Automated Label Applicator with Tabbed Backing for High-Speed Packaging
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Solution Overview
Problem
Manual application of self-adhesive address labels for large quantities of packages is inefficient and increases labor costs, as it becomes difficult to handle the removal of release liners and application of labels.
Innovation Solution
A fully automated system comprising a controller, printer, label feeder, label applicator, and item feeder that prints labels on a tabbed backing, removes the release liner, and affixes the label to the package using a moveable element, such as a robotic arm, to streamline the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual removal of release liner and application of labels is used, then flexibility and simplicity are maintained for small quantities, but productivity and efficiency deteriorate for large quantities
Solution Approach 1:
The label application system is divided into distinct functional modules: a label applicator that removes release liners, a printer that prints labels, a label feeder that transports labels, an item feeder that positions items, and a controller that coordinates operations. Each module performs a specific task, enabling high-speed automated processing while maintaining manageable system complexity through functional decomposition.
Solution Approach 2:
The system enables automated self-service label application where the label applicator automatically removes release liners and applies labels to items without manual intervention. The controller autonomously coordinates between the printer, label feeder, item feeder, and label applicator, allowing the system to operate independently once initiated, thereby achieving high productivity for large quantities.
2Productivity
If automated equipment is used for printing and applying labels, then productivity increases, but the complexity of the system increases
Solution Approach 1:
The patent combines multiple functions into an integrated automated system where the printer, label feeder, item feeder, and label applicator work together under a single controller. This merging of functions enables continuous high-speed operation with automated label printing, transport, and application, achieving high productivity while managing complexity through unified control architecture.
Solution Approach 2:
The controller serves as an intermediary that coordinates between the printer, label feeder, item feeder, and label applicator. It manages the timing and sequencing of operations, ensuring smooth interaction between components without requiring complex direct connections between all modules, thereby enabling high-speed automated operation with manageable control complexity.
3Loss of time
If manual label application is used, then labor flexibility is maintained, but labor costs and time consumption increase for large quantities
Solution Approach 1:
The automated label application system performs all label removal and application operations without manual intervention. The label applicator automatically grasps release liners, removes them from labels, and applies labels to items, while the controller autonomously coordinates all components. This self-service capability eliminates manual labor time and enables continuous high-speed operation for large quantities.
Data Source
AI summary
A printer prints label data on a self-adhesive label that has a tabbed backing to produce a printed label on the tabbed backing. Also, a label feeder is positioned relative to the printer to transport the printed label on the tabbed backing away from the printer. A label applicator is positioned, relative to the feeder, to remove the printed label on the tabbed backing from the feeder. The tabbed backing includes a first section, covering an adhesive area of the printed label, and a tab extending from the first section. The label applicator includes a holder, that is shaped to grasp the tab of the tabbed backing, and a moveable element that is configured to remove the printed label from the tabbed backing and affix the adhesive area of the printed label to an item.