Automated Crate Label Removal with Rotating Nozzles and Recirculation
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Solution Overview
Problem
Existing label removal installations face issues such as frequent stoppages due to incomplete label removal, dirt accumulation leading to system damage, lack of automation, and inefficient water usage, resulting in reduced productivity and increased maintenance needs.
Innovation Solution
An automated installation with a high-pressure circuit using rotating nozzles to remove labels from all sides of crates, combined with a low-pressure circuit for cleaning and filtering, and a conveyor belt system with controlled acceleration and deceleration to manage crate movement efficiently, allowing for continuous operation and reduced stoppages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single one-way path is used for label removal, then the installation structure is simpler, but labels on all four walls cannot be removed in one pass requiring multiple reintroductions
Solution Approach 1:
The patent implements a dynamic path system where the trolley can reverse direction and travel back and forth along the same guide rails. This allows the labeling removal装置 to access all four walls of crates by changing direction at round ends, achieving complete label removal without requiring multiple separate passes while maintaining a relatively simple linear guide structure
Solution Approach 2:
The patent creates a continuous operational cycle where the trolley travels forward to remove labels from two walls, reverses direction at round ends, and returns to remove labels from the remaining two walls. This continuous back-and-forth motion eliminates idle time and ensures all labels are removed in essentially one continuous pass through the tunnel
2Productivity
If crates are processed without speed regulation, then the system is simpler to operate, but desynchronization between crates causes stoppages and requires manual intervention
Solution Approach 1:
The patent incorporates sensors and control systems that monitor the position and speed of crates as they enter and move through the tunnel. This feedback mechanism detects desynchronization between consecutive crates and automatically adjusts the trolley's speed and positioning to maintain proper spacing, preventing stoppages and eliminating the need for manual intervention
Solution Approach 2:
The system dynamically adjusts the speed of the trolley and conveyor based on real-time crate positioning. The control system modifies operational parameters on-the-fly to accommodate variations in crate entry timing, maintaining continuous flow and synchronization without requiring fixed rigid timing
3Ease of manufacture
If water is used in an open circuit for cleaning, then the cleaning process is simpler, but a significant amount of water is wasted
Solution Approach 1:
The patent implements a closed-loop water circulation system where cleaning water is continuously pumped through spray nozzles, collected at the bottom of the tunnel, filtered to remove debris and label remnants, and then reused for subsequent cleaning operations. This recovers and reuses the water resource while maintaining effective cleaning capability
Solution Approach 2:
The system uses hydraulic pumps and pressure-controlled spray mechanisms to circulate water through the cleaning circuit. The hydraulic system provides the necessary pressure for effective label removal while enabling precise control of water flow rates to optimize both cleaning efficiency and water conservation
4Productivity
If high-pressure jets are used to remove labels, then label removal effectiveness is improved, but dirt and labels accumulate inwardly causing system damage
Solution Approach 1:
The patent incorporates extraction systems including suction nozzles and filtration units that actively remove dislodged labels and dirt particles from the tunnel interior. These extraction mechanisms continuously clear the working space, preventing accumulation on motors and mechanical components while maintaining the high-pressure spray capability for effective label removal
Solution Approach 2:
The system converts the potentially harmful effect of high-pressure water jets scattering labels and dirt inwardly into a beneficial cleaning process. The scattered labels and dirt are captured by the low-pressure water circuit and filtration system, which transforms the dispersal effect into an opportunity for comprehensive cleaning and debris collection, ultimately protecting the system from damage
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively removes labels from all sides of crates at a nominal speed of 3000 units per hour, minimizes stoppages, and maintains the installation's cleanliness, enhancing productivity and reducing maintenance requirements while optimizing water usage.
Implementation Method 1
a label removal installation provided with at least one high-pressure water circuit accessible from the outside by the at least one door and comprising at least: a water tank, at least a high-pressure pump operatively connected to said water tank, a plurality of rotating high-pressure nozzles located inside the tunnel and fed by the high-pressure pump, said rotating high pressure nozzles able to discharge pressurized water at the four sides of each crate
Implementation Method 2
a conveyor belt operatively coupled to the trolley and to the perimetral guides so that said the conveyor belt is adapted to round-trip along each of the frame portions, wherein said conveyor belt is moved by at least one power system housed on one of the round ends and comprising a control system configured to control acceleration and deceleration of said conveyor belt
Data Source
AI summary
Installation provided with at least one high-pressure circuit comprising at least one high-pressure pump and rotating nozzles attacking the four sides of crates in order to automatically remove labels, wherein the installation further comprises a low-pressure circuit able to clean the installation inwardly and to transport labels to specific filters so that stoppages are diminished and further able to recirculate the water of the high-pressure and low-pressure circuits, and wherein trolleys holding the crates are able to rotate by means of a predefined path on perimetral guides of the frame so that the jets of the nozzles attack the required walls of the crates on four sides.