CN104943169B - 用于使用光学传感器和可逆热衬底来检测三维物体打印中的不工作喷墨口的系统 - Google Patents

用于使用光学传感器和可逆热衬底来检测三维物体打印中的不工作喷墨口的系统 Download PDF

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CN104943169B
CN104943169B CN201510116683.1A CN201510116683A CN104943169B CN 104943169 B CN104943169 B CN 104943169B CN 201510116683 A CN201510116683 A CN 201510116683A CN 104943169 B CN104943169 B CN 104943169B
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backheating
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CN104943169A (zh
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V·L·沃内
J·L·贾克比
M·R·麦克劳克林
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Xerox Corp
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Abstract

本发明提供一种装置，该装置在三维物体的打印期间检测不工作喷墨口。该装置包括可逆热衬底，该可逆热衬底改变材料滴被喷射到衬底上的区域中的光学密度。光学传感器在材料滴被喷射到衬底上之后生成衬底的图像数据并且对这些图像数据进行分析以识别不工作喷墨口。

Description

用于使用光学传感器和可逆热衬底来检测三维物体打印中的 不工作喷墨口的系统
技术领域
本文中公开的装置涉及产生三维物体的打印机，并且更特别地涉及这样的打印机中的不工作喷墨口的精确检测。
背景技术
也称为数字增材制造的数字三维制造是从数字模型制造实质上任何形状的三维固体物体的过程。三维打印是增材过程，其中一个或多个打印头在衬底上以不同形状喷射材料的连续层。三维打印与主要依赖通过减材过程从工件去除材料的传统物体形成技术、例如切割或钻孔可区分。
用这些打印机生产三维物体会需要数小时，对于一些物体，甚至需要数天。在用三维打印机生产三维物体中出现的一个问题是喷射形成物体的材料滴的打印头中的喷墨口的一致功能性。在物体的打印期间，一个或多个喷墨口会由于以一定角度而不是垂直于打印头喷射，且喷射的滴小于喷墨口应当喷射的或由于根本未能喷射任何滴而退化。遭受这些操作缺陷中的任何一个的喷墨口被称为不工作喷墨口。如果一个或多个喷墨口的操作状态在物体打印期间退化，则在打印操作完成之前不能评估被打印物体的质量。因此，需要数小时或多天的打印作业会产生由于打印头中的不工作喷墨口而不符合规范的物体。一旦检测到这样的物体，被打印物体被废弃，恢复程序被应用于打印头以恢复喷墨口功能性，并且重复打印作业。一种可以在打印的同时检测不工作喷墨口的装置将使得可以在物体打印期间应用恢复程序，因此可以产生正确成形的物体。通过该方式，打印机的产品生产量得以改进并且其打印更高效。该装置应当可以检测喷射大量打印材料(例如透明、彩色、半透明、磷光和蜡状材料)的不工作喷墨口。
发明内容
一种使得可以检测三维打印机中的不工作喷墨口的装置包括：热衬底；光学传感器，该光学传感器配置成生成热衬底的表面的数据；传输件，该传输件配置成将热衬底移动至与光学传感器相对的位置处，以使得该光学传感器可以生成热衬底上的滴的图像数据；和控制器，该控制器操作地连接到传输件和光学传感器，该控制器配置成操作传输件以将热衬底移动到与光学传感器相对的位置处，以操作光学传感器在材料滴已通过打印头中的喷墨口被喷射到热衬底上之后生成热衬底的图像数据，并且以参照从光学传感器接收到的与热衬底上的材料滴相对应的图像数据来识别喷射滴的打印头中的不工作喷墨口。
一种结合了用于检测不工作喷墨口的装置的打印机包括：打印头，该打印头配置成具有喷墨口以喷射材料滴；热衬底，该热衬底配置成移动至与打印头相对的位置处以接收从该打印头喷射的滴；光学传感器，该光学传感器配置成生成与热衬底上的滴相对应的数据；传输件，该传输件配置成将衬底移动至与光学传感器相对的位置处，以使得该光学传感器可以生成热衬底上的滴的图像数据；和控制器，该控制器操作地连接到传输件、光学传感器和打印头，该控制器配置成当热衬底在与打印头相对的位置处保持静止的同时操作打印头以从每个喷墨口将预定数量的滴喷射到热衬底上，以使得预定数量的滴能够在热衬底上形成每个喷墨口的测试点，以操作光学传感器生成热衬底的图像数据，并且以参照从光学传感器接收到的与热衬底上的测试点相对应的图像数据来识别打印头中的不工作喷墨口。
附图说明
在结合附图进行的以下描述中解释在三维打印期间检测不工作喷墨口的装置或打印机的前述方面和其它特征。
图1是三维物体打印机的透视图。
图2是具有外壳的三维物体打印机的前视图，描绘用于模块的外壳内的空间，该模块可以在打印操作期间检测打印头中的不工作喷墨口。
图3是配合在图2中所示的空间中的用于检测不工作喷墨口的模块的侧视图。
图4是用于操作图3的模块的方法的流程图。
具体实施方式
为了本文中公开的装置的环境以及装置的细节的大体理解，参照附图。在附图中，相似的附图标记表示相似的元件。
图1显示产生三维物体零件10的打印机100中的部件的配置。当在本文中使用时，术语“三维打印机”指的是参照物体的图像数据喷射材料以形成三维物体的任何装置。打印机100包括支撑材料容器14，构建材料容器18，一对喷墨打印头22、26，构建衬底30，平面支撑构件34，柱状支撑构件38，致动器42，以及控制器46。管道50将打印头22连接到支撑材料容器14并且管道54将打印头26连接到构建材料容器18。两个喷墨打印头由控制器46参照操作地连接到控制器的存储器中的三维图像数据操作以喷射供应到每个相应的打印头的支撑和构建材料。当构造该零件时，构建材料形成正产生的零件10的结构，而当材料固化时由支撑材料形成的支撑结构58可以使构建材料保持它的形状。在完成该零件之后，通过冲洗、吹气或熔化去除支撑结构58。
控制器46也操作地连接到至少一个和可能多个致动器42以控制平面支撑构件34、柱状支撑构件38和打印头22、26相对于彼此的运动。也就是说，一个或多个致动器可以操作地连接到支撑打印头的结构以参照平面支撑构件的表面在过程方向和交叉过程方向上移动打印头。替代地，一个或多个致动器可以操作地连接到平面支撑构件34以在平面支撑构件34的平面中沿过程和交叉过程方向移动在其上产生所述零件的表面。当在本文中使用时，术语“过程方向”指的是沿着平面支撑构件34的表面中的一个轴线的运动并且“交叉过程方向”指的是沿着与该表面中的过程方向轴线正交的平面支撑构件表面中的轴线的运动。这些方向在图1中用字母“P”和“C-P”表示。打印头22、26和柱状支撑构件38还在正交于平面支撑构件34的方向上移动。该方向在本文中被称为竖直方向、与柱状支撑构件38平行、并且在图1中用字母“V”表示。在竖直方向上的运动由操作地连接到柱状支撑构件38的一个或多个致动器、由操作地连接到打印头22、26的一个或多个致动器或由操作地连接到柱状支撑构件38和打印头22、26两者的一个或多个致动器实现。这些各种配置中的这些致动器操作地连接到控制器46，该控制器操作致动器以在竖直方向上移动柱状构件38、打印头22、26或两者。
在图2中显示具有外壳的三维物体打印机。该打印机60具有外壳64。在外壳64内是形状上大体上为立方体的六个隔室。外壳64在图2中显示为没有闭合以隐藏隔室的门。隔室72包括在可移动平台82上的平面支撑件78。可移动平台82配置成具有一个或多个致动器和引导构件(未显示)以使可移动平台82可以在竖直方向上上下移动。平面支撑件78是三维物体形成于其上的表面。在一些实施例中，打印头86具有的长度大约等于在从隔室72的后壁到在隔室的前面处的开口的方向上的平面支撑件78的长度。在这些实施例中，打印头86在支撑构件92上安装在外壳64的侧壁96和100之间的空间中以便仅仅线性往复运动。在其它实施例中，打印头86具有的长度小于在从隔室72的后壁到在隔室的前面处的开口的方向上的平面支撑件78的长度。在这些实施例中，打印头86在支撑构件92上安装在外壳64的侧壁96和100之间的空间中以便在隔室72之上的平面中的两个正交方向上往复运动。在这些各种实施例中，一个或多个致动器104操作地连接到打印头86。控制器108操作致动器104以在支撑构件92上线性地来回移动打印头86或在平面内的两个正交方向上移动打印头。通过选择性地操作打印头86中的喷墨口并且竖直地移动支撑平台82和水平地移动构件92上的打印头86，三维物体可以形成于平面支撑件78上。
在图2中以虚线描画的区域112识别模块的放置，所述模块使用热膜来检测打印机60中的不工作喷墨口。如上所述，如果在物体的打印期间喷墨口由于完全或部分地未能喷射材料或由于在偏斜方向上错误地喷射材料而出故障，则正在生产的物体变形。目前，在物体的生产完成之前不能检测到该变形。通过使用区域112以便光学地感测不工作喷墨口，打印机60可以配置成在物体生产期间检测不工作喷墨口，如下面更全面地所述。模块300内的一些部件可以在水平方向H、深度方向D和竖直方向V上移动，如图中所示。
在图3的方块图中显示在物体打印期间检测喷射透明材料的不工作喷墨口的模块的一个实施例。模块300配置成配合在打印机60的区域112内。模块300包括光学传感器304、热衬底308、一个或多个致动器316、控制器324、清洁构件320和废料容器328。衬底308配制成围绕两个辊332卷绕的环形带。光学传感器304与带一样宽，但是如果光学传感器304配制成用于在带宽度的方向上通过致动器双向移动的话则该光学传感器可能更窄。控制器324操作地连接到致动器316以驱动辊332中的至少一个以使衬底308的环形带围绕光学传感器304旋转并且通过清洁构件320来扫掠衬底308。
热衬底308是由这样的材料制成的平面构件：该材料支撑从打印头86喷射的构建材料和支撑材料并且响应于构件材料或支撑材料中含有的热而改变颜色。参照输入到热衬底材料的每热能单位的光学密度的已知函数，这些材料的光学密度增大。当热能耗散时，由于热而变暗的区域变回其原始颜色。例如，平面衬底可以是由Glenview,IL的LCRHallcrest制造的膜。示例性材料见http://www.hallcrest.com/digitempsc.cfm。当在本文中使用时，热衬底改变衬底上的区域的输入到该区域的每热能单位光学密度。当在本文中使用时，可逆热衬底指的是恢复到热能被输入到衬底的区域之前该区域所具有的光学密度的热衬底。
清洁构件320被安装于操作地连接到致动器的支撑构件。如下所述，控制器324操作致动器以移动支撑构件从而使衬底332与清洁构件320相接合。该动作将构建和支撑材料从衬底308扫掠到废料容器328中以恢复衬底308的表面用于下一次测试图案打印。清洁构件340可以包括清洁溶剂340的供应装置，控制器324可以操作该供应装置以在清洁构件扫掠衬底之前将清洁溶剂散布到衬底上。清洁溶剂与构建和支撑材料相互化学作用，以使该材料在遇到清洁构件之前疏松。除此之外或替代地，加热器326相对于清洁构件320定位，以在清洁构件扫掠衬底308之前加热构建和支撑材料。在其它实施例中，不提供清洁构件并且控制器使衬底332前进使得可以打印测试图案并且随后通过传感器304成像的量。控制器324检测带308何时接近一次完整旋转并且其然后生成指示带308需要改变的信号。
在图4中显示操作产生三维物体的打印机的方法。在该方法的描述中，过程正在执行某个任务或功能的陈述指的是控制器或通用处理器执行存储在操作地连接到控制器或处理器的存储器中的编程指令以处理数据或操作打印机中的一个或多个部件以执行任务或功能。上述的控制器324可以是这样的控制器或处理器。替代地，控制器324可以用一个以上处理器和关联的电路和部件实现，其中的每个配置成形成本文中所述的一个或多个任务或功能。
在打印操作中的预定时间，控制器108(图2)操作致动器104以将打印头86移动到位于区域112中的模块300中，在该区域112处，控制器108操作打印头86将构建和支撑材料喷射到衬底308上，该衬底308在被打印时是静止的(方块404)。在一个实施例中，重复操作打印头中的每个喷墨口以在与喷墨口相对的衬底308的部分上形成也称为测试点的料堆。在打印测试图案之后，控制器108生成到达控制器324的指示形成测试图案的材料喷射已完成的信号(方块408)。响应于来自控制器108的信号，控制器324操作光学传感器304以生成衬底308的图像数据(方块420)。传感器304的操作几乎在测试图案被打印之后立刻发生，原因是所喷射的材料的热及其对衬底332的影响随着材料离开喷墨口而开始耗散。传感器304所生成的电信号是参照用于形成测试图案的构建和支撑材料的期望位置进行分析以识别不工作喷墨口的图像数据(方块424)并且如果已识别出不工作喷墨口，则为打印机的操作者生成指示缺陷打印头的信号(方块428)。操作者然后可以采取适当行动。控制器324继续操作致动器316以旋转衬底308，从而准备清洁部分用于下一次喷墨口测试(方块430)。如上文所解释的，可以通过使衬底308与清洁构件320相接合以在衬底移动通过清洁构件时从该衬底去除材料或者通过使衬底前进来执行清洁以提供该衬底的清洁部分用于下一个测试图案。如果材料被构件320去除，则该材料被收集在废料容器328中，该废料容器可以不时被从打印机移除并且被更换或清空且随后重新安装。
尽管上文所讨论的实施例属于形成三维物体的打印机，但是热衬底和通过所喷射的材料的热对这种衬底的影响来检测不工作喷墨口的系统也可以用于二维文件打印系统，特别是使用透明墨的二维文件打印系统。在这种系统中，热衬底不时被打印头通过以被打印、成像和分析从而识别不工作喷墨口。类似地，将透明墨喷射到移动条幅或成像构件(例如鼓)上的打印头可以与热衬底相反地移动以用于打印和检测不工作喷墨口。因此，当在本文中使用时，词语“材料”指的是可以用于形成三维物体以及用于文件打印的墨的物质。

Claims (5)

1.一种打印机，包括：
打印头，所述打印头配置成具有喷墨口以喷射材料滴；
围绕多个辊卷绕的可逆热衬底的环形带，所述环形带配置成移动至与所述打印头相对的位置以使得所述可逆热衬底能够接收从所述打印头喷射的滴；
光学传感器，所述光学传感器配置成生成与所述热衬底上的所述滴相对应的数据；
传输件，所述传输件配置成将所述衬底移动至与所述光学传感器相对的位置处，以使得所述光学传感器能够生成所述热衬底上的所述滴的图像数据；
清洁构件；和
控制器，所述控制器操作地连接到所述传输件、所述光学传感器、和所述打印头，所述控制器配置成：操作致动器以使所述可逆热衬底的环形带围绕所述多个辊移动；当所述热衬底在与所述打印头相对的所述位置处保持静止的同时操作所述打印头以从每个喷墨口将预定数量的滴喷射到所述热衬底上，以使得所述预定数量的滴能够在所述热衬底上形成每个喷墨口的测试点；操作所述光学传感器生成所述热衬底的图像数据；参照从所述光学传感器接收到的与所述热衬底上的所述测试点相对应的图像数据来识别所述打印头中的不工作喷墨口；并且操作所述清洁构件以在所述可逆热衬底的环形带移动通过所述清洁构件时与所述可逆热衬底相接合。
2.根据权利要求1所述的打印机，还包括：
清洁溶剂的供应装置；并且
所述控制器还配置成操作所述清洁溶剂的供应装置以在所述清洁构件与所述可逆热衬底相接合之前向所述可逆热衬底施加清洁溶剂。
3.根据权利要求1所述的打印机，所述清洁构件还包括：
加热器，所述加热器配置成在所述可逆热衬底移动通过所述清洁构件时加热所述可逆热衬底。
4.一种打印机，其包括：
打印头，其配置成具有喷墨口以喷射材料滴；
可逆热衬底，其配置成移动至与所述打印头相对的位置以接收从所述打印头喷射的滴；
光学传感器，其配置成生成与所述可逆热衬底上的所述滴相对应的数据，所述光学传感器具有比所述可逆热衬底的宽度大的宽度；
传输件，其配置成将所述衬底移动至与所述光学传感器相对的位置处以使得所述光学传感器能够生成所述可逆热衬底上的所述滴的图像数据；以及
控制器，其操作地连接到所述传输件、所述光学传感器和所述打印头，所述控制器配置成：当所述可逆热衬底在与所述打印头相对的所述位置处保持静止的同时操作所述打印头以从每个喷墨口将预定数量的滴喷射到所述可逆热衬底上，以使得所述预定数量的滴能够在所述可逆热衬底上形成每个喷墨口的测试点；操作所述光学传感器生成所述可逆热衬底的图像数据；并且参照从所述光学传感器接收到的与所述可逆热衬底上的所述测试点相对应的图像数据来识别所述打印头中的不工作喷墨口。
5.一种打印机，其包括：
打印头，其配置成具有喷墨口以喷射材料滴；
可逆热衬底，其配置成移动至与所述打印头相对的位置以接收从所述打印头喷射的滴；
光学传感器，其配置成生成与所述可逆热衬底上的所述滴相对应的数据，所述光学传感器定位在所述可逆热衬底的与所述可逆热衬底接收来自所述打印头的滴的一侧相对的一侧上；
传输件，其配置成将所述衬底移动至与所述光学传感器相对的位置处以使得所述光学传感器能够生成所述可逆热衬底上的所述滴的图像数据；以及
控制器，其操作地连接到所述传输件、所述光学传感器和所述打印头，所述控制器配置成：当所述可逆热衬底在与所述打印头相对的所述位置处保持静止的同时操作所述打印头以从每个喷墨口将预定数量的滴喷射到所述可逆热衬底上，以使得所述预定数量的滴能够在所述可逆热衬底上形成每个喷墨口的测试点；操作所述光学传感器生成所述可逆热衬底的图像数据；并且参照从所述光学传感器接收到的与所述可逆热衬底上的所述测试点相对应的图像数据来识别所述打印头中的不工作喷墨口。
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