The Boeing Company

Luke Charles Ingram

Anthony Wayne Baker

Steven A Dorris

Zachary R Smith

Christopher P Bellavia

Shane Edward Arthur

John Eric Miller

Brandon M Courter

Hugh L Taylor

Kjersta Larson-smith

Matt Christner

Kenny P Bowers

Ryan Petz

Jesse Castleberry

Travis King

Jonathan Schwedhelm

Deepak Khosla

Yang Chen

David J Huber

Matthew H Mellin

Mark S Bunker

Josiah Brubaker

Kenneth Paul Bowers, Iii

Scott Rad

David J Homolak

Jacob Moorman

Ryan Siok

Wendy Zaballos

An end effector and associated systems and methods for printing ink on a surface is disclosed. The end effector comprises a main block including a back plate. The end effector also includes a plurality of slice assemblies slidably coupled to the back plate. Each one of the plurality of slice assemblies includes a printhead and a y-actuator. The y-actuator is selectively operable to extend and retract the printhead, parallel to a y-axis in first directions, and relative to the back plate. The end effector further includes a plurality of z-actuators coupled to the back plate. Each one of the plurality of z-actuators is selectively operable to extend and retract a corresponding one of the plurality of slice assemblies, parallel to a z-axis in second directions, which is perpendicular to the y-axis and relative to the back plate.

Multi-printhead end effector and associated system and method

A computing system includes an input sensor, a processor, and a memory storing executable instructions that, in response to execution by the processor, cause the processor to collect input data related to at least a portion of an object from the input sensor, generate a UV coordinate map based on the input data, use a predetermined process ink density lookup table to produce an ink density bitmap corresponding to the UV coordinate map, the ink density bitmap including process ink densities for each bit in the ink density bitmap, produce and output a dithering of bits of the ink density bitmap to thereby generate dithered image pixel data, and compile and output a control plan, based on the dithered image pixel data, to control a printing array to print an image on a contoured surface of the object.

System and methods for controlling a printing array

An end effector for printing ink on a surface is disclosed. The end effector comprises a primary block comprises a primary-block body. A plurality of primary-printing modules are coupled to the primary-block body and translationally moveable, via a corresponding first actuator. Each one of the primary-printing modules includes at least one printhead which is adjustable, relative to the primary-block body. The printhead may be adjusted by at least one of a second actuator, configured to rotate the printhead about a first axis, or a third actuator, configured to rotate the printhead about a second axis. In some examples, a fourth actuator is configured to rotate at least one printhead, relative to at least one other printhead, about a third axis. Additionally, at least one trailing block can be coupled to the primary block so that the at least one trailing block is movable relative to the primary block.

Apparatuses and methods train a model and then use the trained model to determine a global three dimensional (3D) position and orientation of a fiduciary marker. In the context of an apparatus for training a model, a wider field-of-view sensor is configured to acquire a static image of a space in which the fiducial marker is disposed and a narrower field-of-view sensor is configured to acquire a plurality of images of at least a portion of the fiducial marker. The apparatus also includes a pan-tilt unit configured to controllably alter pan and tilt angles of the narrower field-of-view sensor during image acquisition. The apparatus further includes a control system configured to determine a transformation of position and orientation information determined from the images acquired by the narrower field-of-view sensor to a coordinate system for the space for which the static image is acquired by the wider field-of-view sensor.

Method and apparatus for determining a three-dimensional position and pose of a fiducial marker

One embodiment comprises a method of operating a robotic system. The method comprises defining a Tool Center Point (TCP) for an end effector of the robotic system, providing a primary control plan that defines a tool path for the end effector, where the tool path has a plurality of pre-defined TCP positions. The method further comprises providing a secondary control plan that defines operation of the end effector at the plurality of pre-defined TCP positions, and determining a deviation between a pre-defined TCP position of the end effector and an actual TCP position of the end effector during implementation of the primary control plan by the robotic system. The method further comprises modifying the secondary control plan for the end effector based on the deviation during the implementation of the primary control plan by the robotic system.

End effector compensation of a robotic system

Methods of performing a rotational and translational calibrations of a print control system of an inkjet printer system having an inkjet printhead assembly with one or more inkjet printheads are disclosed. Rotational calibration is performed by printing a first rotational calibration pattern from a first standoff distance and a second rotational calibration pattern from a second standoff distance on a first calibration object. The print control system is calibrated until the rotational calibration patterns are within a direction difference tolerance of each other. Translational calibration is performed by printing a first translation calibration pattern on a second calibration object, rotating the inkjet printhead assembly 180&#xb0;, and printing a second translational calibration pattern on the second calibration object. The print control system is calibrated until the translational calibration patterns are within a direction difference tolerance of each other.

Robotic 3D geometry direct-to-surface inkjet printing calibration process

An apparatus includes a memory configured to store multiple sets of image data. Each of the sets corresponds to a respective portion of a surface of an object and a respective portion of a structured light pattern projected onto the surface. The apparatus includes a processor configured to perform structured light reconstruction of the sets, including matching a first group of image pixels that correspond to a projected pixel of the structured light pattern in a first set of image data with a second group of image pixels that correspond to the projected pixel in a second set of image data. The processor is configured to perform stereo reconstruction of the sets, including matching one or more features detected within the first group of image pixels with one or more features detected within the second group of image pixels, to generate three-dimensional point data of the surface.

Three-dimensional point data based on stereo reconstruction using structured light

A camera vision system for creating 3D reconstructions of objects may include a camera, a distance sensor having a fixed spatial relationship with the camera, and a system controller. The system controller receives distance sensor signals from the distance sensor indicating a sensor-to-object distance, determines a camera-to-object distance and a corresponding camera focus state based on the sensor-to-object distance, and transmits camera focus state control signals to cause the camera to adjust to the camera focus state. The system controller retrieves camera intrinsic parameter values for the camera focus state, transmits image capture control signals to cause the camera to capture an object image of the object, receives object image data from the camera for the captured object image, and stores the object image data and the camera intrinsic parameter values in an image database for use in the 3D reconstruction.

Adaptive camera control and calibration for dynamic focus

A method of collecting a metrology data set of a contoured surface with a metrology system and executing an automatic control plan for printing on a contoured surface is disclosed. The method includes attaching a work piece to a work piece frame and scanning a contoured surface of the work piece to obtain a metrology data set, a three-dimensional point cloud model is generated based on the metrology data set. Additionally, the method includes defining a spatial reference model of the work piece frame, and defining a print path for a print head assembly of a surface treatment assembly. Furthermore, the method includes discretizing the contoured surface into a plurality of regions and the print path is further defined into at least one independent regional print path for each region of the plurality of regions. Moreover, a computer software simulation verifies a control plan for printing on the contoured surface.

Metrology-based path planning for inkjet printing along a contoured surface

Systems and methods are provided for verifying the placement of tows by a robot. One embodiment includes a robot that includes an end effector that lays up tows, actuators that reposition the end effector, a memory storing a Numerical Control (NC) program, and a robot controller that directs the actuators to reposition the end effector based on the NC program, and instructs the end effector to lay up tows based on the NC program. The system also includes a sensor system comprising an imaging device that acquires images of the tows as the tows are laid-up, a measuring device that generates input as tows are laid-up by the end effector, and a sensor controller that receives images from the imaging device and the input from the measuring device, and updates stored data to correlate the images with instructions in the NC program, based on the input.

Verification of tow placement by a robot

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.

Automated controls for contoured surface inkjet printing

Provided are methods and systems for inspecting surfaces of various components, such as evaluating height deviations on these surfaces. A method involves aggregating inspection data from multiple line scanners into a combined data set. This combined data set represents a portion of the surface that is larger than the field of measurement any one of the scanners. Furthermore, each pair of adjacent scanners operate at different periods of time to avoid interference. Because operating periods are offset, surface portions scanned by the pair of adjacent scanners can overlap without interference. This overlap of the scanned portions ensures that the entire surface is analyzed. The position of scanners relative to the inspection surface may be changed in between the scans and, in some embodiments, even during the scan. This approach allows precise scanning of large surfaces.

Growing community of inventors

Summerville, SC, United States of America

Luke Charles Ingram