Patent Description:
The painting of an aircraft is a challenging process due to the large amount of surface area and unique geometry of aircraft surfaces. For example, the nose and tail of an aircraft are typically highly contoured, which presents challenges in applying coatings in a precise manner. Adding to the challenge are complex paint schemes associated with an aircraft livery. For example, the livery of an airline may include images or designs that have complex geometric shapes and color combinations. In addition, an aircraft livery may include the name and logo of the airline, which may be applied to different locations on the aircraft such as the fuselage and the vertical tail. The process of applying the livery to the aircraft surfaces must be carried out with a high level of precision to meet aesthetic requirements, and to ensure that the coating thickness is within desired tolerances to meet aircraft performance (e.g., weight) requirements.

One method of painting an aircraft involves the use of individual robotic devices. Each robotic device includes an end effector mounted on a robotic arm. The robotic arm of each robotic device moves the end effector over the aircraft surfaces while the end effector dispenses any one of a variety of different paint colors, such as for applying an aircraft livery. Although the use of robotic devices reduces the amount of time required for aircraft painting relative to conventional manual methods that involve masking, painting, and demasking, the use of a single end effector on each robotic device results in a relative lengthy painting process.

As can be seen, there exists a need in the art for a system for interconnecting an array of treatment devices for dispensing a treatment (e.g., paint) as the array is moved over an article surface, and which allows for the continuous repositioning of each treatment complementary to the changing contours of the article surfaces, to thereby enable precise application of coatings (e.g., an aircraft livery) in a reduced amount of time relative to conventional methods. Ideally, the actuation system has a compact arrangement to allow for relatively close spacing of the treatment devices in the array.

<CIT>discloses a device for moving a print head.

The above-noted needs associated with interconnecting treatment devices are addressed by the presently-disclosed device actuation system for actuating a treatment device. The device actuation system includes a first drive gear rotatably mountable to the treatment device, a coupler rail slidably mountable to the treatment device, a second drive gear rotatably mountable to the coupler rail, and a coupler gear rotatably mountable to the treatment device and engageable with the coupler rail. In addition, the device actuation system includes a drive rail locatable between the first drive gear and the second drive gear of the gear system. The coupler gear is rotatable to move the coupler rail in a manner maintaining the second drive gear in continuous engagement with the drive rail against the first drive gear. The first drive gear and the second drive gear are rotatable in a manner causing at least one of translation and rotation of the treatment device relative to the drive rail.

Also disclosed is a treatment device support assembly for actuating a plurality of treatment devices relative to each other for treating an article surface of an article. The treatment device support assembly includes a plurality of device actuation systems, each configured to interconnect an adjacent pair of treatment devices. Each device actuation system includes a gear system couplable to each treatment device of the adjacent pair of treatment devices. The gear system of each treatment device includes a first drive gear rotatably mountable to the treatment device, a coupler rail slidably mountable to the treatment device, a second drive gear rotatably mounted to the coupler rail, and a coupler gear rotatably mountable to the treatment device and engaged with the coupler rail. The device actuation system further includes a drive rail configured to interconnect the adjacent pair of treatment devices, and is located between the first drive gear and the second drive gear of each treatment device of the adjacent pair of treatment devices. For each treatment device of the adjacent pair of treatment devices, the coupler gear is rotatable to move the coupler rail in a manner maintaining the second drive gear in continuous engagement with the drive rail against the first drive gear. In addition, the first drive gear and the second drive gear are rotatable in a manner causing at least one of translation and rotation of the treatment device relative to the drive rail.

Also disclosed is a method of actuating at least one treatment device. The method includes rotating a first drive gear and a second drive gear engaged to opposite sides of a drive rail to cause at least one of translation and rotation of a treatment device relative to the drive rail. The first drive gear is mounted to the treatment device, the second drive gear is mounted to a coupler rail slidably mounted to the treatment device, and the coupler rail is engaged to a coupler gear mounted to the treatment device. The method includes rotating the coupler gear to move the coupler rail in a manner maintaining the second drive gear in continuous engagement with the drive rail.

The features, functions and advantages that have been discussed can be achieved independently in various examples of the present disclosure or may be combined in yet other examples, further details of which can be seen with reference to the following description and drawings below.

These and other features of the present disclosure will become more apparent upon reference to the drawings wherein like numbers refer to like parts throughout and wherein:.

Referring now to the drawings, which illustrate preferred and various examples of the disclosure, shown in <FIG> is an example of a treatment device system <NUM> for treating the article surfaces <NUM> of an article <NUM>. The treatment device system <NUM> includes an upper treatment device support assembly <NUM> and a lower treatment device support assembly <NUM> for supporting one or more treatment devices <NUM>. In the example shown, the article <NUM> is a fuselage <NUM> of an aircraft <NUM> having a vertical tail <NUM> and a pair of horizontal tails <NUM>. The fuselage <NUM> is shown supported on the floor <NUM> of a treatment facility <NUM> using fuselage support stands <NUM>.

Each treatment device support assembly <NUM>, <NUM> includes at least one device actuation system <NUM> (<FIG>) for actuating at least one treatment device <NUM>. As described in greater detail below, each device actuation system <NUM> is configured to translate and/or rotate at least one treatment device <NUM>. In one example, each device actuation system <NUM> is configured to position a treatment device <NUM> relative to the changing contours of an article surface <NUM> over which the treatment device <NUM> is being moved. In the example of <FIG>, each treatment device <NUM> includes a device frame <NUM>, and each treatment device <NUM> has one or more device heads <NUM> which are shown arranged in rows and/or columns, and which are supported by the device frame <NUM>.

The treatment devices <NUM> (e.g., the device heads <NUM>) are configured to dispense a treatment toward and/or onto an article surface <NUM>. The treatment may be a coating, such as a primer, a paint, a clear coat, or a sealant. For painting an article <NUM> such as the fuselage <NUM> shown in <FIG>, the treatment devices <NUM> are configured as inkjet printheads <NUM> (<FIG> - e.g., piezoelectric printheads or thermal printheads) each configured to precisely dispense ink onto the surfaces of the fuselage <NUM> as the treatment devices <NUM> are moved along the fuselage <NUM> for printing an aircraft livery. In other examples, the treatment devices <NUM> may be configured to dispense other types of treatments or substances, such as a solvent, an adhesive, a lubricant, abrasive particles, or any type of gas, liquid, semi-solid, or solid (e.g., particles) substance. In still further examples, the treatment devices <NUM> may be configured to emit radiation (e.g., electromagnetic radiation) for performing any one of a variety of operations on an article surface <NUM>.

Although described in the context of treating the surfaces of a fuselage <NUM>, the treatment device system <NUM> may be implemented for treating any one of a variety of different types of articles <NUM>, and is not limited to treating an aircraft <NUM>. For example, the treatment device system <NUM> may be implemented for treating vehicles, such as ships, trains, or other ground-based motor vehicles such as trucks and automobiles. In addition, the treatment device system <NUM> may be implemented for treating stationary objects including, but not limited to, buildings, architectural objects, walls, and/or any one of a variety of other types of structures, systems, subsystems, assemblies, or subassemblies.

In <FIG>, as mentioned above, the treatment device system <NUM> includes an upper treatment device support assembly <NUM> and a lower treatment device support assembly <NUM>, each of which has a plurality of device actuation systems <NUM> for repositioning the treatment devices <NUM> complementary to the contours of an article <NUM> (e.g., a fuselage <NUM>) as the treatment device system <NUM> is moved over the article <NUM> (e.g., along a lengthwise direction of a fuselage <NUM>) during the application of a treatment to the article surfaces <NUM>. The device actuation systems <NUM> interconnect the treatment devices <NUM>. In addition, the device actuation systems <NUM> are configured to actuate the treatment devices <NUM> relative to each other. As described in greater detail below, each device actuation system <NUM> is configured to translate and rotate an adjacent pair of treatment devices <NUM> relative to each other in a manner to maintain each treatment device <NUM> at a predetermined spacing and orientation relative to the local contour of an article surface <NUM> as the treatment devices <NUM> are moved over the article <NUM>.

In the example of <FIG>, the upper treatment device support assembly <NUM> includes a central pillar <NUM> coupled to an overhead gantry <NUM> (<FIG>). The fuselage <NUM> is oriented parallel to the lengthwise direction of the overhead gantry <NUM>, allowing the upper treatment device support assembly <NUM> to move the treatment devices <NUM> along the length of the fuselage <NUM> from the nose section <NUM> section to the tail section <NUM>. A support structure base <NUM> is shown coupled to the central pillar <NUM>. On each of opposing sides of the support structure base <NUM> is a pillar pivot joint <NUM> coupling an attachment pillar <NUM> to the support structure base <NUM>. At the lower end of each attachment pillar <NUM> is an arm pivot joint <NUM> coupling a pair of attachment arms <NUM> to the attachment pillar <NUM>. The ends of the attachment arms <NUM> are respectively coupled via arm pivot joints <NUM> to opposite sides of an array <NUM> of treatment devices <NUM> which, as indicated above, are interconnected by a plurality of device actuation systems <NUM>. In the example shown, the upper treatment device support assembly <NUM> supports two arrays <NUM> of treatment devices <NUM> in side-by-side arrangement.

In <FIG>, the lower treatment device support assembly <NUM> is configured similar to the upper treatment device support assembly <NUM>. For example, the lower treatment device support assembly <NUM> includes a central pillar <NUM> which is supported on a pit gantry <NUM> mounted in a pit <NUM> that extends along a lengthwise direction below the floor <NUM> in parallel to the overhead gantry <NUM>. As shown in <FIG>, a support structure base <NUM> is mounted on the upper end of the central pillar <NUM>. A pair of pillar pivot joints <NUM> on opposite sides of the support structure base <NUM> respectively couple a pair of attachment pillars <NUM> to the support structure base <NUM>. The attachment pillars <NUM> extend upwardly through a pair of floor openings <NUM>. At the upper end of each attachment pillar <NUM> is an arm pivot joint <NUM> coupling a pair of attachment arms <NUM> to the attachment pillar <NUM>. The ends of the pair of attachment arms <NUM> extending from each attachment pillar <NUM> are coupled to opposite sides of an array <NUM> of treatment devices <NUM>. The lower treatment device support assembly <NUM> supports two arrays <NUM> of treatment devices <NUM> in side-by-side arrangement.

Referring to <FIG>, shown are two arrays <NUM> of treatment devices <NUM> supported by the upper treatment device support assembly <NUM>, and two arrays <NUM> of treatment devices <NUM> supported by the lower treatment device support assembly <NUM>. Also shown are the device actuation systems <NUM> interconnecting the treatment devices <NUM> of each array <NUM>. <FIG> show the treatment devices <NUM> positioned and oriented complementary to the local contour of the fuselage <NUM>. Toward this end, the attachment pillars <NUM> are rotatable about the pillar pivot joints <NUM>. In addition, the attachment arms <NUM> are rotatable about the arm pivot joints <NUM>. The pivotability of the attachment pillars <NUM> and attachment arms <NUM> allows the arrays <NUM> of treatment device <NUM> to be positioned complementary to a variety of articles <NUM> of different sizes and shapes. The device actuation systems <NUM> are configured to translate and rotate the treatment devices <NUM> relative to each other in a manner maintaining each treatment device <NUM> at a predetermined distance and orientation relative to the local contour of an article surface <NUM> over which the treatment devices <NUM> are being moved while dispensing a treatment.

Referring to <FIG>, shown is a single array <NUM> of treatment devices <NUM> of the lower treatment device support assembly <NUM>. The array <NUM> is supported on opposite ends respectively by the pair of attachment arms <NUM>. The lower treatment device support assembly <NUM> includes a plurality of device frames <NUM> respectively of the plurality of treatment devices <NUM>. Each device frame <NUM> is configured to support one or more device heads <NUM> which, in the configuration shown, are arranged in rows and columns within each device frame <NUM>.

In <FIG>, the array <NUM> of device frames <NUM> includes an apex device frame <NUM> at the intersection of two device frame rows <NUM>. Each device frame row <NUM> terminates at an end device frame <NUM>, which is coupled to an attachment arm <NUM> via a device actuation system <NUM> that is coupled to an arm pivot joint <NUM>. In addition, each device frame row <NUM> includes one or more intermediate device frames <NUM> between the apex device frame <NUM> and the end device frame <NUM>. Although each device frame row <NUM> in <FIG> has three intermediate device frames <NUM>, a treatment device support assembly may be provided with any number of intermediate device frames <NUM> between the apex device frame <NUM> and the end device frame <NUM>, including a single intermediate device frame <NUM> between the apex device frame <NUM> and the end device frame <NUM>. Alternatively, a treatment device support assembly may be devoid of intermediate device frames <NUM>, and may include only a pair of end device frames <NUM> each coupled to an apex device frame <NUM> via a pair of device actuation systems <NUM>.

The device actuation systems <NUM> interconnecting the device frames <NUM> are configured to move the device frames <NUM> of the treatment devices <NUM> between an expanded configuration <NUM> and a contracted configuration <NUM> (<FIG>), and to any configuration in between, to allow the treatment devices <NUM> to be repositioned and reoriented to match the local size and shape (e.g., curvature) of an article surface <NUM> (<FIG>). In the expanded configuration <NUM>, the intermediate device frames <NUM> and the end device frame <NUM> respectively in the two device frame rows <NUM> are spaced farther apart from each other than in the contracted configuration <NUM> (e.g., <FIG>). In addition, in the expanded configuration <NUM>, the device frame rows <NUM> are non-parallel to each other. In <FIG>, the array <NUM> of treatment devices <NUM> has a V-shaped configuration. However, the treatment devices <NUM> may be arranged in any one of a wide variety of configurations, and are not limited to a V-shaped configuration.

In the semi-contracted or contracted configuration <NUM> (<FIG>), at least one pair of device frames <NUM> respectively of the device frame rows <NUM> are in close proximity to each other. In an example not shown, the device frame rows <NUM> in the contracted configuration <NUM> may be generally parallel to each other. In the contracted configuration <NUM>, at least one pair of treatment devices <NUM> are positioned in close side-by-side proximity to each other, similar to the arrangement shown in <FIG> as described below.

Referring to <FIG>, each of the device actuation systems <NUM> interconnecting the device frames <NUM> includes at least one gear system <NUM> (<FIG>) and a drive rail <NUM> (<FIG>). In this regard, at least one gear system <NUM> is coupled to each device frame <NUM>. In the example of <FIG>, each one of the end device frames <NUM> has a gear system <NUM> mounted to opposing lateral sides <NUM> of the end device frame <NUM>. Likewise, each one of the intermediate device frames <NUM> has a gear system <NUM> mounted to opposing lateral sides <NUM> of the intermediate device frame <NUM>. The apex device frame <NUM> has a pair of gear systems <NUM> mounted to the same lateral side <NUM>, and is devoid of gear systems <NUM> on the opposite lateral side <NUM> of the apex device frame <NUM>.

In <FIG>, each of the end device frames <NUM> is coupled to an arm pivot joint <NUM> by a drive rail <NUM> extending from the gear system <NUM> mounted one of the lateral sides <NUM> of the end device frame <NUM>. The gear system <NUM> on the opposite lateral side <NUM> of each end device frame <NUM> is coupled to the gear system <NUM> of an intermediate device frame <NUM> via a drive rail <NUM>. Likewise, each gear system <NUM> on the opposing lateral sides <NUM> of each intermediate device frame <NUM> is coupled to the gear system <NUM> of an immediately-adjacent intermediate device frame <NUM> via a drive rail <NUM>. In this regard, the gear systems <NUM> respectively of adjacent pairs of treatment devices <NUM> are respectively mounted to the lateral sides <NUM> that generally face each other, thereby allowing adjacent pairs of treatment devices <NUM> to be interconnected by a drive rail <NUM>, and allowing the treatment devices <NUM> to be translated and rotated relative to each other such that at least a portion of the lateral sides <NUM> of the adjacent pair of treatment devices <NUM> directly face each other.

As a result of the arrangement of treatment devices <NUM> in the array <NUM> of <FIG>, when the device treatment system (<FIG>) is moved along a lengthwise direction of an article <NUM> (<FIG>), a treatment band (not shown) dispensed by each treatment device <NUM> onto an article surface is capable of at least partially overlapping the treatment band (not shown) dispensed by an immediately adjacent treatment device <NUM>, thereby avoiding lengthwise gaps (not shown) between adjacent treatment bands that would otherwise occur if the array <NUM> of treatment devices <NUM> were arranged in a non-overlappable manner. In the context of printing an aircraft livery on a fuselage <NUM> (e.g., <FIG>) wherein the treatment devices <NUM> are inkjet printheads <NUM>, the arrangement shown in <FIG> allows for the image band (not shown) printed by each inkjet printhead <NUM> onto the fuselage surface to be aligned in non-gapping and/or non-overlapping relation to the image band printed by an immediately adjacent inkjet printhead <NUM> as the treatment device system <NUM> moves the array of inkjet printheads <NUM> along the length of the fuselage <NUM>. By printing adjacent image bands in non-gapping and/or non-overlapping relation to each other, the aesthetic quality of the aircraft livery is improved relative to the quality of aircraft liveries applied using the above-described conventional methods.

Referring still to <FIG>, the treatment device system <NUM> includes a controller <NUM> (<FIG>) for controlling the movement of the components of the upper and lower treatment device support assemblies <NUM>, <NUM>. In this regard, the controller <NUM> controls the pivoting of the attachment pillars <NUM> about the pillar pivot joints <NUM>, and the pivoting of the attachment arms <NUM> about the arm pivot joints <NUM> to allow the arrays <NUM> of treatment devices <NUM> to accommodate articles <NUM> of different sizes and shapes. In addition, the controller <NUM> controls the device actuation systems <NUM> interconnecting the treatment devices <NUM> in a manner to adjust the position and orientation of the treatment devices <NUM> relative to each other for accommodating the article shape.

The upper and lower treatment device support assemblies <NUM>, <NUM> may include one or more sensors <NUM> mounted to one or more of the device frames <NUM>. The sensors <NUM> may be provided as imaging devices (e.g., cameras), laser scanners, or other metrology devices configured to sense the article surface <NUM>. Each sensor <NUM> is configured to continuously scan the topography of the article surface <NUM> (<FIG>) as the treatment devices <NUM> are moved over the article <NUM> (<FIG>), and continuously generate surface data representative of the local contour of the article surface <NUM>. For example, one or more sensors <NUM> on each treatment device <NUM> continuously senses the distance between a dispensing side <NUM> of each treatment device <NUM> and the article surface <NUM>, in addition to sensing the orientation of the treatment device <NUM> relative to the local contour of the article surface <NUM>. For example, the sensors <NUM> of each treatment device <NUM> continuously sense the orientation of a nominal dispensing direction <NUM> of the treatment device <NUM> relative to the local contour of the article surface <NUM>. The nominal dispensing direction <NUM> of a treatment device <NUM> may be described as the direction along which a treatment is dispensed from a dispensing side <NUM> of the treatment device <NUM>. For examples of treatment devices <NUM> in which the orientation (e.g., pitch or yaw) of the individual device heads <NUM> is adjustable (not shown), the dispensing direction <NUM> is the direction along which the treatment is dispensed prior to any such pitch and/or yaw adjustment of the device heads <NUM>.

The sensors <NUM> (<FIG>) of the treatment devices <NUM> continuously transmit surface data to the controller <NUM> (<FIG>). The controller <NUM> processes the surface data provided by the sensors <NUM> and controls the device actuation systems <NUM> (<FIG>) in a manner to continuously adjust the position of the treatment devices <NUM> (<FIG>) to thereby maintain the dispensing side <NUM> (<FIG>) or dispensing face of the treatment devices <NUM> within a tolerance band (e.g., ± <NUM> (<NUM> inch)) of a predetermined distance (e.g., up to <NUM> (<NUM> inch)) from the article surface <NUM> (<FIG>). Additionally, the controller <NUM> controls the device actuation systems <NUM> in a manner to continuously adjust the orientation of the treatment devices <NUM> to thereby maintain the nominal dispensing direction <NUM> (<FIG>) of each treatment device <NUM> within a predetermined tolerance band (e.g., ± <NUM> degrees) of a desired orientation (e.g., locally normal or perpendicular) relative to the article surface <NUM>. In this regard, the controller <NUM> controls the operation of each gear system <NUM> in a manner to adjust the position and orientation of the treatment devices <NUM> relative to the article surface <NUM> as needed to maintain the treatment devices <NUM> complementary to the article surface <NUM> as the treatment devices <NUM> are moved over the article <NUM> while dispensing the treatment toward the article surface <NUM>.

Referring to <FIG>, shown is an example of a treatment device <NUM>. As mentioned above, the device frame <NUM> of each treatment device <NUM> has a dispensing direction <NUM> along which the treatment device <NUM> dispenses a treatment from a dispensing side <NUM> of the treatment device <NUM>. In the example shown, treatment device <NUM> has an orthogonal shape, and the lateral sides <NUM> of the device frame <NUM> are parallel to the dispensing direction <NUM>. However, a treatment device <NUM> may be provided with a non-orthogonal shape, and/or the lateral sides <NUM> may be non-parallel to the dispensing side <NUM> of the treatment device <NUM>. The device frame <NUM> is configured to support a plurality of device heads <NUM>. In one example, each of the device heads <NUM> may be provided as an inkjet printhead <NUM> configured to dispense ink (i.e., the treatment) along the dispensing direction <NUM>. Each device frame <NUM> is configured to support one or more rows and/or one or more columns of inkjet printheads <NUM>. However, the device heads <NUM> may be provided in alternative configurations, and are not limited to inkjet printheads <NUM>, as mentioned above.

For purposes of illustrating the arrangement and operation of the device activation system, <FIG> show a simplified version of a treatment device <NUM> having a single gear system <NUM>. However, as shown in <FIG>, each treatment device <NUM> in an array <NUM> may have two gear systems <NUM>, including one gear system <NUM> on one lateral side <NUM> of the device frame <NUM>, and another gear system <NUM> on an opposite lateral side <NUM> of the device frame <NUM>. Alternatively, as shown in <FIG>, the apex device frame <NUM> in an array <NUM> has two gear systems <NUM> on the same lateral side <NUM>.

In <FIG>, the gear system <NUM> of the device actuation system <NUM> includes a first drive gear <NUM>, a coupler rail <NUM>, a second drive gear <NUM>, and a coupler gear <NUM>. The first drive gear <NUM>, the second drive gear <NUM>, and the coupler gear <NUM> are independently rotatably driven respectively by a first drive gear motor <NUM>, a second drive gear motor <NUM>, and a coupler gear motor <NUM>, under control of the controller <NUM> (<FIG>). In the example shown, the first drive gear motor <NUM>, the second drive gear motor <NUM>, and the coupler gear motor <NUM> are electric servomotors.

The first drive gear <NUM> is rotatably mounted to the treatment device <NUM>. More specifically, the first drive gear motor <NUM> is mounted to a lateral side <NUM> of the device frame <NUM> in an interior of the device frame <NUM>. The first drive gear motor <NUM> includes a shaft (not shown) that extends to the exterior of the device frame <NUM> through a hole (not shown) in the lateral side <NUM>. The first drive gear <NUM> is mounted on the shaft of the first drive gear motor <NUM>.

The coupler rail <NUM> is slidably mounted to the device frame <NUM> of the treatment device <NUM>. In the example of <FIG>, the coupler rail <NUM> is slidably mounted to the lateral side <NUM> in the interior of the device frame <NUM> via a coupler rail slide mechanism <NUM>. In the example shown, the coupler rail slide mechanism <NUM> comprises a slide channel formed in the coupler rail <NUM>, and which slides along a slide rail located on the lateral side <NUM> of the device frame <NUM>. However, the coupler rail slide mechanism <NUM> may be provided in any one of a variety of alternative configurations allowing sliding motion of the coupler rail <NUM> relative to the device frame <NUM>.

The coupler gear <NUM> is rotatably mounted to the treatment device <NUM>. More specifically, the coupler gear motor <NUM> is mounted to the device frame <NUM> in an interior of the device frame <NUM>. The coupler gear motor <NUM> may be supported by a bracket (not shown) mounted to the lateral side <NUM> of the device frame <NUM>. The coupler gear motor <NUM> includes a shaft (not shown) upon which the coupler gear <NUM> is mounted. The coupler gear <NUM> has gear teeth <NUM> that are in continuous meshing engagement with the rail teeth <NUM> of the coupler rail <NUM>.

The second drive gear <NUM> is rotatably mounted to the coupler rail <NUM>. More specifically, the second drive gear motor <NUM> is mounted to the coupler rail <NUM>. The second drive gear motor <NUM> includes a shaft (not shown) that extends to the exterior of the device frame <NUM> through a hole (not shown) in the coupler rail <NUM>, and through a frame slot <NUM> in the lateral side <NUM>. The second drive gear <NUM> is mounted on the shaft of the second drive gear motor <NUM>.

As shown in <FIG>, a drive rail <NUM> is located between the first drive gear <NUM> and the second drive gear <NUM> of the treatment device <NUM>. The first drive gear <NUM> and the second drive gear <NUM> have gear teeth <NUM> configured to engage or mesh with the rail teeth <NUM> of the drive rail <NUM>. In <FIG>, a plurality of the drive rails <NUM> interconnect adjacent pairs of the treatment devices <NUM>. Each drive rail <NUM> is captured between the first drive gear <NUM> and the second drive gear <NUM> respectively of the treatment device <NUM> of each adjacent pair. For each treatment device <NUM>, the coupler gear <NUM> is rotated to move the coupler rail <NUM> in a manner moving the second drive gear <NUM> toward or away from the first drive gear <NUM>, to thereby maintain the second drive gear <NUM> in continuous engagement with the drive rail <NUM> against the first drive gear <NUM>.

Referring to <FIG>, shown is a first drive gear <NUM> and a second drive gear <NUM> in an alternative example of a gear system <NUM>. The drive rail <NUM> has opposing rail sides <NUM> that define a rail width. The first drive gear <NUM> and the second drive gear <NUM> each have a pair of gear sides <NUM>. The gear sides <NUM> of the first drive gear <NUM> and the second drive gear <NUM> each have circumferential ridges <NUM> that are spaced apart by a distance that is approximately equal to (i.e., but not less than) the rail width. The circumferential ridges <NUM> are sized to extend over the rail sides <NUM>, to thereby maintain the drive rail <NUM> in alignment with the first drive gear <NUM> and the second drive gear <NUM>. In this regard, the circumferential ridges <NUM> prevent the drive rail <NUM> from moving laterally out of alignment with the first drive gear <NUM> and second drive gear <NUM>. The circumferential ridges <NUM> may be integrated into the first drive gear <NUM> and the second drive gear <NUM>, or each circumferential ridge <NUM> may be part of a disc-shaped member (not shown) that is mounted against the gear sides <NUM> of the first drive gear <NUM> and second drive gear <NUM>.

In the illustrated examples, the drive rail <NUM> is straight. However, in other examples not shown, the drive rail <NUM> may be slightly curved. Likewise, the coupler rail <NUM> may be provided in a slightly curved arrangement as an alternative to the straight shape shown in the figures. In the example shown, the first drive gear <NUM>, the coupler rail <NUM>, the coupler gear <NUM>, and the second drive gear <NUM> have outer diameters that are equivalent to each other. However, in other examples, the first drive gear <NUM>, the coupler rail <NUM>, the coupler gear <NUM> may have different outer diameters.

In the example of <FIG>, the first drive gear <NUM>, the second drive gear <NUM>, and the drive rail <NUM> are external to the device frame <NUM>. The coupler rail <NUM> and the coupler gear <NUM> are internal to the device frame <NUM>, and are non-protruding from the lateral side <NUM> of the device frame <NUM>. Advantageously, mounting the coupler rail <NUM> and coupler gear <NUM> inside the treatment device <NUM> provides for a compact form factor, allowing an array <NUM> of treatment devices <NUM> to be packaged in close proximity to each other.

In <FIG> and <FIG>, the drive rail <NUM> defines a plane of rotation <NUM> during actuation (e.g., rotation) of the treatment device <NUM>. In the example shown, the plane of rotation <NUM> is parallel to the dispensing direction <NUM> (<FIG>). The coupler gear <NUM> and the coupler rail <NUM> are located inside the device frame <NUM>, and are therefore outside of the plane of rotation <NUM>, which advantageously increases the angular range of rotation of the treatment device <NUM>, relative to a reduced angular range of rotation of a treatment device <NUM> in an arrangement (not shown) in which the coupler gear <NUM> and the coupler rail <NUM> protrude into the plane of rotation <NUM>. However, in other examples not shown, the coupler rail <NUM> and the coupler gear <NUM> may be external to the device frame <NUM>, and/or the coupler rail <NUM> and the coupler gear <NUM> may protrude through the plane of rotation <NUM>.

As shown in the example of <FIG>, the gear system <NUM> is couplable to the lateral side <NUM> of the device frame <NUM> in a manner such that the coupler rail <NUM> is generally parallel to the dispensing direction <NUM> (<FIG>) of the treatment device <NUM>, and perpendicular to the dispensing side <NUM> (<FIG>) of the treatment device <NUM>. However in other examples, the gear system <NUM> may be configured such that the coupler rail <NUM> is non-parallel to the dispensing direction <NUM> of the treatment device <NUM>.

As shown in <FIG>, the first drive gear <NUM>, the second drive gear <NUM>, and the coupler gear <NUM> have rotational axes <NUM> that are parallel to each other, and are oriented in the same direction. However, in another example (not shown), the rail teeth <NUM> of the coupler rail <NUM> may be located on a side of the coupler rail <NUM> opposite the lateral side <NUM> of the device frame <NUM>, and the rotational axis <NUM> of the coupler gear <NUM> may be oriented perpendicular to the rotational axes <NUM> of the first drive gear <NUM> and the second drive gear <NUM> to enable the gear teeth <NUM> of the coupler gear <NUM> to engage the rail teeth <NUM> of the coupler rail <NUM>. <FIG> shows a reference coordinate system <NUM> having an x-axis, a y-axis, and a z-axis. The device actuation system <NUM> is configured to translate and rotate the treatment device <NUM> along a direction parallel to the x-z plane of the reference coordinate system <NUM>.

Referring to <FIG> and <FIG>, the drive rail <NUM> has a drive rail axis <NUM> extending along a lengthwise direction of the drive rail <NUM>. As mentioned above, the first drive gear <NUM> and the second drive gear <NUM> each have a rotational axis <NUM> (<FIG>). As shown in <FIG>, the gear system <NUM> includes a first-second drive gear axis <NUM> that passes through the rotational axis <NUM> of the first drive gear <NUM> and the rotational axis <NUM> of the second drive gear <NUM>. In the example shown, the gear system <NUM> is coupled to the treatment device <NUM> such that when the drive rail axis <NUM> is perpendicular to the dispensing direction <NUM> (<FIG>) of the treatment device <NUM>, the first-second drive gear axis <NUM> is parallel to the dispensing direction <NUM>. In Figure eight, when the dispensing direction <NUM> is vertically upward, the first drive gear <NUM> and the second drive gear <NUM> are vertically aligned.

During operation of each device actuation system <NUM>, the coupler gear motor <NUM> is operated by the controller <NUM> in a manner to rotate the coupler gear <NUM> for moving the coupler rail <NUM> in a manner maintaining the second drive gear <NUM> in continuous engagement with the drive rail <NUM> against the first drive gear <NUM>. The first drive gear motor <NUM> and the second drive gear motor <NUM> are respectively operated by the controller <NUM> in a manner to respectively rotate the first drive gear <NUM> and the second drive gear <NUM> to cause translation and/or rotation of the treatment device <NUM> relative to the drive rail <NUM>. In this regard, the first drive gear motor <NUM> and the second drive gear motor <NUM> are operated in a manner to position and orient the treatment device <NUM> complementary to the contour of the article surface <NUM>. During rotation of the treatment device <NUM> relative to the drive rail <NUM>, the coupler gear <NUM> is rotated in a manner to maintain the gear teeth <NUM> of the second drive gear <NUM> in continuous engagement with the rail teeth <NUM> on one side of the drive rail <NUM>, while the rail teeth <NUM> on the opposite side of the drive rail <NUM> are in continuous engagement with the gear teeth <NUM> of the first drive gear <NUM>. The controller <NUM> coordinates the timing and direction of rotation of the first drive gear motor <NUM>, the second drive gear motor <NUM>, and the coupler gear motor <NUM> in a manner to adjust the position and orientation of the treatment device <NUM> relative to the article surface <NUM>.

Referring to <NUM>-<NUM>, shown are examples of a pair of treatment devices <NUM> (i.e., a left-hand treatment device and a right-hand treatment device). In any one of the examples disclosed herein, actuation of a treatment device <NUM> is performed by rotating the first drive gear <NUM> and the second drive gear <NUM> of the treatment device <NUM> according to one of two rotation modes. <FIG> illustrate the left-hand treatment device and the right-hand treatment device in a home position prior to translation of the left-hand treatment device (<FIG>) relative to the right-hand treatment device, and prior to rotation of the left-hand treatment device (<FIG>) relative to the right-hand treatment device.

<FIG> illustrate a mode of operation in which the first drive gear <NUM> and the second drive gear <NUM> of the left-hand treatment device are synchronously rotated at the same speed and in opposite directions, to thereby cause translation of the left-hand treatment device relative to the drive rail <NUM>. The synchronous rotation of the first drive gear <NUM> and the second drive gear <NUM> at the same speed and in opposite directions causes translation of the left-hand treatment device back and forth along the lengthwise direction of the drive rail <NUM>. For pure translation, with no rotation, of the left-hand treatment device, the first drive gear <NUM> and the second drive gear <NUM> are counter-rotated at the same speed.

<FIG> illustrate a mode of operation in which the first drive gear <NUM> and the second drive gear <NUM> of the left-hand treatment device are differentially rotated at different speeds and in the same or opposite directions, to at least cause rotation of the left-hand treatment device relative to the drive rail <NUM>. The first drive gear <NUM> and the second drive gear <NUM> are differentially rotatable at different speeds in a manner causing a combination of rotation and translation of the treatment device <NUM> relative to the drive rail <NUM>. In another example, rotation of the left-hand treatment device may be achieved by rotating either the first drive gear <NUM> or the second drive gear <NUM>, while a remaining one of the first drive gear <NUM> and the second drive gear <NUM> is non-rotated or is static.

Referring to <FIG>, shown is an example of a treatment device <NUM> having two gear systems <NUM> mounted on a common lateral side <NUM> of the device frame <NUM>. The device frame <NUM> in <FIG> is the apex device frame <NUM> in the array <NUM> shown in <FIG>. In <FIG>, the first drive gear <NUM> and the second drive gear <NUM> of each gear system <NUM> is configured to receive a drive rail <NUM> that is independent of the drive rail <NUM> received within the first drive gear <NUM> and the second drive gear <NUM> of the other gear system <NUM>. As shown in <FIG>, the drive rail <NUM> of each gear system <NUM> is configured to interconnect with the gear system <NUM> of an adjacent treatment device <NUM>.

Referring to <FIG>, shown is an example of the treatment device system <NUM> of <FIG> positioned over the nose section <NUM> of the fuselage <NUM> and illustrating the treatment devices <NUM> located and oriented complementary to the compound curvature of the nose section <NUM>. In the example shown, the treatment devices <NUM> form an array <NUM> in the above-mentioned expanded configuration <NUM> (e.g., a V-shaped configuration). The device actuation systems <NUM> interconnecting the treatment devices <NUM> have moved the apex device frame <NUM> and the intermediate device frames <NUM> along the dispensing direction <NUM> of the respective treatment devices <NUM>, such that the dispensing face of each treatment device <NUM> is in close proximity to the surface of the nose section <NUM>. In addition, the device actuation systems <NUM> have oriented the treatment devices <NUM> such that the dispensing direction <NUM> (<FIG>) of each treatment device <NUM> is locally perpendicular or normal to the surface of the nose section <NUM>, to facilitate livery printing onto the nose section <NUM> of the fuselage <NUM>.

Referring to <FIG>, shown is an example of the treatment device system <NUM> of <FIG> positioned at the tail section <NUM> of the fuselage <NUM>. On the underside of the fuselage <NUM>, each of the two arrays <NUM> of treatment devices <NUM> have been relocated and reoriented into an arrangement similar to the arrangement shown in <FIG>. On the upper side of the fuselage <NUM> at the tail section <NUM>, each of the two arrays <NUM> of treatment devices <NUM> respectively on opposite sides of the vertical tail <NUM> are in a semi-contracted configuration to allow each array <NUM> of treatment devices <NUM> to fit between the vertical tail <NUM> and one of the horizontal tails <NUM>, thereby facilitating livery printing on the tail section <NUM> of the fuselage <NUM>.

As may be appreciated, the components of the treatment device system <NUM>, including the attachment pillars <NUM>, the attachment arms <NUM>, and the device actuation systems <NUM>, may be operated in a manner to position one or more arrays <NUM> of treatment devices <NUM> against other areas of the aircraft <NUM>, in addition to the fuselage <NUM>. For example, the treatment device system <NUM> may be operated in a manner to position an array <NUM> of treatment devices <NUM> on each of opposing sides of the vertical tail <NUM> for livery printing, and/or on other areas of the aircraft <NUM>.

Advantageously, the device actuation systems <NUM> facilitate compound movements of translation and rotation of treatment devices <NUM> while occupying a relatively small amount of space. The relatively small amount of space occupied by the device actuation systems <NUM> allows for the integration of multiple treatment devices <NUM> within an array <NUM>, enabling automated processing (e.g., livery printing) of large articles <NUM> (e.g., commercial aircraft <NUM>) in a precise manner and in a significantly reduced amount of time relative to conventional methods.

Referring to <FIG>, shown is a method <NUM> of actuating one or more treatment devices <NUM>. As indicated above, each treatment device <NUM> is configured to dispense a treatment toward an article surface <NUM>. The method <NUM> includes supporting one or more device heads <NUM> from at least one of a plurality of device frames <NUM> respectively associated with a plurality of the treatment devices <NUM>, as shown in <FIG>. As described above, each device frame <NUM> has at least one gear system <NUM> coupled to the device frame <NUM>, and each gear system <NUM> has a first drive gear <NUM>, a second drive gear <NUM>, a coupler gear <NUM>, and a coupler rail <NUM>. In the example of <FIG>, the end device frames <NUM> and the intermediate device frame <NUM> each have a gear system <NUM> mounted to each of opposing lateral sides <NUM> of the device frame <NUM>.

Step <NUM> of the method <NUM> comprises rotating the first drive gear <NUM> and the second drive gear <NUM>, which are engaged to opposite sides of a drive rail <NUM>, to thereby cause translation and/or rotation of a treatment device <NUM> relative to the drive rail <NUM>. As shown in <FIG> and described above, the first drive gear <NUM> is mounted to the treatment device <NUM>, and the second drive gear <NUM> is mounted to the coupler rail <NUM>. The coupler rail <NUM> is slidably mounted to the treatment device <NUM>. The coupler rail <NUM> is engaged to the coupler gear <NUM>, which is mounted to the treatment device <NUM>, as described above.

Step <NUM> of rotating the first drive gear <NUM> and the second drive gear <NUM> includes independently rotating, under control of the controller <NUM>, the first drive gear <NUM> and the second drive gear <NUM> respectively via the first drive gear motor <NUM> and the second drive gear motor <NUM>. In addition, the method includes independently rotating the coupler gear <NUM> via the coupler gear motor <NUM>, which is also controlled by the controller <NUM>. As mentioned above and shown in <FIG>, the first drive gear motor <NUM> and the coupler gear motor <NUM> are mounted to the device frame <NUM>, and the second drive gear motor <NUM> is mounted to the coupler rail <NUM>.

Step <NUM> of rotating the first drive gear <NUM> and the second drive gear <NUM> of a treatment device <NUM> additionally comprises rotating the first drive gear <NUM> and the second drive gear <NUM> according to one of two rotation modes. One rotation mode includes synchronously rotating the first drive gear <NUM> and the second drive gear <NUM> at the same speed and in opposite directions to cause translation of the treatment device <NUM> relative to the drive rail <NUM>. In this regard, the treatment device <NUM> is translated back and forth along the lengthwise direction of the drive rail <NUM> during synchronized rotation of the first drive gear <NUM> and the second drive gear <NUM>. Another rotation mode includes differentially rotating the first drive gear <NUM> and the second drive gear <NUM> at different speeds and in the same or opposite directions to at least cause rotation of the treatment device <NUM> relative to the drive rail <NUM>. As mentioned above, in some examples, the process of differentially rotating the first drive gear <NUM> and the second drive gear <NUM> of a treatment device <NUM> comprises differentially rotating the first drive gear <NUM> and the second drive gear <NUM> at different speeds in a manner causing a combination of rotation and translation of the treatment device <NUM> relative to the drive rail <NUM>. In a still further example, differentially rotating the first drive gear <NUM> and the second drive gear <NUM> comprises rotating either the first drive gear <NUM> or the second drive gear <NUM>, while the remaining first drive gear <NUM> or the second drive gear <NUM> is static.

Step <NUM> of the method <NUM> comprises rotating the coupler gear <NUM> to move the coupler rail <NUM> in a manner to maintain the second drive gear <NUM> in continuous engagement with the drive rail <NUM>. As mentioned above, the drive rail <NUM> is captured between the first drive gear <NUM> and the second drive gear <NUM>. Differential rotation of the first drive gear <NUM> and the second drive gear <NUM> causes rotation of the treatment device <NUM> relative to the drive rail <NUM>. As shown in <FIG> and described above, rotation of the treatment device <NUM> relative to the drive rail <NUM> requires continuous adjustment of the distance of the second drive gear <NUM> from the first drive gear <NUM> in order to maintain the second drive gear <NUM> (and first drive gear <NUM>) in continuous engagement with the drive rail <NUM>. The force applied by the second drive gear <NUM> against the drive rail <NUM> maintains the rail teeth <NUM> on the opposite side of the drive rail <NUM> in continuous engagement with the gear teeth <NUM> of the first drive gear <NUM>.

Referring briefly to the example of the gear system <NUM> of <FIG>, the method <NUM> includes maintaining the drive rail <NUM> in alignment with the first drive gear <NUM> and second drive gear <NUM> via a pair of circumferential ridges <NUM> respectively on a pair of gear sides <NUM> of the first drive gear <NUM> and the second drive gear <NUM>. As mentioned above, the circumferential ridges <NUM> on each gear side <NUM> of the first drive gear <NUM> and the second drive gear <NUM> extend over the rail sides <NUM>, which prevents the drive rail <NUM> for moving out of alignment with the first drive gear <NUM> and the second drive gear <NUM>.

Referring briefly to <FIG>, the operation of the treatment device system <NUM> comprises operating a plurality of device actuation systems <NUM> as a means to locate and orient a plurality of treatment devices <NUM>. In this regard, step <NUM> of rotating the first drive gear <NUM> and the second drive gear <NUM> comprises rotating the first drive gear <NUM> and the second drive gear <NUM> of at least one treatment device <NUM> of at least one adjacent pair of treatment devices <NUM> interconnected by a drive rail <NUM>, thereby causing translation and/or rotation of the pair of treatment devices <NUM> relative to each other. The treatment devices <NUM> are actuated relative to each other in a manner to maintain each treatment device <NUM> at a predetermined spacing and orientation relative to an article surface <NUM>, while the treatment devices <NUM> are moved over the article <NUM>.

With continued reference to the example of <FIG>, the method <NUM> comprises supporting the plurality of device frames <NUM> as an array <NUM>, wherein each adjacent pair of device frames <NUM> is interconnected by a drive rail <NUM> located between the first drive gear <NUM> and the second drive gear <NUM> of the device frames <NUM>. For such an arrangement, the method includes rotating the first drive gear <NUM>, the second drive gear <NUM>, and the coupler gear <NUM> respectively of the plurality of devices frame in a manner to move the array <NUM> between an expanded configuration <NUM> and a contracted configuration <NUM>, and any configuration therebetween, to facilitate conforming the treatment devices <NUM> to the local geometry of an article surface <NUM>.

In the example of <FIG>, the method <NUM> comprises supporting at least one array <NUM> of treatment devices <NUM> from a treatment device support assembly <NUM>, <NUM> having a pair of attachment pillars <NUM>, each pivotably coupled to a pair of attachment arms <NUM>. The opposite ends of each attachment arm <NUM> are coupled respectively to opposite ends of an array <NUM> of treatment devices <NUM>. In the example shown, the treatment device system <NUM> includes an upper treatment device support assembly <NUM> and a lower treatment device support assembly <NUM> each having arrays <NUM> of treatment devices <NUM> in side-by-side arrangement, as described above. For such an arrangement, the method includes pivoting the attachment arms <NUM> relative to each other, and in coordination with the operation of the device actuation systems <NUM> in a manner to move each array <NUM> of treatment devices <NUM> between an expanded configuration <NUM> and a contracted configuration <NUM>, to thereby position and orient each treatment device <NUM> complementary to the local contour of an article surface <NUM>, as the overhead gantry <NUM> and the pit gantry <NUM> respectively move the upper treatment device support assembly <NUM> and the lower treatment device support assembly <NUM> along the lengthwise direction of the article <NUM> (e.g., fuselage <NUM>) being processed.

The method <NUM> additionally includes dispensing a treatment from one or more device heads <NUM> of the treatment devices <NUM>. A treatment may be dispensed from the device heads <NUM> while the treatment devices <NUM> are moved over the article <NUM>. In addition, a treatment may be dispensed from the device heads <NUM> while the device actuation systems <NUM> continuously adjust the position and orientation of the treatment devices <NUM> relative to the article surface <NUM> as the treatment devices <NUM> are moved over the article <NUM>. Treatment may also be dispensed from the device heads <NUM> while the treatment devices <NUM> are stationary relative to the article surfaces <NUM>.

The dispensing of the treatment from the device heads <NUM> may include dispensing a treatment from device heads <NUM> configured as inkjet printheads <NUM>. For example, the dispensing of the treatment may include dispensing ink from the inkjet printheads <NUM>. The ink may be provided in a variety of compositions including, but not limited to, a primer, a paint, a clear coat, a sealant, or any one of a variety of other substances capable of being dispensed from an inkjet printhead <NUM>. In one example, the inkjet printheads <NUM> may dispense ink for printing an aircraft livery on a fuselage <NUM>, as shown in the example of <FIG> and <FIG>. However, as indicated above, the dispensing of treatment from the treatment devices <NUM> may include dispensing substances such solvents, adhesives, lubricants, abrasive particles, or any one a variety of other types of gas, liquid, semi-solid, or solid substances. Even further, the dispensing of treatment from the treatment devices <NUM> may include emitting radiation from the treatment devices <NUM> for performing any one of a variety of functions, such as curing an article <NUM> formed of composite (e.g., graphite-epoxy) material.

Claim 1:
A device actuation system (<NUM>) for actuating a treatment device (<NUM>), comprising:
a gear system (<NUM>) couplable to a treatment device (<NUM>), including:
a first drive gear (<NUM>) rotatably mountable to the treatment device (<NUM>);
a coupler rail (<NUM>) slidably mountable to the treatment device (<NUM>);
a second drive gear (<NUM>) rotatably mounted to the coupler rail (<NUM>);
a coupler gear (<NUM>) rotatably mountable to the treatment device (<NUM>) and engaged with the coupler rail (<NUM>);
a drive rail (<NUM>) located between the first drive gear (<NUM>) and the second drive gear (<NUM>) of the gear system (<NUM>);
the coupler gear (<NUM>) being rotatable to move the coupler rail (<NUM>) in a manner maintaining the second drive gear (<NUM>) in continuous engagement with the drive rail (<NUM>) against the first drive gear (<NUM>); and
the first drive gear (<NUM>) and the second drive gear (<NUM>) being rotatable in a manner causing at least one of translation and rotation (<NUM>) of the treatment device (<NUM>) relative to the drive rail (<NUM>).