Full-Servo Label Inspection Machine with Automated Defect Removal
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Solution Overview
Problem
Manual removal and replacement of defective labels in printing rolls are labor-intensive, costly, and prone to inefficiencies and quality control issues due to the difficulty in achieving high-precision positioning.
Innovation Solution
A full-servo label inspection machine with an unrolling mechanism, visual inspection mechanism, label removal mechanism, and label replacement mechanism, utilizing a drive component, waste label traction mechanism, and label replacement mechanism to automatically detect and replace defective labels with a controller managing the entire process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual removal and replacement of labels is used, then labor cost and labor intensity are high, but the process is simple and requires no complex positioning systems
Solution Approach 1:
The patent replaces manual mechanical operations with an automated servo-driven positioning system. The servo motor controls the label removal and replacement mechanisms with high precision, eliminating the need for complex mechanical positioning arrangements while achieving both high efficiency and high accuracy.
Solution Approach 2:
The system automatically detects defective labels through visual inspection, positions the label removal mechanism, removes the defective label, and replaces it with a new label without human intervention. The controller coordinates all operations autonomously, making the system self-sufficient and highly efficient.
2Productivity
If automatic removal and replacement of labels is implemented, then productivity is improved, but positioning precision becomes difficult to achieve
Solution Approach 1:
The patent employs a servo motor-driven positioning system that provides high precision through electronic control rather than complex mechanical arrangements. The servo motor's precise control capabilities enable accurate positioning during automatic label removal and replacement operations.
Solution Approach 2:
The visual inspection mechanism provides feedback to the controller about the position and condition of labels. This feedback enables the controller to adjust the positioning system in real-time, ensuring high precision during automatic operations while maintaining high productivity.
3Reliability
If manual label removal is used, then device complexity is low, but quality control is difficult and accidents may occur
Solution Approach 1:
The system performs automatic visual inspection, defect detection, label removal, and replacement without human intervention. The controller coordinates all operations autonomously, ensuring consistent quality control and eliminating human error while maintaining manageable system complexity through integrated automation.
Solution Approach 2:
The patent replaces manual quality control operations with an automated visual inspection system and servo-driven positioning system. This substitution provides more reliable and consistent quality control while keeping the overall system complexity manageable through coordinated automation of multiple functions.
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
Enables high-efficiency and accurate automatic removal and replacement of defective labels, reducing labor costs and improving quality control by using a controller-connected visual inspection mechanism, label removal triggering mechanism, and label replacement mechanism to automate the process.
Implementation Method 1
the paper pressing roller is at the label removal position, it presses the material to be inspected downwards so that the material to be inspected abuts a rear end of the label removal plate and forms an angle of less than 180° between the material to be inspected and the rear end of the label removal plate
Implementation Method 2
a label removal paper, which has a sticky outer surface, winds around the waste label traction mechanism; when the defective label is in contact with the label removal paper, it sticks onto the label removal paper
Implementation Method 3
the frame is provided with an unrolling mechanism, a rolling mechanism, a visual inspection mechanism, a label removal mechanism, and a label replacement mechanism
Data Source
AI summary
The present invention provide a full-servo label inspection machine and a control method thereof; the machine includes a frame, the frame is provided with an unrolling mechanism, a rolling mechanism, a visual inspection mechanism, a label removal mechanism, and a label replacement mechanism. In the label removal mechanism, when the paper pressing roller is at the label removal position, it presses the material to be inspected downwards to form an angle of less than 180° with the rear end of a label removal plate. After a defective label on the material to be inspected passes the label removal plate, a front end of the defective label curls up and eventually sticks onto the label removal paper. The present invention allows fully automation of the removal and replacement of labels, achieving high inspection efficiency and accuracy.