Description:4. DESCRIPTION

Technical Field of the invention

The present invention relates to robotic systems for direct-to-shape printing. More specifically, it concerns a gantry robot with six-axis mobility designed to print accurately and efficiently on three-dimensional objects with complex surfaces like cylindrical, Oval round etc.,

Background of the invention

Direct-to-shape printing offers a method for applying patterns and colors directly onto three-dimensional (3D) objects, eliminating the need for flat surfaces or dedicated build platforms. This technology is valuable for customizing designs on complex shapes and large-scale objects. However, traditional direct-to-shape printing systems often face significant limitations in terms of maneuverability, precision, and scalability. Conventional robotic arms used in these systems can suffer from inaccuracies due to flexing and backlash in the joints, leading to inconsistent print quality. Additionally, the need to move the ink supply along with the printhead in robotic arm systems can cause disruptive pressure fluctuations, further degrading print accuracy and reliability.

Existing gantry systems, while offering a stable base for linear movements, typically lack the full range of motion and flexibility required to print on intricate 3D surfaces effectively. The inability to position the printhead at precise angles relative to the target surface can result in suboptimal printing outcomes. Moreover, calibrating these systems to achieve consistent and high-quality prints on complex geometries can be challenging and time-consuming.

The present invention addresses these challenges by introducing a gantry robot specifically designed for direct-to-shape printing. It combines a rigid gantry structure with six-axis mobility, allowing for precise and versatile positioning of the print head. Additionally, the integration of a static ink supply system ensures stable ink pressure and flow, enhancing the consistency and quality of prints. This innovative design provides a robust solution to the limitations of existing direct-to-shape printing systems, enabling more efficient and accurate printing on a wide variety of 3D objects.

Brief Summary of the invention

The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

It is a primary object of the present invention is to provide a gantry robot system that offers superior precision and accuracy in positioning the print head for direct-to-shape printing applications.

It is yet another object of invention is to incorporate six-axis mobility (X, Y, Z linear axes and A, B, C rotary axes) into the gantry design to allowing for versatile and flexible positioning of the print head to achieve optimal printing on complex three-dimensional surfaces.
It is yet another object of invention is to integrate a static ink supply system within the gantry robot, ensuring stable and regulated ink pressure, thereby minimizing pressure fluctuations and enhancing print quality and consistency.

It is yet another object of invention is to enable the print head to access and print on complex geometries and surfaces from various angles, improving the ability to print detailed and intricate designs directly onto 3D objects.
It is yet another object of invention is to ensure high-quality print output by maintaining consistent drop ejection rates, volumes, and trajectories, which are critical for high-fidelity patterning on complex surfaces.
It is yet another object of invention is to enable the print head to access and print on complex geometries and surfaces from various angles, improving the ability to print detailed and intricate designs directly onto 3D objects.
According to an aspect of the present invention, a gantry robot system specifically designed for direct-to-shape printing applications. This innovative design combines a robust gantry structure with six-axis mobility (X, Y, Z linear axes and A, B, C rotary axes) to achieve precise and versatile positioning of the print head.

The primary features and benefits of this invention are outlined as follows:
Gantry Design: The gantry robot features a stable and rigid structure, ensuring precise linear movements in the X, Y, and Z axes. This rigidity minimizes vibrations and enhances the overall accuracy and quality of the printing process.

6-Axis Mobility: The system incorporates three additional rotary axes (A, B, C) that provide comprehensive maneuverability. These rotary axes allow the print head to tilt and rotate, enabling it to maintain a consistent orientation relative to the target surface, regardless of its complexity or shape.

Print head Integration: A print head, capable of handling various printing materials and technologies, is integrated into the system. This allows for a wide range of applications, from traditional inkjet printing to advance additive manufacturing processes.

Static and Regulated Ink Supply System: The gantry robot design includes a static ink supply system, where the ink reservoirs, tubing, and fluid components remain fixed in position. This design minimizes pressure and flow fluctuations, ensuring a stable and consistent ink supply to the print head. This stability is critical for maintaining high-quality printing, especially on complex three-dimensional surfaces.

Control System: A control system manages the movement of all six axes and the printing process. It interprets input from 3D models to generate precise tool paths, coordinating the linear and rotary axes to accurately position the print head and maintain the desired orientation during printing.

Enhanced Print Quality: The combination of precise positioning, stable ink supply, and advanced control system results in high-quality print output. The system ensures consistent drop ejection rates and volumes, critical for detailed and accurate printing on complex surfaces.

Scalability and Flexibility: The gantry robot design is scalable, allowing for the accommodation of larger print volumes and objects. Its modular nature also enables customization to suit different printing technologies and materials, making it versatile for various industrial applications.

Overall, the invention addresses the limitations of existing direct-to-shape printing systems by providing enhanced precision, maneuverability, and scalability. It represents a significant advancement in the field of 3D/direct to shape printing, offering a reliable and efficient solution for printing directly onto complex three-dimensional surfaces.

Further objects, features, and advantages of the invention will be readily apparent from the following description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings.

Brief Description of the Drawings

The invention will be further understood from the following detailed description of a preferred embodiment taken in conjunction with an appended drawing, in which:

Fig. 1 illustrates the block diagram of printing system, in accordance with an exemplary embodiment of the present invention.

Fig. 2 illustrates 3-axis rotary of the gantry robotic printing system, in accordance with an exemplary embodiment of the present invention.

Fig. 3 illustrates the block diagram of printing system, in accordance with an exemplary embodiment of the present invention.

Detailed Description of the invention

It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

According to an exemplary embodiment of the present invention, A gantry robotic printing system for direct-to-shape printing is disclosed. The system comprises gantry structure, linear actuators or motors, printhead, 6-axis mobility system, ink supply system, control system.

In accordance with an exemplary embodiment of the present invention, wherein the gantry structure consists of a base frame, six vertical columns, and a mobile horizontal beam. The base frame provides stability and support for the entire system, while the vertical columns serve as upright supports. The mobile horizontal beam connects the columns and provides a rigid structure for mounting the printhead and other components.

In accordance with an exemplary embodiment of the present invention, wherein the linear actuators or motors are integral components mounted on the vertical columns and mobile horizontal beam of the gantry structure. These actuators or motors facilitate precise movements along the X, Y, and Z axes. They are responsible for translating electrical signals into mechanical motion, enabling accurate /precise positioning of the printhead assembly during printing operations.

In accordance with an exemplary embodiment of the present invention, wherein the printhead is affixed to the gantry structure and serves as the primary component responsible for dispensing printing materials onto three-dimensional surfaces. The printhead is equipped with nozzles through which the printing material is ejected onto the target surface. It is designed to ensure uniform deposition of material, resulting in high-quality prints.

In accordance with an exemplary embodiment of the present invention, wherein the 6-axis mobility system comprises rotary axes A, B, and C. Rotary axis A allows rotation to tilt the printhead assembly upwards or downwards, axis B permits rotation to tilt the printhead assembly side-to-side, and axis C enables rotation to maintain the printhead assembly perpendicular to the target surface. This mobility system provides the flexibility needed to accurately position the printhead in relation to the target surface.

In accordance with an exemplary embodiment of the present invention, wherein the ink supply system is an integrated component of the gantry structure. It includes various components such as ink reservoirs, tubing, pumps, filters, dampers, pressure sensors, and an inlet tank. The ink supply system ensures a consistent and regulated flow of ink to the printhead assembly during printing operations.

In accordance with an exemplary embodiment of the present invention, wherein the control system is responsible for managing the movement of linear and rotary axes, as well as the printing process.

In accordance with an exemplary embodiment of the present invention, wherein the control system comprises a motion controller, printhead controller, software interface, and sensors providing real-time feedback. It coordinates the movements of the gantry system, regulates ink flow, temperature settings, and nozzle operations, generates toolpaths based on input from a 3D model, and monitors operational parameters for precise control and adjustment.

Referring to figures, Figure 1 illustrates the printing system operates through a meticulously coordinated process, beginning with the preparation of input data, typically in the form of a 3D model. This model guides the subsequent steps of material preparation and deposition onto the target surface. Within the system, the ink supply system plays a crucial role in ensuring the smooth flow of printing material. It starts with the input pump (Pin), which propels ink through dampers and filters, meticulously removing impurities. Pressure sensors strategically placed within the system continuously monitor ink flow and provide real-time feedback to the control system, ensuring optimal pressure levels are maintained throughout the printing process.

Meanwhile, the gantry system and printhead work together to position the printing material precisely over the target surface. The printhead, mounted on the gantry, maneuvers in multiple dimensions, including X, Y, Z, and rotational axes (A, B, and C), allowing for intricate material deposition at various angles and orientations.

During printing, the control system orchestrates the movement of the gantry and printhead while also regulating the temperature within the printhead to optimize material deposition. Pressure regulation remains a critical aspect, with the control system dynamically adjusting the input pump based on feedback from pressure sensors. This meticulous pressure control prevents issues such as ink drooling or bubbling, ensuring consistent and high-quality prints.

Upon completion of the printing process, the control system conducts quality checks to verify the integrity of the printed object. Any detected errors or inconsistencies prompt further inspection or corrective measures. Overall, the printing system operates seamlessly, leveraging advanced mechanisms and real-time feedback to deliver precise and reliable printing results.

Figure 2 illustrates the 3-axis rotary of the gantry robotic printing system, which includes rotary axes A, B, and C, and the printhead. Rotary Axis A allows the printhead to tilt upwards or downwards around the Y-axis, Axis B facilitates side-to-side tilting around the Z-axis, and Axis C maintains the printhead perpendicular to the target surface by rotating around the X-axis. These coordinated movements, combined with the printhead's ability to move along the X, Y, and Z axes via linear actuators or motors, enable precise and flexible printing on complex three-dimensional surfaces. This system ensures accurate material deposition, making it ideal for direct-to-shape printing on large and intricate objects such as automotive parts, enhancing print quality and operational efficiency.

Figure 3 illustrates the 6-axis servo gantry of the gantry robotic printing system that enhances precision and flexibility for direct-to-shape printing. This system integrates six servo-driven axes, including linear axes X, Y, and Z, and rotary axes A, B, and C. The linear axes facilitate precise movements along horizontal and vertical planes, while the rotary axes allow the printhead to tilt and rotate in three dimensions. This comprehensive range of motion enables the printhead to accurately position itself over complex and irregular surfaces, ensuring consistent material deposition and high-quality prints. The servo motors provide precise control and real-time feedback, optimizing the system's performance for intricate printing tasks on large and detailed objects such as automotive parts. The integration of six axes allows for enhanced maneuverability and precision, making the 6-Axis Servo Gantry a crucial element for achieving superior print quality and operational efficiency in direct-to-shape printing applications.

Based on the detailed description, there are several key advantages of using the gantry system with a static ink supply for direct-to-shape printing compared to a robotic arm with a moving ink supply:

1. Stable Ink Pressure: The gantry system allows the ink reservoirs, tubing, and other fluid supply components to be mounted in a fixed position on the gantry frame. This static ink supply minimizes disruptive pressure and flow fluctuations that can occur when the supplies are accelerated and decelerated during the rapid motion of robotic arm joints.

2. Consistent Drop Formation: Even minor fluctuations in hydraulic pressure can impact the precise jetting behavior and drop formation in inkjet printheads. The static supply in the gantry system exhibits highly stable ink pressure, enabling consistent drop ejection rates, volumes, and velocities.

3. Better Print Quality: The inconsistent pressure at the printhead in a robotic arm system leads to variations in drop formation, drop volumes, and drop velocities during jetting, reducing print quality and accuracy. The gantry system's static and regulated ink supply enables reliable and precise drop generation, resulting in enhanced print quality, resolution, and color fidelity.

4. Multiple Printhead Support: In CMYK print systems with multiple printheads, controlling the pressure becomes more critical. The gantry design can provide a more stable and consistent pressure environment for multiple printheads compared to a robotic arm system, where the motion inertia can affect drop placement and lead to inconsistent dot positioning.

5. Productivity and Throughput: The gantry system can access a larger print area without extensive robot arm movements, resulting in faster printing speeds and higher throughput. The rigid gantry structure also provides a more stable and predictable motion profile, enabling better control over drop placement accuracy.

While robotic arms offer flexibility, the gantry system with a static ink supply appears to have significant advantages in terms of pressure stability, consistent drop formation, print quality, and productivity for direct-to-shape inkjet printing applications, particularly for complex 3D surfaces and intricate color gradients.

Here are some additional commercial and technical differences between using a gantry system with a static ink supply versus multiple robotic arms for direct-to-shape printing of large objects like automotive parts:

Commercial Differences:

Cost: A gantry system is generally more cost-effective compared to deploying multiple industrial robotic arms, which are expensive pieces of equipment.

Floor Space: A single gantry system has a smaller footprint and requires less floor space than positioning multiple robotic arms around a large object.

Maintenance: Gantry systems typically have fewer moving parts and are simpler to maintain compared to the complexities of multiple robotic arm systems.

Technical Differences:

Coverage Area: A large gantry system can span a larger print area to accommodate big objects like car bodies, while multiple robotic arms may struggle to reach all surfaces without frequent repositioning.

Path Planning: Path planning and coordination for multiple robotic arms to avoid collisions and optimize coverage becomes increasingly complex for irregularly shaped objects.

Scalability: It is easier to scale up the size of a gantry system by extending the rail lengths than adding and coordinating more robotic arms.

Precision: The rigid gantry structure provides higher positioning accuracy and repeatability compared to the compounded positioning errors from multiple robotic arm joints.

Surface Access: A gantry system can easily access hard-to-reach areas and cavities on complex 3D surfaces, while robotic arms may struggle with line-of-sight issues and limited reach.

Continuous Printing: The gantry system can maintain continuous printing during long traversals, while robotic arms may require frequent stops and starts, impacting print quality.

In summary, for large-scale direct-to-shape printing applications like automotive painting, a gantry system with a static ink supply offers advantages in cost, floor space, maintenance, coverage area, path planning simplicity, scalability, precision, surface access, and continuous printing capability compared to using multiple robotic arms.
, Claims:CLAIMS
I/We Claim:
1. A gantry robotic printing system for direct-to-shape printing, comprising:
a. a gantry structure including a base frame, two vertical columns, and a mobile horizontal beam;
b. linear actuators or motors mounted on the columns and beam to facilitate precise movements along X, Y, and Z axes;
c. a printhead affixed to the gantry structure, capable of dispensing printing materials directly onto three-dimensional surfaces;
d. a 6-axis mobility system including rotary axes A, B, and C, enabling the printhead to maintain a consistent orientation relative to the target surface, wherein:
rotary axis A allows rotation around the Y-axis to tilt the print head upwards or downwards;
rotary axis B allows rotation around the Z-axis to tilt the print head side-to-side;
rotary axis C allows rotation around the X-axis to maintain the print head perpendicular to the target surface;
e. a static and regulated ink supply system integrated onto the gantry structure, comprising ink reservoirs, tubing, input and recirculation pumps, filters, dampers, pressure sensors, and an inlet tank, wherein:
the input pump propels ink towards the print head;
the filters remove impurities from the ink;
the dampers ensure smooth and consistent ink flow;
the pressure sensors at the inlet and outlet of the print head monitor and regulate pressure levels;
the recirculation pump maintains ink recirculation and minimizes waste;
f. a control system for managing the movement of the linear and rotary axes and the printing process, wherein:
a motion controller manages the movements of the linear and rotary axes;
a print head controller manages material flow, temperature settings, and nozzle operations;
a software interface receives input from a 3D model and generates toolpaths for the robot to follow;
sensors provide real-time feedback on position, pressure, and other operational parameters.

2. The gantry robotic printing system as claimed in claim 1, wherein the linear actuators or motors facilitate movements with a precision of less than 0.1 millimeters.

3. The gantry robotic printing system as claimed in claim 1, wherein the 6-axis mobility system includes encoders for precise position control of the rotary axes A, B, and C.

4. The gantry robotic printing system as claimed in claim 1, wherein the printhead further comprises a cleaning mechanism for maintaining nozzle functionality during printing operations.

5. The gantry robotic printing system as claimed in claim 1, wherein the ink supply system further comprises a fluid level sensor for monitoring ink levels in the reservoirs.

6. The gantry robotic printing system as claimed in claim 1, wherein the control system further comprises a feedback loop for adjusting printing parameters based on real-time sensor data.

7. A method for direct-to-shape printing using a gantry robotic printing system, comprising:
a. initializing the gantry robotic printing system;
b. loading printing material into the ink reservoirs of the ink supply system;
c. preparing a target surface for printing;
d. inputting printing instructions into the control system;
e. generating toolpaths based on a 3D model and specified printing parameters;
f. managing movements of linear and rotary axes to follow generated toolpaths;
g. controlling dispensing of printing material onto the target surface;
h. monitoring operational parameters with sensors in real-time;
i. adjusting printing parameters based on real-time sensor data; and
j. completing the printing process and performing post-processing steps as needed