4-Axis Label Applicator With Vision-Guided Placement
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Solution Overview
Problem
Current labeling systems struggle to handle high volumes of shipping items with varying sizes and orientations, inaccurately apply labels over existing indicia, and fail to avoid tape seams, leading to inefficient logistics and reduced throughput.
Innovation Solution
A 4-axis label printing and applicator assembly with a vision system that captures item data to adjust label placement in real-time, ensuring existing indicia remains visible or is covered as needed, and avoids tape seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed position labeler assembly is mounted at a height to accommodate the tallest shipping item, then the system can handle various item heights, but it becomes difficult to load labels and service the assembly
Solution Approach 1:
The label applicator is made movable along the conveyor line rather than being fixed in position. The applicator can dynamically adjust its position to accommodate different item heights while remaining accessible for loading and servicing. This dynamic positioning resolves the contradiction by allowing the system to adapt to various item dimensions without compromising ease of operation.
2Ease of operation
If the applicator pad returns to the home position after each label application, then the system prepares for the next item, but the overall process becomes time-intensive with reduced throughput
Solution Approach 1:
The applicator maintains continuous engagement with items passing along the conveyor rather than returning to a home position after each application. This continuous action eliminates idle return trips and maintains constant productivity, resolving the contradiction between operational readiness and throughput by keeping the applicator in a constant state of useful action.
Solution Approach 2:
The applicator operates in a periodic manner, engaging with each item at the appropriate moment as it passes by, rather than performing a full return cycle. This periodic engagement maintains high throughput while ensuring proper label application timing, balancing operational preparation with productivity.
3Device complexity
If traditional labeling systems use fixed position printers and applicators, then the system structure is simple, but it cannot accurately place labels on items of varying sizes and orientations
Solution Approach 1:
The applicator is designed to move dynamically along the conveyor and adjust its position based on item characteristics. This dynamic capability enables accurate label placement on items of varying sizes and orientations without requiring a complex fixed-position system with multiple adjustable components, resolving the contradiction between simplicity and precision.
Solution Approach 2:
The system adds the dimension of motion along the conveyor line, allowing the applicator to reach items at different positions rather than requiring multiple fixed applicators at different locations. This dimensional approach simplifies the overall system structure while maintaining high placement accuracy across diverse item types.
4Device complexity
If current labeling systems lack vision systems and multi-axis movement, then the system is simpler, but it cannot identify existing labels to avoid covering essential indicia or avoid tape seams
Solution Approach 1:
A vision system is integrated to provide real-time feedback about item characteristics, existing labels, and tape seam locations. This feedback enables the applicator to adjust its position and avoid covering essential indicia or applying labels over tape seams, resolving the contradiction between system simplicity and application reliability through intelligent sensing and response.
Solution Approach 2:
The system replaces purely mechanical positioning with a combination of vision-based detection and controlled motion. The vision system identifies critical features optically, and the control system translates this information into precise applicator positioning, substituting mechanical trial-and-error with intelligent optical-mechanical integration for improved reliability.
Data Source
AI summary
The present invention provides systems and methods of applying labels to shipping items, such as parcels, packages, or envelopes, in an automated fashion while the shipping items move along a conveyor. The systems and methods of the present invention include use of a uniquely designed label printing and applicator assembly having multi-axis label application capabilities, specifically the ability to move in 4-axes relative to a given shipping item when applying a label thereto. The systems and methods of the present invention further utilize a vision system to collect data of a given shipping item, including, but not limited to, physical dimensions of the item, orientation and skew of the item along the conveyor, and identification of any existing labels and/or indicia on the item. Such data is used by the label printing and applicator assembly to accurately place a given label in desired location on a given shipping item.