三维喷绘机理及大幅面3D喷绘机器人关键技术研究
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摘要
近年来，随着计算机3D技术的成熟和平面喷绘的发展，浮现出越来越多的三维喷绘的需求，成为喷绘技术发展的一个新方向，具有良好的发展潜力和广阔的应用前景。但业内对三维喷绘还没有形成统一的定义和概念，相关的研究和应用都与平面喷绘有很大的区别，没有成熟的理论体系支持。本文在原型样机的基础上，结合平面喷墨技术和机器人控制技术，搭建大幅面3D喷绘机器人系统。利用该系统平台，对三维喷绘的关键技术和典型应用展开研究，为下一步3D喷绘机器人产业化奠定基础。
论文围绕三维喷绘的机理及3D喷绘关键技术展开研究。在机理研究的基础上搭建三维喷绘机器人平台，同时对影响三维喷绘效果的若干关键因素进行分析，得到了三种减小误差的优化算法。在此基础上对三维喷绘的应用点展开探索，设计并实现了真彩色实景地理模型和立体照片的制作方法。
论文整体工作概述如下：
(1)三维喷绘机理研究。论文首先对三维喷绘的工作原理和作业流程进行分析和设计，确定适用于三维喷绘的喷墨技术和墨水。同时，针对三维喷绘过程中喷头在z方向往复运动这一特点，对三维喷绘供墨系统原理和可行技术方案也展开研究。通过对这些核心模块机理的研究，为搭建3D喷绘机器人系统提供理论依据和指导。
(2)3D喷绘机器人系统研制。基于实现系统功能和保证系统稳定的设计原则，论文对大幅面三维喷绘机器人工程样机的机械系统、控制系统和软件系统进行了总体规划和结构设计，并通过实验验证了系统的性能，为下一步研制具有自主知识产权的3D喷绘机器人奠定了基础。
(3)三维喷绘关键技术的研究。在样机平台基础上，论文对墨滴的下落过程进行观测和分析，总结在三维喷绘中引起颜色失真和喷绘误差的各项因素。在此基础上，针对三维模型曲面变化导致着色面积变大、平均喷绘距离过大引起墨点不能准确落在理想落点和喷头老化堵塞导致输出图像出现规律性条纹这三种影响三维喷绘效果的情况，分别设计基于高斯曲率的三维喷绘半色调处理算法、三维喷绘角度优化算法和三维喷绘轨迹优化算法，有效地解决了以上问题。
(4)实景地理模型真彩色喷绘方法的设计与实现。结合Google提供的地理信息服务，将地理高程模型DEM和卫星影像引入到三维喷绘中，形成了全自动真彩色实景地理模型制作方法，提升当前沙盘制作精度和自动化水平。同时，提出一种地理模型优化和图像补偿算法，解决了三维喷绘的应用适应性问题。此外，设计一种基于小波变换的多分辨率简化雕刻方法，解决大幅面高落差模型的雕刻难题，提高了雕刻的效率。
(5)设计了一种制作立体照片的方法。首先从单张照片提取基本深度信息，结合三维喷绘对立体模型的约束条件进行优化。在此基础上利用图像细节纹理，得到细节深度。将两者通过曲面浮雕生成方法叠加，得到用于制作立体照片的模型，进而对立体照片进行制作和加工。
(6)3D喷绘实验设计。为验证机器人系统的精度、功能和稳定性，利用聚氨酯泡沫和代木材料，结合具体的作业流程，分别进行了包括高精度深圳模型、大幅面台湾模型、多块拼接钓鱼岛模型和“林荫”立体照片等多项三维喷绘实验，获得了较好的效果。
In recent years, with the development of computer3D technology, more andmore demands of3D printing emerge.3D printing becomes a new direction for thedevelopment of inkjet printing technology, with good development potential andbroad prospects for application. Howerver, as there is no uniform definition andconcept on3D printing in the industry, researches are focused on3D rapidprototyping field, which has great differences with traditional printing applications.Therefore, aiming at the key and difficulties of3D printing, a3D printing robotsystem is built in this thesis. Based on this system, which has combined robotics andprinting technologies, the mechanism and key technology of3D printing aredeveloped and also the basic theory of3D printing system has been built.
Based on the research of the mechanism and key technology of3D printing,3Dprinting robot using a3-DOF cartesian-coordinate robot as platform is built. Byinvestigating the reason of color distortions in3D printing, a novel multi-stepcompensation algorithm is developed. Futher more, the application of3D printingrobot is explored, and the method of manufacturing3D photo and true-color terrainmodel is developed.
The main outcomes can be cited as follows:
(1) Research on3D printing mechanism. First, the working principle andoperating flow of3D printing is developed and the technical scheme of inkjet methodand ink is confirmed. Then, the principle and scheme of3D ink supply system isstudied. The research on the core modules provides a theoretical basis and guidanceto the design of3D printing robot.
(2) The general planning and structure design of3D printing robot are presented,including mechanical system, control system and software system. Then systemcapability is checked, laid a foundation for further development of proprietary3Dprinting robot.
(3) The factors that cause color distortion and printing errors in3D printing process have been summarized. Then, to overcome the problems which affect theprinting result: the coloring area being larger caused by3D model surface, printaverage distance much larger then2D printing and the regularity stripes caused by thenozzle blockage and mechanical error, three optimization algorithms have beenproposed in Chapter3: three dimensional halftoning algorithm based on surfacefeatures, an error statistical and angle optimization method in3D printing and amulti-pass trajectory optimization methods in3D printing.
(4) Method of making true-color terrain model. Based on the geographicalinformation service provided by Google, the extraction methods of DEM and satelliteimage have been proposed. To improve the compatibility of3D printing, twoalgorithms are developed: model optimization and image compensation in3Dprinting and multi-resolution analysis of grid point clouds based on wavelet transform.Then, a fast processing method of high precision and true color actual scene model isimplemented. The experimental results demonstrate the performance of the3Dprinting robot platform and the proposed algorithms.
(5) A method of basal depth estimation from a single image using MRF-MAP.According to the limit of manufacturing3D photo, the rough depth is extracted andoptimized firstly. Then the depth of details is obtained by using the texture andshadow of the image. The rough depth and the details depth are superposition toachieve the image’s relief model. Finally,3D photo’s manufacture is implemented,including carving and printing using the relief model and image data by3D printingrobot.
(6)3D printing experiments have been designed to verify the accuracy,functionality and reliability of3D printing robot. The experments include the highprecision terrain model of Shenzhen, the large format terrain model of Taiwan, thesplicing terrain model of Diaoyu Island and3D photo named “Linyin”.
论文围绕三维喷绘的机理及3D喷绘关键技术展开研究。在机理研究的基础上搭建三维喷绘机器人平台，同时对影响三维喷绘效果的若干关键因素进行分析，得到了三种减小误差的优化算法。在此基础上对三维喷绘的应用点展开探索，设计并实现了真彩色实景地理模型和立体照片的制作方法。
论文整体工作概述如下：
(1)三维喷绘机理研究。论文首先对三维喷绘的工作原理和作业流程进行分析和设计，确定适用于三维喷绘的喷墨技术和墨水。同时，针对三维喷绘过程中喷头在z方向往复运动这一特点，对三维喷绘供墨系统原理和可行技术方案也展开研究。通过对这些核心模块机理的研究，为搭建3D喷绘机器人系统提供理论依据和指导。
(2)3D喷绘机器人系统研制。基于实现系统功能和保证系统稳定的设计原则，论文对大幅面三维喷绘机器人工程样机的机械系统、控制系统和软件系统进行了总体规划和结构设计，并通过实验验证了系统的性能，为下一步研制具有自主知识产权的3D喷绘机器人奠定了基础。
(3)三维喷绘关键技术的研究。在样机平台基础上，论文对墨滴的下落过程进行观测和分析，总结在三维喷绘中引起颜色失真和喷绘误差的各项因素。在此基础上，针对三维模型曲面变化导致着色面积变大、平均喷绘距离过大引起墨点不能准确落在理想落点和喷头老化堵塞导致输出图像出现规律性条纹这三种影响三维喷绘效果的情况，分别设计基于高斯曲率的三维喷绘半色调处理算法、三维喷绘角度优化算法和三维喷绘轨迹优化算法，有效地解决了以上问题。
(4)实景地理模型真彩色喷绘方法的设计与实现。结合Google提供的地理信息服务，将地理高程模型DEM和卫星影像引入到三维喷绘中，形成了全自动真彩色实景地理模型制作方法，提升当前沙盘制作精度和自动化水平。同时，提出一种地理模型优化和图像补偿算法，解决了三维喷绘的应用适应性问题。此外，设计一种基于小波变换的多分辨率简化雕刻方法，解决大幅面高落差模型的雕刻难题，提高了雕刻的效率。
(5)设计了一种制作立体照片的方法。首先从单张照片提取基本深度信息，结合三维喷绘对立体模型的约束条件进行优化。在此基础上利用图像细节纹理，得到细节深度。将两者通过曲面浮雕生成方法叠加，得到用于制作立体照片的模型，进而对立体照片进行制作和加工。
(6)3D喷绘实验设计。为验证机器人系统的精度、功能和稳定性，利用聚氨酯泡沫和代木材料，结合具体的作业流程，分别进行了包括高精度深圳模型、大幅面台湾模型、多块拼接钓鱼岛模型和“林荫”立体照片等多项三维喷绘实验，获得了较好的效果。
In recent years, with the development of computer3D technology, more andmore demands of3D printing emerge.3D printing becomes a new direction for thedevelopment of inkjet printing technology, with good development potential andbroad prospects for application. Howerver, as there is no uniform definition andconcept on3D printing in the industry, researches are focused on3D rapidprototyping field, which has great differences with traditional printing applications.Therefore, aiming at the key and difficulties of3D printing, a3D printing robotsystem is built in this thesis. Based on this system, which has combined robotics andprinting technologies, the mechanism and key technology of3D printing aredeveloped and also the basic theory of3D printing system has been built.
Based on the research of the mechanism and key technology of3D printing,3Dprinting robot using a3-DOF cartesian-coordinate robot as platform is built. Byinvestigating the reason of color distortions in3D printing, a novel multi-stepcompensation algorithm is developed. Futher more, the application of3D printingrobot is explored, and the method of manufacturing3D photo and true-color terrainmodel is developed.
The main outcomes can be cited as follows:
(1) Research on3D printing mechanism. First, the working principle andoperating flow of3D printing is developed and the technical scheme of inkjet methodand ink is confirmed. Then, the principle and scheme of3D ink supply system isstudied. The research on the core modules provides a theoretical basis and guidanceto the design of3D printing robot.
(2) The general planning and structure design of3D printing robot are presented,including mechanical system, control system and software system. Then systemcapability is checked, laid a foundation for further development of proprietary3Dprinting robot.
(3) The factors that cause color distortion and printing errors in3D printing process have been summarized. Then, to overcome the problems which affect theprinting result: the coloring area being larger caused by3D model surface, printaverage distance much larger then2D printing and the regularity stripes caused by thenozzle blockage and mechanical error, three optimization algorithms have beenproposed in Chapter3: three dimensional halftoning algorithm based on surfacefeatures, an error statistical and angle optimization method in3D printing and amulti-pass trajectory optimization methods in3D printing.
(4) Method of making true-color terrain model. Based on the geographicalinformation service provided by Google, the extraction methods of DEM and satelliteimage have been proposed. To improve the compatibility of3D printing, twoalgorithms are developed: model optimization and image compensation in3Dprinting and multi-resolution analysis of grid point clouds based on wavelet transform.Then, a fast processing method of high precision and true color actual scene model isimplemented. The experimental results demonstrate the performance of the3Dprinting robot platform and the proposed algorithms.
(5) A method of basal depth estimation from a single image using MRF-MAP.According to the limit of manufacturing3D photo, the rough depth is extracted andoptimized firstly. Then the depth of details is obtained by using the texture andshadow of the image. The rough depth and the details depth are superposition toachieve the image’s relief model. Finally,3D photo’s manufacture is implemented,including carving and printing using the relief model and image data by3D printingrobot.
(6)3D printing experiments have been designed to verify the accuracy,functionality and reliability of3D printing robot. The experments include the highprecision terrain model of Shenzhen, the large format terrain model of Taiwan, thesplicing terrain model of Diaoyu Island and3D photo named “Linyin”.
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