Automated controls for contoured surface inkjet printing

Patent metadata

Field	Value
Publication number	US-10293601-B2
Application number	US-201715646705-A
Country	US
Kind code	B2
Filing date	Jul 11, 2017
Priority date	Jul 11, 2017
Publication date	May 21, 2019
Grant date	May 21, 2019

Abstract

A method of developing an automatic control plan for printing on a contoured surface is disclosed. The method includes scanning a contoured surface with a surface scanning device to produce a contoured data set, and creating a multi-dimensional model, with a computing device, of the contoured surface based on the contoured surface data set. Additionally, the method includes inputting a multi-dimensional model of a printing array and an image to be printed onto the contoured surface, into the computing device. The method further includes simulating, on the computing device, a plurality of movements performed by the printing array and a printing by the printing array to apply the image on the contoured surface. Additionally, the method includes, compiling, on the computing device, the automatic control plan which is programmed to execute the plurality of movements of the printing array to apply the image on the contoured surface.

First claim

What is claimed is:

1. A method of developing an automatic control plan for printing on a contoured surface, the method comprising:
scanning a contoured surface, with a surface scanning device, to produce a contoured surface data set;
creating a three-dimensional surface mesh model, with a computing device, of the contoured surface based on the contoured surface data set;
inputting, into the computing device, a three-dimensional model of a printing array configured for printing on the contoured surface;
inputting, into the computing device, a two-dimensional image to be printed on the contoured surface and overlaying the two-dimensional image onto the three-dimensional surface mesh model of the contoured surface;
generating, on the computing device, a UV coordinate map based on the two-dimensional image;
overlaying, on the computing device, the UV coordinate map onto the three-dimensional surface mesh model of the contoured surface, wherein the UV coordinate map defines a plurality of UV coordinates of the two-dimensional image that correspond to a location on the three-dimensional surface mesh model;
executing a simulation on the computing device, the simulation including:
generating a plurality of movements of the three-dimensional model of the printing array based on the three-dimensional surface mesh model of the contoured surface and the two-dimensional image to be printed on the contoured surface, and
confirming the plurality of movements will be executed and the two-dimensional image will be printed on the contoured surface without issue,

compiling, on the computing device, the automatic control plan based on confirmation that the plurality of movements can be executed without issue; and
outputting the automatic control plan to a surface treatment assembly configured to execute the automatic control plan and print the two-dimensional image along the contoured surface.

2. The method of claim 1 , wherein defining the plurality of UV coordinates of the UV coordinate map of the two-dimensional image includes assigning a plurality of pixels of the two-dimensional image, and wherein each pixel of the plurality of pixels correspond with a specific set of vertices of the three-dimensional surface mesh model.

3. The method of claim 2 , wherein the UV coordinate map of the two-dimensional image and the three-dimensional surface mesh model of the contoured surface are broken up into a plurality of polygon regions and wherein compiling the automatic control plan further includes meshing the plurality of polygon regions back together.

4. The method of claim 1 , wherein the printing array comprises an inkjet printing array and simulating the printing includes configuring each nozzle, of the plurality of nozzles, to dispense a color droplet from one of a cyan color, a magenta color, a yellow color, or a black color.

5. The method of claim 4 , wherein simulating the dispensing of the color droplet further includes determining a spacing between the color droplet dispensed from each nozzle, of the plurality of nozzles, to produce the two-dimensional image on the contoured surface.

6. The method of claim 4 , wherein simulating the dispensing of the color droplet further includes determining a dispense gap between each nozzle, of the plurality of nozzles, and the contoured surface.

7. The method of claim 1 , wherein inputting the three-dimensional model of the printing array includes defining an array center point and mapping out a location of each nozzle, of the plurality of nozzles, with respect to the array center point.

8. A system for developing a control plan for a printing array configured to print along a contoured surface, the system comprising:
at least one sensor configured to scan the contoured surface and produce a contoured data set;
an input module configured to receive the contoured data set, a two-dimensional image file to be printed on the contoured surface, and a three-dimensional model of the printing array;
a computing device communicably coupled to the at least one sensor and the input module, the computing device programmed to analyze the contoured data set and assemble a three-dimensional surface mesh model of the contoured surface, wherein the computing device generates a UV coordinate map based on the two-dimensional image, and wherein the UV coordinate map is overlaid onto the three-dimensional surface mesh model of the contoured surface such that the UV coordinate map defines a plurality of UV coordinates of the two-dimensional image that correspond to a location on the three-dimensional surface mesh model; and
a simulation module operably coupled to the computing device, the simulation module receives the three-dimensional surface mesh model of the contoured surface, the two-dimensional image file, and the three-dimensional model of the printing array, wherein the simulation module executes a simulation programmed to generate a plurality of movements of the multi-dimensional model of the printing array based on the multi-dimensional model of the contoured surface and the image to be printed on the contoured surface, and wherein the simulation module compiles and outputs the control plan based on confirmation that the plurality of movements can be executed without issue.

9. The system of claim 8 , wherein the plurality of UV coordinates of the UV coordinate map define a plurality of pixels of the two-dimensional image, and wherein each pixel of the plurality of pixels correspond with a specific set features of the three-dimensional mesh model.

10. The system of claim 9 , wherein the UV coordinate map of the two-dimensional image and the three-dimensional surface mesh model of the contoured surface is broken up into a plurality of polygon regions, and wherein the control plan further includes meshing the plurality of polygon regions together to print the two-dimensional image on the contoured surface.

11. The system of claim 8 , wherein the printing array includes a plurality of nozzles and wherein the input module receives a three-dimensional model of the printing array that defines an array center point such that a location of each nozzle, of the plurality of nozzles, is mapped out with respect to the array center point.

12. The system of claim 11 , wherein the printing array comprises an inkjet printing array and the each nozzle, of the plurality of nozzles, is configured to dispense a color droplet from one of a cyan color, a magenta color, a yellow color, or a black color.

13. The system of claim 11 , wherein the simulation module being further configured to determine a spacing between a color droplet dispensed onto the contoured surface by each nozzle, of the plurality of nozzles.

14. The system of claim 11 , wherein the simulation module being further configured to determine a dispense gap between each nozzle, of the plurality of nozzles and the contoured surface.

15. An automated surface assembly configured for printing on a contoured surface, the automated surface assembly comprising:
an automated printing array configured for printing a surface treatment along the contoured surface;
an automated robot operably coupled to the automated printing array and configured to position and move the automated printing array along the contoured surface;
at least one sensor operably coupled to the automated printing array and configured to scan the contoured surface and produce a contoured data set;
a control system communicably coupled to the automated surface assembly and configured to execute an automated control plan programmed for operating the automated surface assembly;
a computing device

Assignees

• Boeing Co

Inventors

• Baker Anthony W
• Ingram Luke C
• Bowers Iii Kenneth P
• Smith Zachary R
• Homolak David J

Classifications

• G06F30/00

  Computer-aided design [CAD] · CPC title

• B41J3/4073 Primary

  Printing on three-dimensional objects not being in sheet or web form, e.g. spherical or cubic objects (B41J3/283, B41J3/286 take precedence; building up a 3D object using individual droplets from jetting heads B29C64/112) · CPC title

• B41J2/04586

  controlling heads of a type not covered by groups B41J2/04575 - B41J2/04585, or of an undefined type · CPC title

• B41J2/04508 Primary

  aiming at correcting other parameters · CPC title

• G06F17/50

  Physics · mapped topic