The Boeing Company

Zachary R Smith

Anthony Wayne Baker

Luke Charles Ingram

Amir Afrasiabi

Kenneth Paul Bowers, Iii

David J Homolak

A system for automated surface anomaly detection includes at least one processor which is configured to retrieve from non-volatile memory a 3D control image; capture a 3D target image depicting at least the portion of the exterior of a target object; generate 2D target planar images of the target object based on the 3D target image, using a first plurality of virtual cameras; generate 2D control planar images of the control object based on the 3D control image using a second plurality of virtual cameras, the 2D control planar images corresponding to the 2D target planar images of the target object; detect at least one difference between the 2D target planar images and the 2D control planar images; and generate and cause to be displayed an output image comprising a depiction of the target object with the at least one difference indicated.

System and method for automated surface anomaly detection

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

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

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

An apparatus and related methods for applying two-dimensional (2D) texture maps onto three-dimensional (3D) objects are described. A computing device can receive differing first and second meshes representing respective first and second 3D objects and a 2D texture associated with the first 3D object. The computing device can determine correspondence points between the first and second meshes and can align the first and second meshes using an alignment transformation based on the correspondence points. The computing device can determine texture portions of the 2D texture associated with first corresponding portions of the first mesh. The computing device can assign the texture portions to second corresponding portions of the aligned second mesh. For each texture portion, the computing device can: project the texture portion onto a 2D plane related to a particular second corresponding portion and fit the projected texture portion to the particular second corresponding portion.

Growing community of inventors

Hanahan, SC, United States of America

Zachary R Smith