection) for receiving position and orientation data for the printhead 8.
  • An EtherCat connection 33 connects the printhead position control unit 22 to the x,y,z stages of the printhead 8 for vibration control and positional corrections of the printhead 8.
  • a debug terminal 35 which may be combined with the input terminal 16, is connected to the printhead position control unit 22 by Ethernet connection 34.
  • the pressure control system 13 consists of a primary Pressure Control Unit that sets meniscus and recirculation pressures of the ink jet nozzles of the printhead 8, an off-board manifold that consists of solenoids and pressure sensors that are within 14 cm of the print face, and pressure reading and control software that responds to the pose or orientation of the printhead faces.
  • the pressure control system 13 comprises a computer program for the conversion data files to print signals.
  • the printhead position control unit 22 preferably is a real-time control system, wherein the position sensor 17 may comprise but is not limited to the a combination of one or more real-time cameras that acquire images at a minimum of 30 frames per second, and an inertial measurement unit, where the output data is combined in the control unit 22 to generate a state and position estimate of the robot 2 and the printhead 8 that can continuously enable the tracking of a reference feature.
  • This will also include the means to track stand-off of the print face from the printing surface via laser triangulation to maintain proper ink face stand-off.
  • the printhead position control unit 22 comprises a computer program for vision and real time tracking.
  • Stages and drives 10 form a compensation system that mitigates gross and small errors due to system vibration or inaccuracies inherent to traditional manipulator approaches. These stages may be mounted on the final axis to compensate for any variation experienced within the system to enable compensation based on read information from the real-time system 17, 22 actuating the stages in x, y, and, if required z relative to the print surface and direction. Encoder output from the robot encoders 19, 19’ may be utilised to control the position and orientation of the printhead 8.
  • Head drives 15 enable the communication of the decomposed image into the discrete voltages that need to be driven to the nozzles of the printhead 8.
  • the software known as“ripping” software decomposes a multi-colour image into its 4, 6 or 7 colour components depending on ink configuration, and provides the bits to the print driver that deliver the voltage signals to the discrete arrays of nozzles of the printhead 8 as dictated via the output of the rip software.
  • the robot operating system/print control unit 21 provides state and gross movement and manipulation of a printing end effector that is mounted to the end extent of a manipulator at the end of the transverse robot arm 6.
  • the robot operating system/print control unit 21 comprises a computer program for pressure control and machine state control.
  • a control computer 16, 35 is provided with an interface enabled for user control and set up, monitoring, and maintenance or trouble shooting of the process, as well as lower bandwidth process monitoring, in particularthe correlation ofthe orientation ofthe printhead 8 to adjust the pressure control system 13 to support the multi-orientation continuous curvature printing.
  • the control computer 16,35 comprises a computer program for image file processing.
  • the three dimensional printing system described above contains the stated parts that share information in a logical fashion and work cooperatively.
  • the system is not limited to the configuration that has been specifically disclosed including separate real-time vision based control hardware 22 for the real-time vision control, with separate lower bandwidth separate PC 21 for pressure control. Variations are intended to be merged onto one central computational processing unit where a large number of different types of sensors and cameras may be leveraged that offer additional advantages relative to resolution, frame rate, and performance.
  • Robot 2 gross move to new location; Robot 2 signals Move Complete and Ready to Spit to robot operating system/print control unit 22 /VCB; Robot 2 waits to move.
  • Control unit 22 gets Robot position, calculates ink pressures, controls and verifies ink supply unit 12 (LC-LFR); Control unit 22 signals Spit to terminal/ HMI 16 (via pressure control system 13/PCC) (it should be noted that spit occurs between all macro moves).
  • Terminal/HMI 16 Spit signals Spit Complete to control unit 22/VCB (again, via pressure control system 13/PCC).
  • Control unit 22/VCB signals Ready to Move to Robot 2, activates Z-axis control.
  • Robot 2 moves to print standoff distance; Robot 2 signals Swath Print, Swath Direction, and Move Complete to Control unit 22 /VCB; Robot 2 waits to move.
  • Control unit 22/ VCB seeks index, initializes position sensor 17/IMU 18, stabilizes Y axis, estimates encoder (X), updates encoder output (TBD), signals Print Enable to terminal 16/ HMI, signals Ready to Move to Robot.
  • Robot 2 moves along swath; Control unit 22/VCB stabilizes & outputs encoder; printer prints a swath.
  • Robot 2 moves past final index; (Control unit 22/VCB encoder is digital pulse generated); Robot signals Swath Complete. 10. Swath Complete will be Swath Print set 1 to 0, or vice versa via digital I/O.
  • Control unit 22/VCB has error if encoder estimate is invalid.
  • Control unit 22/VCB signals Print Disable to terminal 16/HMI; disables Z control; withdraws Z.
  • Robot 2 Withdraws along Z (swath printing loop can end here).
  • top-level states may be applied to facilitate safety implementation and control of maintenance and debug processes:
  • Start up (may be a subset or a complete self-test & communication / system test)
  • the combination of all the components of the printing system according to the invention, and the way they interact provide a complex contour capable drop-on-demand or inkjet printing system.
  • the components may be interchanged but the function that they provide and the minimum performance that is executed, as well as how information is exchanged between the components provide a unique capability for complex graphic creation, irrespective of print surface orientation or gravity.
  • Figs. 3A, 3B and 3C each show a schematic embodiment of a printhead as may be mounted on a robot arm in the system of the invention
  • Fig. 3D shows a bottom side view a nozzle plate 301 as is used in each of these printheads.
  • ink is ejected through the nozzle plate 301 onto the surface to be printed.
  • Electrical signals for controlling printing by the printhead as well as electrical power for operating the printhead, are provided through signal and power cable 305.
  • the printhead 300 shown in Fig. 3A is of the recirculation type and includes an ink inlet 31 1 for receiving ink, and an ink recirculation outlet 331 for discharging ink to be recirculated.
  • an inflow pressure sensor 312 is provided directly upstream from the inlet of the printhead for measuring an pressure of the ink at a first side of the printhead.
  • a recirculation pressure sensor 332 is provided directly downstream from the outlet of printhead for measuring a pressure of the ink at a second side of the printhead, and the two sensors are arranged for measuring a pressure indicative of ink pressure at two different sides in the printhead.
  • respective dampers 313, 333 are provided, for damping sudden changes in ink pressure in the printhead that may be caused by changes in orientation and/or by acceleration of the robot arm relative to the moveable support.
  • an ink circuit comprising both a refill channel and a recirculation channel.
  • the printhead 300’ shown in Fig. 3B is also of the recirculation type, but in this case the printhead is provided with separate ink inlets 31 1 , 321 connected respectively to an internal refill channel of the printhead and an internal recirculation channel of the printhead. Likewise, separate ink recirculation outlets 331 , 341 are provided for recirculating ink back to the ink supply. Conduits 310, 320 connect respectively to the inlets 31 1 ,321 , and conduits 330, 340 connect respectively to outlets 331 ,341 .
  • a respective inflow pressure sensor 312, 312 is provided, and directly downstream of each of the outlets 331 ,341 a respective recirculation pressure sensor 332,342 is provided.
  • Dampers 313,323 and 333,344 are provided just upstream from the inflow pressure sensors, and just downstream from the recirculation pressure sensors.
  • Fig. 3C shows yet another printhead 300” as may be mounted on the robot arm ofthe invention, wherein the printhead is of the non-recirculating type having only a single ink inlet 31 1 , a single inflow ink pressure sensor 312, and a damper 313.
  • Fig. 3D shows a bottom view of the printheads of Figs. 3A, 3B and 3C.
  • the bottom of these printheads comprises a nozzle plate 301 .
  • the nozzle plate comprises a number of rows 302a, 302b, 302c, 302c of nozzles, each row containing at least 24 separate nozzle openings.
  • the different rows of nozzles can be used for depositing different colors of ink.
  • the first jet row 302a may deposit red ink, while the row 302b next deposits green and the next row 302c blue.
  • the image is formed when very small colored droplets are deposited so close to one another that they appear to cover the surface. It is important that the individual colored droplets do not contact one another, while still wet, to avoid the droplets from coalescing an forming an unintended color.
  • Figs. 4A, 4B and 4C schematically show how ink may flow through the system of the invention, when using a printhead of Fig. 3A, 3B or 3C respectively.
  • Fig. 4A shows a main ink supply 401 , a temperature control device 403 for conditioning ink from the main ink supply to a temperature within a predetermined temperature range, and a main pump 402 connected between the main ink supply 401 and the temperature control device.
  • the main ink supply 401 , the main pump 402 and the temperature control device 403 are located on the movable support of the system, e.g. the support 3 of Fig. 2.
  • the temperature control device is in fluid connection, via damper 410, with an ink tank 41 1 that is arranged on the robot arm and which acts as a buffer for storing ink close to printhead 440.
  • the distance between the main ink supply and the printhead will typically be more than 6 meters, and by placing buffer tank 411 on the robot arm, responsiveness of the system is improved, and in particular the flow of ink to the printhead, and thus the pressure of ink in the printhead, can be quickly adjusted be within a predetermined range of printhead ink pressure operating values.
  • a further pump 412 is arranged on the robot arm for pumping ink from the ink tank 41 1 , via damper 430 and inflow pressure sensor 440, into the printhead 450 that is mounted on the robot arm.
  • the printhead 450 may be a printhead as shown in Fig. 3A. Recirculated ink leaves the printhead past recirculation pressure sensor 442 and then damper 432.
  • the ink tank 440 on the robot arm, i.e. closer to the printhead than the main ink supply 401 , it is possible to quickly adjust the flow of ink to the printhead.
  • Fig. 4B shows a main ink supply 401 , temperature control device 415, pump 41 1 connected to an ink tank 440.
  • the elements within the dotted rectangle are arranged on the robot arm, whereas the main ink supply 401 , main pump 302 and the temperature control device 403 are arranged on the moveable support.
  • the printhead which may be the printhead of Fig. 3B, comprises separate inlets for the refill and recirculation channels as well as separate outlets therefor.
  • Two separate further pumps 412, 413 are provided on the robot arm for pumping ink towards the printhead 450.
  • Inflow pressure sensors 440,441 are arranged directly upstream from the printhead and connected respectively to a refill channel and a recirculation channel of the printhead.
  • Recirculation pressure sensors 442,443 are arranged directly downstream from the printhead 450, for measuring the recirculation pressure at the outlets of the printhead.
  • Dampers 430 - 433 are provided for reducing sudden changes in pressure of ink in the printhead due to acceleration of the robot arm.
  • Pump 412 can be individually controlled based on the output from sensors 440,442 to adjust the ink pressure in the refill channel, and pump 413 can be individually controlled to adjust the pressure in recirculation channel to the respective predetermined ink pressure operating values for the printhead.
  • Fig. 4C shows a main ink supply 401 , pump 402 and temperature control device 403, which are arranged on the moveable support, and an ink tank 41 1 , pump 412 that are arranged on the robot arm and are in fluid connection with the printhead 450.
  • the printhead which may be the printhead of Fig. 3C, is of the non-recirculating type. However, it is still possible to estimate the ink pressure in the printhead based on the data from the IMU, and on the data from inflow pressure sensor 440.
  • the controller of the robot can control the pump 412 to ensure that the pressure measured by sensor 440 remains above a predetermined lowest operating ink pressure of the printhead.

Landscapes

  • Engineering & Computer Science (AREA)
  • Robotics (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Ink Jet (AREA)

Abstract

La présente invention concerne un système d'impression permettant d'imprimer sur des surfaces d'impression tridimensionnelles. Le système comprend un bras robot mobile monté sur un support mobile, une tête d'impression supportée sur le bras robot et un dispositif d'alimentation en encre qui est relié à la tête d'impression par l'intermédiaire d'une conduite de fluide permettant d'alimenter la tête d'impression en encre. Un système de positionnement est relié au support, au bras robot et à la tête d'impression afin de mesurer la position et l'orientation de la tête d'impression. Une unité de compensation est reliée à la tête d'impression afin de positionner mécaniquement la tête d'impression dans une position définie. Une unité de commande est fonctionnellement reliée : au système de positionnement afin de positionner la tête d'impression dans une position d'impression prédéterminée, au dispositif d'alimentation en encre afin de réguler le débit d'encre vers la tête d'impression en fonction d'une orientation de la tête d'impression, et à l'unité de compensation afin de compenser des mouvements de vibration et/ou des erreurs de position du support et du bras robot et de maintenir la tête d'impression dans une position définie.
PCT/NL2020/050116 2019-02-22 2020-02-24 Système d'impression et procédé d'impression sur des surfaces tridimensionnelles Ceased WO2020171714A1 (fr)

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WO2022171417A1 (fr) * 2021-02-12 2022-08-18 Tinymobilerobots Aps Robot mobile doté d'un outil de pulvérisation pouvant être déplacé
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EP4201682A1 (fr) * 2021-12-21 2023-06-28 Angelo Schiestl Agencement de tête d'impression pour une imprimante à jet d'encre
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