Directly Driven Carousel Pallets for Labeling Machine Torque Control
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Solution Overview
Problem
Conventional labeling machines face challenges with high torque requirements due to varying pivoting movements and mechanical resistance, leading to slow operation speeds and limited capacity for processing larger labels, as well as issues with label removal and transfer efficiency.
Innovation Solution
A labeling machine with directly driven, individually controlled pallets on a carousel, featuring programmable motor drives and integrated rotary encoders for precise control, along with vacuum suction pads and a non-contact glue printer for reduced torque and inertia, enabling faster and more precise label transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual electric motor drives are used for each pallet to enable precise control of pivoting movements, then positioning precision and control accuracy are improved, but torque requirements and mechanical resistance increase leading to slower operation speeds
Solution Approach 1:
The patent replaces traditional mechanical drive systems with direct electric motor drives for each pallet. This substitution enables precise control of pivoting movements through electronic control while reducing mechanical resistance and torque requirements compared to mechanical transmission systems. The electric motors provide controlled motion without the friction and mechanical losses inherent in gear-driven or belt-driven systems.
Solution Approach 2:
The patent divides the labeling system into individually driven pallets, each with its own electric motor. This segmentation allows independent control of each pallet's pivoting movement, enabling precise positioning while optimizing the drive requirements for each specific pallet position and load condition, rather than using a single high-torque drive for the entire system.
2Device complexity
If conventional pallets are used on carousels with limited pivoting ranges, then device simplicity is maintained, but the ability to process larger labels is restricted
Solution Approach 1:
The patent implements dynamically adjustable pivoting ranges for the pallets on the carousel. Rather than being fixed in position, the pallets can pivot through extended angular ranges controlled by the individual electric motors. This dynamic capability allows the same carousel structure to accommodate various label sizes by adjusting the pivoting amplitude and timing, thereby increasing versatility without requiring multiple fixed-position carousels.
Solution Approach 2:
The system changes operational parameters such as pivoting angle, pivot speed, and timing to accommodate different label sizes. By programmatically adjusting these parameters through the control system, the carousel can process small, medium, and large labels using the same physical structure, eliminating the need for hardware modifications while expanding adaptability.
3Force
If high torque drive motors are used to overcome mechanical resistance during label gluing and transfer, then force requirements are met, but operation speed decreases and productivity is reduced
Solution Approach 1:
The patent replaces high-torque mechanical drive systems with electric motor drives that provide precisely controlled torque only when needed. The electric motors can deliver high torque during critical moments such as label pickup and transfer, then immediately reduce to minimal torque during transport phases, thereby maintaining high average operating speed while meeting peak force requirements.
Solution Approach 2:
The drive system operates with periodic torque application, providing high torque only during specific phases of the pallet cycle (label pickup, pivoting to transfer position, and label release) rather than continuous high torque. This periodic action pattern allows the system to maintain high speeds during low-torque phases while still achieving the necessary force during critical operations.
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 solution allows for efficient and precise label transfer with reduced torque and inertia, enabling the processing of larger labels and maintaining high machine performance by optimizing pivoting movements and reducing mechanical resistance.
Implementation Method 1
the individual drives have integrated rotary encoders, which are preferably designed as Hall effect sensors
Implementation Method 2
vacuum suction pads and a non-contact glue printer
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a labeling machine (1) for containers (2), comprising: a transporting means (3) for the containers; at least one magazine (7) for labels (6); a carousel (4), which in particular is directly driven and which has pallets (5) circulating thereon for removing the labels from the magazine and for transferring the labels to the containers; and a progammable controller (9) for individual drives (8), which are associated with respective pallets in order to separately pivot the pallets. Optimized motion sequences, in particular also for the processing of labels having excessive length, can be produced because the controller is designed to produce different pivoting motions of the pallets on the magazine and on the containers.