Computerized Apparatus and Method for Applying Graphics to Surfaces

• US 20080252671A1
• Filed: 04/10/2008
• Published: 10/16/2008
• Est. Priority Date: 06/03/2003
• Status: Active Grant

• Current Assignee: Hexagon Technology Center GmbH (Hexagon AB)
• Original Assignee: Dreamscape Interiors, Inc.
• Inventors: Fox, James, Cannell, Robert L., Hudd, Alan, Wilkinson, Richard
• Granted Patent: US 8,123,350 B2
• Time in Patent Office: Days
• US Class Current: 347/9
• CPC Class Codes: B41J 3/28 for printing downwardly on flat surfaces, e.g. of books, drawings, boxes , envelopes, e.g. flat-bed ink-jet printers

Abstract

A system and method for applying an image to a substrate surface are disclosed. The method comprises receiving a set of color matrix maps representing color pixel overlays forming the image, effecting a positioning of a print head array relative to the substrate surface, the print head array comprising at least one print head having a plurality of nozzles, receiving real-time geometry data representing the print head array position and orientation in space, determining, in response to the real-time geometry data, the print head array position and orientation relative to the substrate surface, determining, in response to the print head array position and orientation relative to the substrate surface and the set of color matrix maps, a set of pixels to be applied by the print head array to the substrate surface, and generating instructions to the print head array, in response to the set of pixels to be applied, to actuate particular nozzles in the print head array to apply the set of pixels to the substrate surface.

Claims

1. A method for applying an image to a substrate surface, comprising:

receiving a set of color matrix maps representing color pixel overlays forming the image;

effecting a positioning of a print head array relative to the substrate surface, the print head array comprising at least one print head having a plurality of nozzles;

receiving real-time geometry data representing the print head array position and orientation in space;

determining, in response to the real-time geometry data, the print head array position and orientation relative to the substrate surface;

determining, in response to the print head array position and orientation relative to the substrate surface and the set of color matrix maps, a set of pixels to be applied by the print head array to the substrate surface; and

generating instructions to the print head array, in response to the set of pixels to be applied, to actuate particular nozzles in the print head array to apply the set of pixels to the substrate surface.

2. The method of claim 1, wherein receiving real-time geometry data comprises receiving X, Y, and Z coordinates of the position of the print head array relative to X, Y, and Z axes, and angles A, B, and C of the orientation of the print head array relative to the X, Y, and Z axes, respectively.

3. The method of claim 1, wherein receiving real-time geometry data comprises receiving the geometry data thousands of time per second.

4. The method of claim 1, wherein effecting a positioning of a print head array relative to the substrate surface comprises using a portable coordinate measuring machine having a temporarily fixed end and a free end holding the print head array, and calibrating the portable coordinate measuring machine with respect to the substrate surface.

5. The method of claim 4, further comprising defining a print region on the substrate surface effectively reachable by the free end of the portable coordinate measuring machine without moving its temporarily fixed end.

6. The method of claim 5, further comprising maintaining a local copy of the set of color matrix maps representing color pixel overlays forming the image in the defined print region.

7. The method of claim 5, further comprising completing pixel application of the defined print region on the substrate surface, and repositioning the fixed end of the portable coordinate measuring machine to enable processing a new print region.

8. The method of claim 1, wherein effecting a positioning of a print head array comprises advancing the print head array and following non-planar contours of the substrate surface.

9. The method of claim 1, wherein generating instructions to the print head array comprises determining whether the particular nozzle is within a predefined target print area of a pixel to be applied as defined by the color matrix maps.

10. The method of claim 7, further comprising applying an ink of a color by the particular nozzle in response to the particular nozzle being within the predefined target print area of the pixel to be applied.

11. The method of claim 1, further comprising updating the set of color matrix maps in response to the set of pixels being applied to the substrate surface.

12. A system for applying an image to a substrate surface, comprising:

a memory storing a set of color matrix maps representing color pixel overlays forming the image;

a portable machine having a base and a free end adapted to hold a colorant applicator positioned proximate the substrate surface, the portable machine operable to generate real-time geometry data indicative of a position and orientation of the colorant applicator in space;

a processor coupled to the portable coordinate measuring machine to receive the real-time geometry data and operable to determine the position and orientation of the colorant applicator relative to the substrate surface; and

a driver coupled to the processor and colorant applicator operable to receive colorant application instructions from the processor, and applying the colorants to the substrate surface at locations specified by the processor instructions.

13. The system of claim 12, wherein the colorant applicator comprises a print head array having at least one print head with a plurality of nozzles.

14. The system of claim 12, wherein the portable machine comprises a multi-axial articulated arm.

15. The system of claim 14, wherein the multi-axial articulated arm comprises first, second and third segments joined linearly by first, second and third joints, the first segment being coupled to the base and the third segment holding the colorant applicator.

16. The system of claim 12, further comprising a local memory storing a set of color matrix maps representing color pixel overlays forming the image in a print region.

17. The system of claim 12, wherein the free end of the portable machine is adaptable to be advanced along a planar contour of the substrate surface.

18. The system of claim 12, wherein the free end of the portable machine is adaptable to be advanced along a non-planar contour of the substrate surface.

19. A method for applying an image to a substrate surface, comprising:

selecting an image from a collection of images;

processing the selected image into a set of color matrix maps representing color pixel overlays mapped to the substrate surface;

positioning a print head array proximate to the substrate surface, the print head array having a plurality of print heads, and each print head having a plurality of nozzles operable to apply colorants of a single color;

receiving real-time geometry data representing the print head array position and orientation in space;

determining, in response to the real-time geometry data, the print head array position and orientation relative to the substrate surface;

determining, in response to the print head array position and orientation relative to the substrate surface and the set of color matrix maps, a set of pixels to be applied by the print head array to the substrate surface at the current position and orientation of the print head array;

generating instructions to the print head array, in response to the set of pixels to be applied, to actuate particular nozzles in the print head array to apply the set of pixels to the substrate surface; and

advancing the print head array along contours of the substrate surface to complete the application of the image to the substrate surface.

20. The method of claim 19, wherein receiving real-time geometry data comprises receiving X, Y, and Z coordinates of the position of the print head array relative to X, Y, and Z axes, and angles A, B, and C of the orientation of the print head array relative to the X, Y, and Z axes, respectively.