WO2019116395A1

WO2019116395A1 - System and method for surface enhancement

Info

Publication number: WO2019116395A1
Application number: PCT/IN2018/050840
Authority: WO
Inventors: Michael Victor Rodney Foley; Daniel Fu; Jesal SHAH
Original assignee: Foley Designs Private Limited
Priority date: 2017-12-14
Filing date: 2018-12-14
Publication date: 2019-06-20

Abstract

A surface enhancement system (100) for enhancing or modifying surface of a material is provided. The surface enhancement system (100) includes an image scanner (102), at least one laser engraving head (106), an ink-jet printer head (104), and a system controller unit (602). The system controller unit (602) includes an image controller (1002), an engraver controller (1004) and a print controller (1006). The image scanner (102) obtains digital image data periodically in real-time of the workpiece material (104). The at least one laser engraving head (106) moves on a fixed gantry with respect to laser work area on the workpiece material (104). The ink-jet printer head (108) moves along with the fixed gantry from one end of work area on the workpiece material (104) to another end of the workpiece material (104) to enhance the surface of the work piece material (104).

Description

SYSTEM AND METHOD FOR SURFACE ENHANCEMENT

BACKGROUND

Technical Field

[0001] The embodiments herein generally relate to surface modification and finishing methodologies, and more particularly to an automated system and method which continuously modifies and enhances the surface properties of compatible materials.

Description of the Related Art

[0002] All existent operations related to the modification and finishing of any surface shall hereby be referred to as surface enhancements, in the context of the present invention.

[0003] A variety of surface enhancements exist to enable the modification of surfaces in both physical and visual senses, giving surfaces selective colour application, or, through selective additive or subtractive methods, giving the surface a physical texture. However, these enhancements are generally not dependent on the existing surface features (either visual or physical) of the surface.

[0004] Existing enhancement/modification methods are generally used separately and the material is transferred from one workstation to the next, where each workstation specifically deals with one method. Also, conventional system does not allow for much flexibility in a surface modification other than smoothening, roughening and tinting of color. Some existing technologies allow a custom print on a veneer but these are completely independent of original surface features and have less to do with enhancement and more to do with customization. The UV printing method on wood is a commonly utilized process, but not on the scale of mass production. The costs of UV printing process are also high. The UV printing yields a layer of ink which may or may not carry the original grain of the wood based on the type of grain carried by the same wood. The UV ink yields are of desirable color rendition but has very little penetration into the wood. Laser galvanometer engraving systems are capable of cutting, marking and engraving a number of materials, hence are tentative ideal. Other laser systems, such as Gantry type laser engraving systems can also be used, but will yield a much longer work time. [0005] Three-dimensional CNC routing is another option to modify surface features. However, it is the most time consuming of all, and levels of detail are entirely dependent on the size of the router bit. Sand blasting is another option, but in order to achieve fine details, an equally detailed masking sheet may be made and applied to the surface. Sanding and wire brushing are also candidates for this process, but it is nearly impossible to achieve fine levels of detail, unless there is a masking sheet applied to the surface.

[0006] The incorporation of digital modification process for wood on large scale is desirable and has not been known. Further, a multi-functional system that can perform simultaneous functions including scanning, printing and laser etching on substrates remains a major challenge, particularly in existing technologies.

[0007] Accordingly, there remains a need for a system and method in order to enhance/modify the surface digitally in correlation to its existing visual and physical features in real-time.

SUMMARY

[0008] In view of the foregoing, an embodiment herein provides a surface enhancement system for enhancing or modifying surface of a material. The surface enhancement system includes an image scanner, at least one laser engraving head, an ink-jet printer head, and a system controller unit. The system controller unit includes an image controller, an engraver controller and a print controller. The image scanner obtains digital image data periodically in real-time of a workpiece material and the obtained digital image data are stored in a scan data buffer. The laser engraving head moves on a fixed gantry with respect to laser work area on the workpiece material. The laser engraving head includes a laser source for vaporizing the workpiece material. The ink-jet printer head moves along with the fixed gantry from one end of work area on the workpiece material to another end of the workpiece material to enhance the surface of the work piece material. The image controller includes a node -based digital image processor which modifies the digital image data obtained by the image scanner based on predefined effect definitions and stored in a scanned data buffer. The engraver controller receives modified digital image data from the image controller to engrave the work piece material using the laser engraving head based on at least one of features extracted from the digital image data processed by the node-based digital image processor of the image controller. The modified digital image data for engraving is stored in an engraving data buffer. The print controller receives modified image data for printing from the image controller and enhances the surfaces of the work piece material using the inkjet print head. The modified digital image data for printing is stored in a print data buffer.

[0009] In an embodiment, the image scanner is a linear image scanner.

[0010] In another embodiment, the image scanner includes at least one adjustable pressure roller that is connected to at least one side of the image scanner. The at least one adjustable pressure roller eliminates distortions in the captured image arising from warp in the work piece material.

[0011] In yet another embodiment, the laser engraving head includes one or more laser engraving heads placed side by side.

[0012] In yet another embodiment, the laser engraving head includes an infrared laser engraver.

[0013] In yet another embodiment, the predefined effect definitions are obtained from a database or list.

[0014] In one aspect, a method for enhancing or modifying the surface of a material in real time using a surface enhancement system is provided. The method includes the steps of (i) obtaining real-time digital image data of a workpiece material using an image scanner and the obtained image data is stored in a scan data buffer; (ii) applying modifications to the digital image data stored in the scan data buffer based on effect definitions predefined by a node-based digital image processor the image controller and the modified image data is stored in the scan data buffer; (iii) engraving the work piece material using an infrared laser engraver provided on a laser engraving head by an engraver controller based on at least one of the features extracted from the modified digital image data received from the image controller and (iv) printing the modified digital image data received from the image controller on the engraved workpiece material by a print controller using an ink-jet printer head. The modified digital image data for engraving is stored in an engraving data buffer. The modified digital image data for printing is stored in a print data buffer.

[0015] In an embodiment, the modifications are driven by secondary image data. The secondary image data is obtained from an image bank.

[0016] In another aspect, a method for enhancing or modifying the surface of a material using a surface enhancement system is provided. The method incudes the steps of (i) obtaining a full bitmap image data of the workpiece material using an image scanner and the digital image data are stored in a scan data buffer, (ii) processing the full bitmap image data at a bitmap processing module based on bitmap processing instructions by a node -based digital image processor of an image controller, (iii) engraving the work piece material by an engraving controller using an infrared laser engraver provided on a laser engraving head based on at least one of the features extracted from the processed full bitmap image received from the image controller and (iv) printing the full bitmap image data received from the image controller on the engraved workpiece material by a print controller using an ink-jet printer head. The processed full bitmap image is stored in the scan data buffer. The processes full bitmap image for engraving is stored in an engraving data buffer. The full bitmap image data for printing is stored in a print data buffer.

[0017] In an embodiment, the image data is a secondary image data obtained from an image library. The secondary image data is used as a basis to modify the scanned full bitmap image data.

[0018] The surface enhancement system is complete automation of the surface enhancement process. The surface enhancement system requires low cost per unit surface area as compared to many manual processes or existing surface enhancing methodologies. The surface enhancement system requires little to no labor costs per unit area of surface. The surface enhancement system increases production speed and repeatability of output. The surface enhancement system near-infinite range of visual and tactile finishes possible. The surface enhancement system is a scalable technology. Combination of scanning, printing and laser treatment into a simultaneous operation allows for a near-infinite range of finishes for any workpiece. Multiple visual and physical treatments on one surface are also achievable. [0019] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The embodiments herein will be better understood from the following detailed descriptions with reference to the drawings, in which:

[0021] FIG. 1 illustrates a perspective view of a surface enhancement system according to an embodiment herein;

[0022] FIG. 2 illustrates a right side view of the surface enhancement system of FIG. 1 according to an embodiment herein;

[0023] FIG. 3 illustrates a left side view of the surface enhancement system of FIG. 1 according to an embodiment herein;

[0024] FIG. 4 illustrates a top view of the surface enhancement system of FIG. 1 according to an embodiment herein;

[0025] FIGS. 5A and 5B illustrate a front and back view of rollers of the surface enhancement system according to an embodiment herein;

[0026] FIG. 6 illustrates a block diagram of the surface enhancement system of FIG. 1 according to an embodiment herein;

[0027] FIG. 7 illustrates a side view of the surface enhancement system at a stage of material loading according to an embodiment herein;

[0028] FIG. 9 illustrates a sampling view of material engraving biased to dark pixel values of a material image according to an embodiment herein;

[0029] FIG.9 illustrates a sampling view of material printing and engraving based on input pixel values of the surface enhancement system according to an embodiment herein; [0030] FIG. 10 is a block diagram of a system controller unit according to an embodiment herein;

[0031] FIGS. 11A-11B are block diagrams of image capturing according to an embodiment herein;

[0032] FIG.12 illustrates a memory usage of the surface enhancement system according to an embodiment herein;

[0033] FIG. 13 is a block diagram of a engraving controller according to an embodiment herein;

[0034] FIG. 14 is a block diagram of a print controller of FIG. 10 according to an embodiment herein;

[0035] FIG. 15 illustrates an exemplary view of different blended images according to an embodiment herein;

[0036] FIG. 16 is a flow diagram illustrating a method of performing simultaneously and continuously on successive parts of captured image data according to an embodiment herein;

[0037] FIG. 17 is a flow diagram illustrating a method of performing at non-real time using the surface enhancement system according to an embodiment herein;

[0038] FIG. 18 is a flow diagram that illustrates a method of enhancing or modifying surface of a material in real time using the surface enhancement system according to an embodiment herein; and

[0039] FIG. 19 is a schematic diagram of computer architecture of the system controller unit accordance to an embodiment herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0040] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0041] As mentioned, there remains a need for a system and method for enhancing or modifying the surface of the material digitally in correlation to its existing visual and physical features in real-time. Referring now to the drawings, and more particularly to FIGS. 1 through 19, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.

[0042] FIG. 1 illustrates a perspective view of a surface enhancement system 100 according to an embodiment herein. The surface enhancement system 100 includes an image scanner 102, a workpiece material 104, at least one laser engraving head 106, an ink-jet printer head 108, workpiece thickness adjustment knobs 110, feed rollers 112, a set of adjustable pressure rollers 114A-B, a vertical fixed gantry 116A, a horizontal fixed gantry 116B, chassis 118, a slide plate 120, a drive motor unit 122, a drive pulley 124 and a drive belt 126. In an embodiment, the workpiece material 104 moves in forward direction on the slide plate 120 with the aid of the feed rollers 112 and the set of adjustable pressure rollers 114A-B. The image scanner 102 obtains digital image data periodically in real-time of the workpiece material 104. The digital image data are stored in a scan data buffer. In one embodiment, the image scanner 106 is fixed rigidly to a separate gantry. The at least one laser engraving head 106 is configured to move on the vertical fixed gantry 116A with respect to laser work area on the workpiece material 104. The at least one laser engraving head 106 includes a laser source configured to vaporize the workpiece material 104. The at least laser engraving head 106 moving on the vertical fixed gantry 116A that engraves the workpiece material 104 using an infrared laser engraver.

[0043] In one embodiment, the laser engraving head 106 includes of two or more heads placed side by side such that the engraving process load is distributed between them to increase maximum working speed of the surface enhancement system 100. The ink-jet printer head 108 moves along with the horizontal fixed gantry 116B from one end of work area on the workpiece material 104 to another end of the workpiece material 104 to enhance the surface of the workpiece material 104. The drive motor unit l22moves the workpiece material 104, through the slide plate 120 and feed rollers 112.

[0044] The set of adjustable pressure rollers 114A-B are attached each side of the image scanner 102 in order to eliminate distortions in the captured image arising from warp in the workpiece material 104. In one embodiment, the image is captured through a linear image scanner, which may incorporate either CIS (Contact Image Sensor) or CCD (Charge Coupled Device) or any other suitable technology which require predetermined fixed distance between the workpiece material and the scanning device for accurate results. In one embodiment, image capture is achieved with a camera placed at a fixed distance from the workpiece material 104. However, this may not be ideal in practice, as the thicknesses of different materials are not constant, and the image capture result may vary in size due to change in distance from the workpiece to the camera, in the case of a fixed camera setup. Compensation for this enlargement or reduction in size may be achieved in image processing system or by adjusting the camera position vertically. It is also to be noted that materials with significantly uneven surfaces or warping may be partially out of focus. Another limitation of the camera based imaging system is the level of detail due to resolving power of the camera lens itself. Optical distortions may also have to be considered as a defining factor in terms of image quality. In another embodiment, it is these considerations that leads to line-by-line image scanning as the tentative ideal. Other, more suitable methods may also be used in case they are more compatible with the workpiece and environmental factors. The image capture method is not limited to contact image scanning. However, in the surface enhancement system 100, it has been used for its compatibility with the needs.

[0045] The surface enhancement system 100 further includes a system controller unit (not shown in FIG. 1). The system controller unit an image controller, an engraver controller and a print controller. The image controller includes a node -based digital image processor that is configured to modify the digital image data obtained by the image scanner 102 based on predefined effect definitions. The modified digital image data is stored in the scanned data buffer. The engraver controller receives the modified digital image data from the image controller to engrave the work piece material 104 using the at least one laser engraving head 106 based on at least one of features extracted from the digital image data processed by the node-based digital image processor of the image controller. The modified digital image data for engraving is stored in an engraving data buffer. The print controller receives modified image data for printing from the image controller and enhances the surfaces of the work piece material 104 using the inkjet print head 108. The modified digital image data for printing is stored in a print data buffer.

[0046] In one embodiment, the surface enhancement system 100 is operated in both real time and non-real-time to achieve a high-speed method of surface enhancement. In one embodiment, the workpiece material 104 is continuously driven through the surface enhancement system 100 in real-time operation without the need to stop or pause, other than the time needed for the inkjet print head 108 carriage to reverse direction once it has reached the end of its travel at either end of the horizontal fixed gantry 116B. In one embodiment, the slight delay is eliminated by replacing the movable inkjet print head 108 with a multitude of fixed print heads staggered along the width of the horizontal fixed gantry 116B, as an array, such that they cover the entire width of the workpiece material 104, and all the print heads may jet ink continuously as the workpiece material 104 moves beneath them.

[0047] The system controller unit may synchronize operations of scanner 102, the at least one laser engraving head 106 and the ink-jet printer head 108 such that each system operates on a relevant part of the workpiece material 104 passing under it, therefore allowing for continuous movement of the workpiece material 104 through the system.

[0048] In one embodiment, the digital images are stored on a network based digital storage device. The system controller unit processes the digital images to extract features of the workpiece material 104 in each of the digital images. In one embodiment, the surface enhancement system 100 achieves multiple finishes (e.g. visual enhancement or physical modification) on one surface. In the surface enhancement system 100, screen printing and offset printing are not ideal, as the same print is to be repeated multiple times in these processes, whereas the required output in the surface enhancement system lOOis dependent on the existing visual features on the material, which may or may not change from one workpiece to another. [0049] In one embodiment, in the case of non-real time surface enhancement, the material is held still, while the image scanner 102, at least laser engraving head 106 and the ink-jet printer head 108 are attached to a sliding gantry which is able to move over the length of the workpiece material 104, and the surface enhancement system 100 perform their respective operations in succession.

[0050] In one embodiment, the surface enhancement system 100 utilizes a moving inkjet carriage, the inkjet carriage that actively interrupts motion of the workpiece material 104 through a machine, or the movement of the gantry in case it is a moving part, whose range of motion extends from one end of the workpiece material 104 to the other, lengthwise. The enhancement operations are performed exactly the same way as in the case of moving material. In case the gantry is a moving part, the material is placed on the system, processed, removed and replaced with the next piece of material.

[0051] FIG. 2 illustrates a right side view of the surface enhancement system 100 of FIG. 1 according to an embodiment herein; The right side view includes the image scanner 102, the workpiece material 104, the at least one laser engraving head 106, the ink-jet printer head 108, the set of adjustable pressure rollers 114A-B, the vertical fixed gantry 116A and the chassis 118. The function of the parts has been described above.

[0052] FIG. 3 illustrates a left side view of the surface enhancement system 100 of FIG. 1 according to an embodiment herein. The left side view includes the image scanner 102, the workpiece material 104, the at least one laser engraving head 106, the ink-jet printer head 108, the set of adjustable pressure rollers 114A-B, the vertical fixed gantry 116A and the chassis 118. The function of the parts has been described above.

[0053] FIG.4 illustrates a top view of the surface enhancement system 100 of FIG. 1 according to an embodiment herein. The top view includes the image scanner 102, the workpiece material 104, the at least one laser engraving head 106, the ink-jet printer head 108, the work piece thickness adjustment knobs 110, the feed rollers 112, the set of adjustable pressure rollers 114A-B, the vertical fixed gantry 116A, the horizontal fixed gantry 116B, the chassis 118, the slide plate 120 and the drive motor unit 122. The function of the parts has been described above. [0054] FIGS. 5A and 5B illustrate a front and back view of rollers of the surface enhancement system 100 according to an embodiment herein. The front and back side views depict the pressure rollers 114 and the feed rollers 112. The function of the parts has been described above.

[0055] FIG. 6 illustrates a block diagram of the surface enhancement system 100 of FIG. 1 according to an embodiment herein. The block diagram includes the system controller unit 602, the image scanner 102, the workpiece material 104, the at least one laser engraving head 106 and the inkjet print head 108. The workpiece material 104 is engraved based on the input pixel values. The function of the parts has been described above.

[0056] FIG. 7 illustrates a side view of the surface enhancement system 100 at the stage of material loading according to an embodiment herein. The surface enhancement system 100 includes the image scanner 102, the workpiece material 104, the at least one laser engraving head 106, the ink-jet printer head 108, the set of adjustable pressure rollers 114A- B, the horizontal fixed gantry 116B and the workpiece thickness adjustment knobs 110. The function of the parts has been described above.

[0057] FIG. 8 illustrates a sampling view of the material engraving biased to dark pixel values of the material image according to an embodiment herein. The sampling view depicts the workpiece material 104 before engraving 802 and the workpiece material 104 after engraving 804 in the surface enhancement system 100.

[0058] FIG. 9 illustrates a sampling view of the material printing and engraving based on input pixel values of the surface enhancement system 100 according to an embodiment herein. The sampling view depicts the workpiece material 104 at input stage 902 and the workpiece material 104 at output stage 904 in the surface enhancement system 100.

[0059] FIG. 10 is a block diagram of the system controller unit 602 according to an embodiment herein. The system controller unit 602 includes the imaging controller 1002, the engraver controller 1004, the print controller 1006, the scanned data buffer 1008, the engraving data buffer 1010 and the print data buffer 1012. The image controller 1002 includes the node -based digital image processor that is configured to modify the digital image data obtained by the image scanner 102 based on predefined effect definitions. The modified digital image data is stored in the scanned data buffer 1008. The engraver controller 1004 receives the modified digital image data from the image controller 1002 to engrave the work piece material 104 using the at least one laser engraving head 106 based on at least one of features extracted from the digital image data processed by the node-based digital image processor of the image controller 1002. The modified digital image data for engraving is stored in the engraving data buffer 1010. The print controller 1006 receives modified image data for printing from the image controller 1002 and enhances the surfaces of the work piece material 104 using the inkjet print head 108. The modified digital image data for printing is stored in the print data buffer 1012.

[0060] FIGS. 11A-11B are block diagrams of image capturing according to an embodiment herein. The block diagram includes the image scanner 102, the system controller unit 602, the image controller 1002, the engraving data buffer 1010, the print data buffer 1012, a storage 1102, a media drive motor 1104, an image bank 1106 and a node -based digital image processor 1108. The image scanner 102 scans the surface of the workpiece material 104 to obtain the scanned data. The modified digital image data is stored in the scanned data buffer 1008. In one embodiment, the scanned data is stored. In one embodiment, the image controller 1002 controls scanner operations including but not limited to synchronization of image capture with material/ gantry movement. The workpiece material 104 is continuously driven through such that the image scanner 102 continuously produces image data, one line or band at a time. This is relevant to CIS scanner technology. In this case, one line of image data consists an image spanning the width of the material, one pixel in height. A multitude of these lines placed successive in rows would define a band. In the case of CCD technology, the native form of data output from the scanner would be a band, as each CCD sensor module captures a 2-D image, which is then digitally stitched to the image captured from the adjacent CCD. In either case, the image data is stored in the scanned data buffer 1008, and may optionally be stored in the storage 1102, which may be a disk drive. The node-based digital image processor 1108 reads data from the scanned data buffer 1008, which is sent by the imaging controller 1002. The node-based digital image processor 1108 applies modifications to the image data based on pixel manipulation algorithms, which allow for localized displacement of pixels based on hue/saturation or brightness of the pixels, and also on color adjustment algorithms, which allow for various existing effect definitions to be applied, such as but not limited to blurring, sharpening, color washes, brightness/contrast adjustments, color shifts, etc. These modifications may optionally be driven by secondary image data from another source such as the image bank 1106. The node-based digital image processor 1108 outputs 3 streams of data. Storage, which may be a hard disk or equivalent archival memory device, optionally receives either color image data, intended for the print data buffer 1012, monochrome image data, intended for the engraving data buffer 1010. Storage is accessed by the image bank 1106 function, such that stored image data may be re used in the processing of new image data from the scanned data buffer 1008. In on embodiment, image bank 1106 function also access images on other memory devices.

[0061] FIG. 12 illustrates a memory usage of the surface enhancement system 100 according to an embodiment herein. In one embodiment, effect definitions are pre-defined before the invention is put into operation, and are located in effect definition (node set) from database/list, which in turn is located on a storage device, and may be modified as required. The print data buffer 1012 and the engraving data buffer 1010 hold relevant bands of image data, that are utilized by the respective modules print head(s) and the at least one laser engraving head 106. Each physical, widthwise line on the surface of the workpiece material 104 has a corresponding line of digital image data in the print data buffer 1012 and the engraving data buffer 1010, which is constantly shifted downwards as the material progresses through the machine. The data is only retained until its corresponding operation is fulfilled, and is discarded, line-by-line, or band-by band, to free up space for new image data that is received from the node -based digital image processor 1108, as the print data buffer 1012 and the engraving data buffer 1010 have a predefined storage capacity. In one embodiment, the new image data is added to the top of the band stored in both buffers. The node-based digital image processor 1108 may compute image modifications based on neighboring pixels, the maximum size of pixel neighborhood being the distance between the image scanner 102 and the at least one laser engraving head 106, in the case of engraving image data processing, and between the image scanner 102 and the ink-jet printer head 108 in the case of print image data processing. The entire imaged width of the workpiece material 104 is available for sampling in both cases.

[0062] FIG. 13 is a block diagram of the engraving controller 1004 according to an embodiment herein. The block diagram includes the engraver controller 1004, the engraving data buffer 1010 and an infrared laser engraver 1302. The engraver controller 1004 communicates instruction or feedback with the infrared laser engraver 1302 (e.g. galvanometer type) of the at least one laser engraving head 106. The function of these components has been described above.

[0063] FIG. 14 is a block diagram of the print controller 1006 of FIG. 10 according to an embodiment herein. The block diagram includes the print controller 1006, the print data buffer 1012, a raster image processor 1402, a printer interface 1404, a printer control board 1406, a carriage motor 1408 and printer heads 1410. The print controller 1006 may receive instructions or feedback from the printer interface 1404 or the printer control board 1406. The print controller 1006 receives print data to further process to the raster image processor 1402. The function of these components has been described above.

[0064] FIG. 15 illustrates an exemplary view of different blended images according to an embodiment herein. The user interface view depicts the different blended images are shown in 1502, different modifications features tab in 1504, and preview tab the final output image in 1506.

[0065] FIG. 16 is a flow diagram illustrating a method of performing simultaneously and continuously on successive parts of the captured image data according to an embodiment herein. At step 1602, the workpiece material 104 or media is loaded in the surface enhancement system 100. At step 1604, a selected user input is obtained. At step 1606, the image is captured or the workpiece material 104 is scanned. At step 1608, the data is processed for printing. The data is obtained from at least one of (i) at step 1606 or (ii) the secondary image 1608 that is selected from database or online resource via network by a user. At step 1610, the processed image data is communicated to the print controller 1006, and then the output (modified material) is obtained at 828. At step 1612, the data is processed for engraving. The data for engraving is obtained from at least one of (i) at step 1606 or (ii) secondary image 1614 that is selected from database or online resource by the user. At step 1616, the processed image data is communicated to the engraver controller 1004. At step 1620, the workpiece material 104 is passed to the print area. At step 1622, the scan data is processed for print. At step 1624, the image data is communicated to the print controller 1006, and then the output (modified material) is obtained at step 1626.

[0066] FIG. 17 is a flow diagram illustrating a method of performing at non-real time using the surface enhancement system 100 according to an embodiment herein. At step 1702, the workpiece material 104 is scanned by the image scanner 102 to obtain the scan data. At step 1704, the scan data is stored in buffer memory block A. At step 1706, the scan data is processed by a BITMAP processing module. At step 1708, bitmap processing instructions are obtained from effect library. At step 1710, the bitmap processing instructions are communicated to the BITMAP processing module. At step 1712, data is obtained from a web source. At step 1714, data is obtained from a local source. At step 1716, the data is stored in an image library. At step 1718, the secondary image data is provided to the BITMAP processing module. At step 1720, processed data from the BITMAP processing module is stored in buffer memory block B. At step 1722, the processed data from the BITMAP processing module is stored in buffer memory block C. At step 1724, the processed data is communicated to the printer through the printer interface for printing. The printer includes media sensors and print heads. At step 1730, the scan data is passed to the engraver for engraving. The laser engraver includes laser heads. The printer and laser engraver include the drive motor unit 122.

[0067] FIG. 18 is a flow diagram that illustrates a method of enhancing or modifying surface of a material in real time using a surface enhancement system 100 according to an embodiment herein. At step 1802, the real-time digital image data of the workpiece material 104 is obtained using the image scanner 102. At step 1804, the at least one laser engraving head 106 is moved on the vertical fixed gantry 116A with respect to laser work area on the workpiece material 104. At step 1806, the ink-jet printer head 108 is moved along with the horizontal fixed gantry 116B from one end of work area on the workpiece material 104 to another end of the workpiece material 104 to enhance the surface of the workpiece material 104. At step 1808, the digital image data obtained by the image scanner 102 is modified based on predefined effect definitions using a node -based digital image processor 1108 in the image controller 1002. At step 1810, the work piece material 104 is engraved using the at least one laser engraving head 106 based on at least one of features extracted from the digital image data processed by the node-based digital image processor 1108 of the image controller 1002. At step 1812, the surfaces of the work piece material 104 are printed using the inkjet print head 108 based on the modified image data from the image controller 1002 using the print controller 1006.

[0068] FIG. 19 illustrates a schematic diagram of computer architecture of the system controller unit 602 according to an embodiment herein. This schematic drawing illustrates a hardware configuration of an information handling/computer system in accordance with the embodiments herein. The system includes at least one processor or central processing unit (CPU) 10. The CPUs 10 are interconnected via system bus 12 to various devices such as a random-access memory (RAM) 14, read-only memory (ROM) 16, and an input/output (I/O) adapter 18. The I/O adapter 18 can connect to peripheral devices, such as disk units 11 and tape drives 13, or other program storage devices that are readable by the system. The system can read the inventive instructions on the program storage devices and follow these instructions to execute the methodology of the embodiments herein.

[0069] In an embodiment, the system further includes a user interface adapter 19 that connects a keyboard 15, mouse 17, speaker 24, microphone 22, and/or other user interface devices such as a touch screen device (not shown) or a remote control to the bus 12 to gather user input. Additionally, a communication adapter 20 connects the bus 12 to a data processing network 25, and a display adapter 21 connects the bus 12 to a display device 23 which may be embodied as an output device such as a monitor, printer, or transmitter, for example.

[0070] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the sprit and scope of the appended claims.

Claims

CLAIMS I/We Claim:

1. A surface enhancement system (100) for enhancing or modifying surface of a material, said surface enhancement system (100) system comprising:

an image scanner (102) that obtains digital image data periodically in real-time of a workpiece material (104), wherein said digital image data are stored in a scan data buffer (506);

at least one laser engraving head (106) that is configured to move on a vertical fixed gantry (116A) with respect to laser work area on said workpiece material (104), wherein said at least one laser engraving head (106) comprises a laser source configured to vaporize said workpiece material (104);

an ink-jet printer head (108) that moves along with a horizontal fixed gantry (116B) from one end of work area on said workpiece material (104) to another end of said workpiece material (104) to enhance the surface of said workpiece material (104); and

a system controller unit (602) that comprises

an image controller (1002), wherein the image controller (1002) comprises a node-based digital image processor (1108) that is configured to modify said digital image data obtained by said image scanner (102) based on predefined effect definitions, wherein said modified digital image data is stored in said scanned data buffer (1008),

an engraver controller (1004) that receives said modified digital image data from said image controller (1002) to engrave said work piece material (104) using said at least one laser engraving head (106) based on at least one of features extracted from the digital image data processed by said node -based digital image processor of said image controller (1002), wherein said modified digital image data for engraving is stored in an engraving data buffer (1010); and

a print controller (1006) that receives modified image data from said image controller (1002) to print and enhance the surfaces of said work piece material (104) using the inkjet print head (108), wherein said modified digital image data for printing is stored in a print data buffer (1012).

2. The surface enhancement system as claimed in claim 1, wherein said image scanner (102) is a linear image scanner.

3. The surface enhancement system as claimed in claim 1, wherein said image scanner (102) comprises a set of adjustable pressure roller (114A-B) each connected to the left side and right side of said image scanner (102), wherein the set of one adjustable pressure roller

(114A-B) eliminates distortions in the captured image arising from warp in said workpiece material (104).

4. The surface enhancement system as claimed in claim 1, wherein said laser engraving head (106) comprises a plurality of laser engraving heads placed side by side.

5. The surface enhancement system as claimed in claim 1, wherein said at least one laser engraving head (106) comprises an infrared laser engraver.

6.The surface enhancement system as claimed in claim 1, wherein said predefined effect definitions are obtained from a database or list.

7. A method for enhancing or modifying the surface of a workpiece material (104) in real time using a surface enhancement system (100), said method comprising:

obtaining, using an image scanner (102), digital image data periodically in real-time of a workpiece material (104), wherein said digital image data are stored in a scan data buffer (506);

moving, at least one laser engraving head (106) on a vertical fixed gantry (116 A) with respect to laser work area on said workpiece material (104), wherein said at least one laser engraving head (106) comprises a laser source configured to vaporize said workpiece material (104); moving an ink-jet printer head (108) along with a horizontal fixed gantry (116B) from one end of work area on said workpiece material (104) to another end of said workpiece material (104) to enhance the surface of said workpiece material (104);

modifying said digital image data obtained by said image scanner (102) based on predefined effect definitions using a node-based digital image processor (1108) in an image controller (1002), wherein said modified digital image data is stored in said scanned data buffer (1008), wherein said modified digital image data is stored in said scanned data buffer (1008);

engraving said work piece material (104) using said at least one laser engraving head (106) based on at least one of features extracted from the digital image data processed by said node -based digital image processor (1108) of said image controller (1002), wherein said modified digital image data for engraving is stored in an engraving data buffer (1010); and

printing, using a print controller (1006), the surfaces of said work piece material (104) using the inkjet print head (108) based on the modified image data from the image controller (1002), wherein said modified digital image data for printing is stored in a print data buffer (1012).

8.The method as claimed in claim 7, wherein said modifications are driven by secondary image data, wherein said secondary image data is obtained from an image hank.

9. A method for enhancing or modifying the surface of a material using a surface enhancement system (100), said method comprising:

obtaining, using an image scanner (102), a full bitmap image data of said workpiece material (104), wherein said digital image data are stored in a scan data buffer (506);

processing, using an image controller (1002), said full bitmap image data at a bitmap processing module based on bitmap processing instructions by a node -based digital image processor (602) of said image controller (1002), wherein said processed full bitmap image is stored in said scan data buffer (506);

engraving, using an engraver controller (1004), said workpiece material (104) using an infrared laser engraver provided on a laser engraving head (106) by said engraver controller (1004) based on at least one of the features extracted from said processed full bitmap image received from said image controller (1002), wherein said processes full bitmap image for engraving is stored in an engraving data buffer (1010); and

printing, using a print controller (1006), said full bitmap image data received from said image controller (1002) on said engraved workpiece material (104) by said print controller (1006) using an ink-jet printer head (108), wherein said full bitmap image data for printing is stored in a print data buffer (1012).

10. The method as claimed in claim 9, wherein said image data is a secondary image data, wherein said secondary image data is obtained from an image bank, wherein the secondary image data is used as a basis to modify said scanned full bitmap image data.