Automated dye pattern application system

• US 4,979,380 A
• Filed: 09/12/1989
• Issued: 12/25/1990
• Est. Priority Date: 09/12/1989
• Status: Expired due to Fees

• Current Assignee: S. Berendsen AB
• Original Assignee: Sakowski and Robbins Corporation
• Inventors: Sakowski, John D., Robbins, Ronald B., Walden, William R.
• Primary Examiner(s): Coe, Philip R.
• Application Number:
  US07/406,367
• Time in Patent Office: 469 Days
• Field of Search: 68/205 R, 346/29, 118/697, 118/704, 118/323
• US Class Current: 68/205.00R
• CPC Class Codes: D06B 11/0059 by spraying

Abstract

An automated dye pattern application system includes a support bed to support a mat or other dye receiving medium; perpendicular guide tracks supporting a carrier on which a dye spray head is mounted; stepper motors engaged between the tracks, the support bed, and the spray head carrier and forming an x-y plotter apparatus to move the spray head in two dimensions over the mat; and a pneumatic dye supply mechanism to supply liquid dye to the spray head and including control valves to actuate the spray of dye from the spray head. A dye control computer is interfaced to the stepper motors and valves and controls their operation. Data representing a digitized image is converted to a file of plotter commands to control the motors to scan the spray head over the mat and spray dye from the spray head at selected picture element locations to reproduce the digitized image in a colored dye pattern on the mat.

Claims

1. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye spray head means including liquid spray means for spraying a liquid from said head and being adapted for at least indirect connection to dye medium support means for relative movement therebetween in at least two dimensions;

(b) spray head motor means adapted for at least indirect driving engagement between said head means and the support means and operable to cause relative movement therebetween in said at least two dimensions;

(c) remote dye supply means flow connected to said spray means and controllable to communicate a dye to said liquid spray means; and

(d) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to cause said relative movement between said head means and the support means and to cause communication of said dye to said liquid spray means in such a manner as to apply said dye to said dye receiving medium in said selected dye image pattern.

2. An apparatus as set forth in claim 1 wherein said control means includes:

(a) a dye control computer;

(b) interface means connecting said motor means and said dye supply means to said computer;

(c) memory means storing a dye application program and dye pattern data; and

(d) said computer executing said program to process said dye pattern data to cause said motor means to cause relative movement of said spray head means and the support means in a selected path relative to a dye receiving medium on the support means and to cause communication of dye from said supply means to said head means at selected locations along said path according to said dye pattern data to thereby apply said dye to the medium in a selected dye image pattern.

3. An apparatus as set forth in claim 2 and including:

(a) scanner means interfaced with said computer and operable to optically scan an image, generate said dye pattern data representing said image, and input said data into said computer.

4. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) a dye spray head including spray means for spraying a liquid from said head;

(b) plotter means adapted to support the dye receiving medium, having said head mounted thereon, and including motor means controllable to cause relative movement between said head and the dye receiving medium to position said head at selected rectangular coordinates of said plotter means;

(c) remote dye supply means including dye conveying conduit means communicating with said head; and

(d) control means having said motor means and said supply means connected thereto and controlling said motor means to cause said relative movement and to cause said supply means to selectively communicate said dye to said spraying means in such a manner as to apply said dye to the dye receiving medium in said selected dye image pattern.

5. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye medium support means having at least a two dimensional extent for supporting a dye receiving medium;

(b) a dye spray head including spray means for spraying a liquid from said head and including mounting means for mounting said head on said support means for movement in at least two dimensions;

(c) spray head motor means drivingly engaged between said support means and said head and operable to move said head in said at least two dimensions;

(d) remote dye supply means flow connected to said spray means; and

(e) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to move said dye spray head in relation to said dye receiving medium and to cause communication of said dye to said spray means in such a manner as to apply said dye to said medium in said selected dye image pattern.

6. An apparatus as set forth in claim 5 wherein:

(a) said support means includes a planar dye medium support bed;

(b) an elongated fixed track is connected to said bed and extends in a first direction;

(c) an elongated movable track is oriented in a second direction perpendicular to said fixed track, has one end engaging said fixed track and guided thereby to maintain a perpendicular relationship to said fixed track, and has an opposite end movably engaging said bed;

(d) a dye spray head carrier engages said movable track and has said spray head mounted thereon;

(e) said motor means includes a first motor and a second motor;

(f) said first motor is drivingly engaged between said fixed track and said movable track and is operable to cause reciprocation of said movable track relative to said fixed track; and

(g) said second motor is drivingly engaged between said movable track and said carrier and is operable to cause reciprocation of said carrier along said movable track.

7. An apparatus as set forth in claim 6 wherein:

(a) each of said motors is a stepper motor.

8. An apparatus as set forth in claim 5 wherein said control means includes:

(a) a dye control computer;

(b) interface means connecting said motor means and said dye supply means to said computer;

(c) memory means storing a dye application program and dye pattern data; and

(d) said computer executing said program to process said dye pattern data to cause said motor means to move said spray head in a selected path and to cause communication of dye from said supply means to said head at selected locations along said path according to said dye pattern data to thereby apply said dye to a dye medium in a selected dye image pattern.

9. An apparatus as set forth in claim 8 and including:

(a) scanner means interfaced with said computer and operable to optically scan an image, generate said dye pattern data representing said image, and input said data into said computer.

10. An apparatus as set forth in claim 5 and including:

(a) limit switch means associated with said spray head motor means, connected to said control means, and communicating a reference coordinate signal to said control means upon said motor means positioning said head at a two dimensional reference position of said support means.

11. An apparatus as set forth in claim 10 and including:

(a) a pair of perpendicular dye medium guides positioned on said support means and intersecting at a dye spray starting location positioned in spaced relation to said reference position.

12. An apparatus as set forth in claim 5 wherein said support means includes:

(a) a planar dye medium support bed structure;

(b) bed base means adapted for connection to said bed structure to support same above a floor; and

(c) said bed structure being formed of a plurality of similar bed sections connected by removable fasteners to facilitate transportation of said bed structure.

13. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) planar, rectangular dye medium support means supporting a dye receiving medium;

(b) an elongated fixed track connected to said support means and extending in a first direction;

(c) an elongated movable track oriented in a second direction perpendicular to said fixed track, having one end engaging said fixed track and guided thereby to maintain a perpendicular relationship to said fixed track, and has an opposite end movably engaging said support means;

(d) a dye spray head carrier engaging said movable track;

(e) a first motor drivingly engaged between said fixed track and said movable track and operable to cause reciprocation of said movable track relative to said fixed track;

(f) a second motor drivingly engaged between said movable track and said carrier and operable to cause reciprocation of said carrier along said movable track;

(g) a dye spray head mounted on said carrier;

(h) dye container means containing a dye and communicating with said spray head;

(i) pneumatic dye supply means communicating with said container means and said head to pneumatically urge said dye from said container means and through said head; and

(j) control means having said motors and said dye supply means interfaced thereto and controlling said motor means and said dye supply means to move said dye spray head in relation to said dye receiving medium and to cause communication of said dye to said head in such a manner as to apply said dye to said medium in said selected dye image pattern.

14. A dye control system for a dye applying apparatus including dye receiving medium support means, a dye spray head, dye motor means connected between said support means and said head and operable to cause movement of said head relative to said support means, dye supply means, and dye valve means controlling communication between said dye supply means and said head, said system comprising:

(a) a dye control computer;

(b) interface means connecting said motor means and said valve means to said computer;

(c) memory means storing a dye application program and dye pattern data; and

(d) said computer executing said program to process said dye pattern data to cause said motor means to effect relative movement between said spray head and said support means in a selected relative path therebetween and to release said valve means at selected locations along said path to thereby apply said dye to said medium in a selected dye image pattern.

15. An apparatus as set forth in claim 14 and including:

(a) scanner means interfaced with said computer and operable to optically scan an image, generate said dye pattern data representing said image, and input said data into said computer.

16. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye spray head means adapted for at least indirect connection to dye medium support means for relative movement therebetween in at least two dimensions;

(b) elongated track means adapted for mounting on the support means;

(c) spray head motor means being drivingly engaged between said head means and said track means and operable to cause relative movement therebetween in said at least two dimensions;

(d) said spray head means being positioned on said track means and movable therealong;

(e) dye supply means controllable to communicate a dye to said head means;

(f) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to cause said relative movement between said head means and the support means and to cause communication of said dye to said head means in such a manner as to apply said dye to said dye receiving medium in said selected dye image pattern;

(g) flexible umbilical piping means connected between said dye supply means and said spray head means;

(h) a first arm section pivotally connected to said track means by a shoulder joint;

(i) a second arm section pivotally connected to said first section by an elbow joint and pivotally connected to said head means by a wrist joint;

(j) first umbilical support means supporting said piping means along said first section between said shoulder and elbow joints;

(k) second umbilical support means supporting said piping means along said second section between said elbow and wrist joints; and

(l) said piping means being unsupported at said joints to prevent interference of pivoting of said joints by said piping means.

17. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye spray head means adapted for at least indirect connection to dye medium support means for relative movement therebetween in at least two dimensions;

(b) spray head motor means adapted for at least indirect driving engagement between said head means and the support means and operable to cause relative movement therebetween in said at least two dimensions;

(c) dye supply means controllable to communicate a dye to said head means;

(d) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to cause said relative movement between said head means and the support means and to cause communication of said dye to said head means in such a manner as to apply said dye to said dye receiving medium in said selected dye image pattern;

(e) an elongated track member having a cross-section including generally downwardly projecting web means with opposite spaced apart faces having lower ledges extending in opposite directions therefrom, said ledges forming generally upwardly facing respective support shoulders;

(f) said spray head means including a spray head carrier with a dye spray head mounted thereon, said carrier including at least one pair of spaced apart wheels journaled thereon and positioned substantially in a common plane, each of said wheels having a circumferential surface and a sidewall surface;

(g) said carrier is positioned on said track member with said circumferential surface of each wheel engaging a respective face of said web means and with said sidewall surface engaging a support shoulder of a respective ledge; and

(h) means adapted for supporting said track member on the dye medium support means.

18. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye medium support means having at least a two dimensional extent for supporting a dye receiving medium;

(b) a dye spray head including means mounting said head on said support means for movement in at least two dimensions;

(c) spray head motor means drivingly engaged between said support means and said head and operable to move said head in said at least two dimensions;

(d) dye supply means controllable to supply dye to said head;

(e) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to move said dye spray head in relation to said dye receiving medium and to cause communication of said dye to said head in such a manner as to apply said dye to said medium in said selected dye image pattern;

(f) said support means includes a planar dye medium support bed;

(g) an elongated fixed track connected to said bed and extending in a first direction;

(h) an elongated movable track oriented in a second direction perpendicular to said fixed track, and having one end engaging said fixed track and guided thereby to maintain a perpendicular relationship to said fixed track, and having an opposite end movably engaging said bed;

(i) a dye spray head carrier engaging said movable track and having said spray head mounted thereon;

(j) said motor means includes a first motor and a second motor;

(k) said first motor being drivingly engaged between said fixed track and said movable track and being operable to cause reciprocation of said movable track relative to said fixed track;

(l) said second motor being drivingly engaged between said movable track and said carrier and being operable to cause reciprocation of said carrier along said movable track;

(m) said movable track having a cross-section including generally downwardly projecting web means with opposite spaced apart faces having lower ledges extending in opposite directions therefrom, said ledges forming generally upwardly facing respective support shoulders;

(n) said carrier including at least one pair of spaced apart wheels journaled thereon and being positioned substantially in a common plane, each of said wheels having a circumferential surface and a sidewall surface; and

(o) said carrier being positioned on said movable track with said circumferential surface of each wheel engaging a respective face of said web means and with said sidewall surface engaging a support shoulder of a respective ledge.

19. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye medium support means having at least a two dimensional extent for supporting a dye receiving medium;

(b) a dye spray head including means mounting said head on said support means for movement in at least two dimensions;

(c) spray head motor means drivingly engaged between said support means and said head and operable to move said head in said at least two dimensions;

(d) dye supply means controllable to supply dye to said head;

(e) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to move said dye spray head in relation to said dye receiving medium and to cause communication of said dye to said head in such a manner as to apply said dye to said medium in said selected dye image pattern;

(f) said support means includes a planar dye medium support bed;

(g) an elongated fixed track connection to said bed and extending in a first direction;

(h) an elongated movable track oriented in a second direction perpendicular to said fixed track, having one end engaging said fixed track and guided thereby to maintain a perpendicular relationship to said fixed track, and having an opposite end movably engaging said bed;

(i) a dye spray head carrier engaging said movable track and having said spray head mounted thereon;

(j) said motor means including a first motor and a second motor;

(k) said first motor being drivingly engaged between said fixed track and said movable track and being operable to cause reciprocation of said movable track relative to said fixed track;

(l) said second motor being drivingly engaged between said movable track and said carrier and being operable to cause reciprocation of said carrier along said movable track;

(m) said fixed track having a cross-section including generally downwardly projecting web means with opposite spaced apart faces having lower ledges extending in opposite directions therefrom, said ledges forming generally upwardly facing respective support shoulders;

(n) said movable track being engaged with said fixed track by a track bogie connected to said movable track, said bogie including at least one pair of spaced apart wheels journaled thereon and being positioned substantially in a common plane, each of said wheels having a circumferential surface and a sidewall surface; and

(o) said bogie being positioned on said fixed track with said circumferential surface of each wheel engaging a respective face of said web means and with said sidewall surface engaging a support shoulder of a respective ledge.

20. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye medium support means having at least a two dimensional extent for supporting a dye receiving medium;

(b) a dye spray head including means mounting said head on said support means for movement in at least two dimensions;

(c) spray head motor means drivingly engaged between said support means and said head and operable to move said head in said at least two dimensions;

(d) dye supply means controllable to supply dye to said head;

(e) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to move said dye spray head in relation to said dye receiving medium and to cause communication of said dye to said head in such a manner as to apply said dye to said medium in said selected dye image pattern;

(f) said support means including a planar dye medium support bed;

(g) an elongated fixed track being connected to said bed and extending in a first direction;

(h) an elongated movable track being oriented in a second direction perpendicular to said fixed track, having one end engaging said fixed track and being guided thereby to maintain a perpendicular relationship to said fixed track, and having an opposite end movably engaging said bed;

(i) a dye spray head carrier engaging said movable track and has said spray head mounted thereon;

(j) said motor means including a first motor and a second motor;

(k) said first motor being drivingly engaged between said fixed track and said movable track and being operable to cause reciprocation of said movable track relative to said fixed track;

(l) said second motor being drivingly engaged between said movable track and said carrier and being operable to cause reciprocation of said carrier along said movable track;

(m) flexible umbilical piping means being connected between said dye supply means and said spray head;

(n) a first arm section pivotally being connected to said movable track means by a shoulder joint;

(o) a second arm section being pivotally connected to said first section by an elbow joint and being pivotally connected to said head means by a wrist joint;

(p) first umbilical support means supporting said piping means along said first section between said shoulder and elbow joints;

(q) second umbilical support means supporting said piping means along said second section between said elbow and wrist joints; and

(r) said piping means being unsupported at said joints to prevent interference to pivoting of said joints by said piping means.

21. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye medium support means having at least a two dimensional extent for supporting a dye receiving medium;

(b) a dye spray head including means mounting said head on said support means for movement in at least two dimensions;

(c) spray head motor means drivingly engaged between said support means and said head and operable to move said head in said at least two dimensions;

(d) dye supply means controllable to supply dye to said head;

(e) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to move said dye spray head in relation to said dye receiving medium and to cause communication of said dye to said head in such a manner as to apply said dye to said medium in said selected dye image pattern;

(f) dye container means containing a dye and communicating with said spray head; and

(g) air compressor means communicating with said container means and said head to pneumatically urge said dye from said container means and through said head.

22. An apparatus as set forth in claim 21 and including:

(a) a spray drive conduit communicating between said compressor means and said head and communicating air under pressure to said head to drive said dye from said head in a spray pattern.

23. An apparatus as set forth in claim 22 and including:

(a) spray pattern control means positioned in said spray drive conduit and adjustable to vary pressure therein to thereby control said spray pattern from said head.

24. An apparatus as set forth in claim 21 and including:

(a) a pneumatic spray control valve positioned in said head to control spray of said dye from said head; and

(b) a pneumatic spray valve control conduit communicating between said compressor means and said spray control valve and controlling the operation of said spray control valve.

25. An apparatus as set forth in claim 21 and including:

(a) air valve means interposed between said compressor means and said container means and head, said air valve means being connected to said control means whereby said control means controls flow of compressed air to said container means and said head.

26. An apparatus for applying dye to a dye receiving medium in a selected dye image pattern and comprising:

(a) dye medium support means having at least a two dimensional extent for supporting a dye receiving medium;

(b) a dye spray head including means mounting said head on said support means for movement in at least two dimensions;

(c) spray head motor means drivingly engaged between said support means and said head and operable to move said head in said at least two dimensions;

(d) dye supply means controllable to supply dye to said head;

(e) control means having said motor means and said dye supply means connected thereto and controlling said motor means and said dye supply means to move said dye spray head in relation to said dye receiving medium and to cause communication of said dye to said head in such a manner as to apply said dye to said medium in said selected dye image pattern;

(f) a plurality of dye containers each containing a respective dye and a plurality of dye conduits connected respectively to said containers and communicating an associated dye therefrom;

(g) a quick disconnect connector terminating each dye conduit, said connector providing flow communication when connected and automatically preventing flow communication when disconnected, the connectors allowing disconnection of one dye conduit and connection of another dye conduit for selection of a dye;

(h) a selected one of said dye conduits being connected to said spray head to flow communicate an associated dye thereto; and

(i) air compressor means communicating with each dye container and said head to pneumatically urge said associated dye through said head.

27. An apparatus as set forth in claim 26 and including

(a) a spray drive conduit communicating between said compressor means and said head and communicating air under pressure to said head to drive said dye from said head in a spray pattern;

(b) air valve means interposed between said compressor means and said container means and head, said air valve means being connected to said control means whereby said control means controls flow of compressed air to said container means and said head;

(c) purge sink means positioned at a purge position on said support means to receive a purge spray from said spray head, said control means normally causing said motor means to park said spray head at said purge position prior and subsequent to spraying a selected dye image pattern; and

(d) a purge control interfaced to said control means and operable when said head is parked at said purge position to activate said spray head air valve means to thereby purge said spray head of a previous dye after disconnection of a previous dye conduit from said head and reconnection of a new dye conduit thereto.