Label Application System with Sensor Feedback Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing label application systems lack precision and consistency in applying labels to moving packages due to variations in package position, speed, and conveyor speed, leading to unsatisfactory label placement and reduced efficiency in subsequent machine reading operations.
Innovation Solution
A label application system that includes an applicator apparatus, a control system, and a sensor system with edge, distance, and speed detectors to accurately position and time the application of labels on packages moving along a conveyor, ensuring precise placement and consistent application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional actuators with no position or speed control are used, then the device complexity is reduced, but the manufacturing precision of label placement deteriorates
Solution Approach 1:
The patent implements feedback control by using sensors to detect package position and conveyor speed, then using this information to adjust actuator operation. The control system receives feedback from detectors about package location and conveyor velocity, and modifies actuator timing and positioning accordingly to maintain precise label placement despite variations in package position or conveyor speed.
Solution Approach 2:
The patent replaces traditional mechanically-controlled actuators with electronically-controlled actuators that receive signals from a control system. Instead of relying purely on mechanical timing and positioning, the system uses electronic sensors and control circuits to detect package position and trigger label application at the precise moment, substituting mechanical precision requirements with electronic detection and control.
2Ease of operation
If pneumatic actuators are used, then the ease of operation is improved, but the reliability of label application deteriorates due to air pressure variations
Solution Approach 1:
The control system uses feedback from position detectors and speed detectors to compensate for variations in pneumatic actuator performance. By monitoring actual package position and conveyor speed, the system adjusts the timing and triggering of pneumatic actuator activation to ensure consistent label application despite air pressure fluctuations.
Solution Approach 2:
The system dynamically changes operational parameters such as actuator trigger timing and duration based on detected package position and conveyor speed. The control system modifies these parameters in real-time to account for variations in pneumatic system performance, ensuring reliable label application across different operating conditions.
3Manufacturing precision
If guides are used to constrain package position, then the manufacturing precision of label placement is improved, but the productivity of the system deteriorates due to reduced package rate
Solution Approach 1:
The patent replaces mechanical guides that physically constrain package position with a sensor-based detection system. Optical or electronic detectors monitor package position without requiring physical contact or restriction, allowing packages to move freely at high speeds while still enabling precise detection and timing of label application.
Solution Approach 2:
The system allows packages to self-position on the conveyor without external mechanical constraints. The sensor system detects where packages are positioned naturally, and the control system adapts its timing and positioning accordingly, eliminating the need for productivity-reducing mechanical guides while maintaining label placement precision.
4Ease of operation
If the conveyor speed varies, then the ease of operation is improved, but the manufacturing precision of label placement deteriorates due to inconsistent application cycle
Solution Approach 1:
The control system uses feedback from speed detectors to monitor conveyor velocity in real-time. When variations in conveyor speed are detected, the system adjusts the timing of actuator activation and applicator positioning to compensate, ensuring that labels are applied at the correct position on packages regardless of speed fluctuations.
Solution Approach 2:
The system dynamically adjusts its operation based on detected conveyor speed. Rather than operating at a fixed predetermined timing, the control system continuously adapts actuator trigger timing and applicator positioning speed to match actual conveyor conditions, maintaining precision across varying operating speeds.
Data Source
AI summary
A label application system and method for applying a label to a package travelling on a conveyor along a conveying path includes: an applicator apparatus which is operable to move a label into contact with a package, a control system, which controls operation of the applicator apparatus, and a sensor system operable to detect an edge of the package, a distance from a reference point to the package, and the speed at which the package is travelling, wherein the control system is operable to receive and process the data from the sensor system relating to the package and initiate operation of the applicator apparatus such that the label is applied to the package in a desired position as the package moves in a direction of travel.