Automated Label Defect Detection and Pneumatic Ejection
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Solution Overview
Problem
Current packaging techniques for labeling products are inefficient in detecting and discarding defective labels, leading to product wastage and potential consumer misguidance, as manual checking is error-prone and automated systems often fail to accurately identify and remove defective labels without damaging products or incurring high operational costs.
Innovation Solution
An apparatus and process that includes a label path with an inspection unit to detect defective labels using a defect detector, a push mechanism to mechanically peel off defective labels, and a collecting unit with a motorized roll winder to collect and remove defective labels, ensuring accurate identification and removal while minimizing product damage and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual checking is used to detect defective labels, then operational costs are reduced, but detection accuracy decreases leading to product wastage
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses cameras and image processing algorithms to detect defective labels. This substitution maintains high detection accuracy while enabling continuous operation at full production speed, eliminating the trade-off between manual checking and automated detection.
Solution Approach 2:
The inspection system automatically detects, identifies, and triggers rejection of defective labels without human intervention. The system self-regulates by comparing labels against predefined criteria and automatically activates the rejection mechanism, eliminating the need for manual checking while maintaining high accuracy.
2Reliability
If automated suction mechanism is used to remove defective labels, then detection accuracy improves, but energy consumption increases
Solution Approach 1:
Instead of continuous suction, the system uses periodic pneumatic blasts that are activated only when a defective label is detected. This on-demand operation dramatically reduces energy consumption compared to continuous suction mechanisms, while maintaining high detection accuracy through the optical inspection system.
Solution Approach 2:
The patent employs pneumatic ejection using compressed air blasts to remove defective labels instead of mechanical suction mechanisms. This pneumatic approach consumes significantly less energy while achieving the same label removal function, addressing the energy consumption issue.
3Object-affected harmful factors
If defective labels are removed from product, then consumer safety is improved, but product damage occurs
Solution Approach 1:
The system extracts only the defective label from the product using targeted pneumatic ejection or precision cutting, leaving the product itself intact. This selective removal eliminates the harmful defective label while preserving product integrity, avoiding damage that would occur with more aggressive removal methods.
Solution Approach 2:
The rejection mechanism applies force or cutting action only at the specific location of the defective label, not to the entire product. This localized action ensures that only the problematic label is removed while the rest of the product remains undamaged and can potentially be reused or properly labeled.
4Productivity
If high-speed automated labeling is used, then productivity improves, but defective label detection accuracy decreases
Solution Approach 1:
The optical inspection system captures and analyzes label images before the labeling process completes, allowing sufficient time for defect detection even at high speeds. The system preliminarily identifies defective labels and triggers rejection mechanisms in advance, maintaining both high productivity and detection accuracy.
Solution Approach 2:
The patent uses optical sensing and image processing technology to detect defects at high speeds, replacing slower mechanical inspection methods. This electronic/optical substitution enables accurate defect identification to keep pace with high-speed labeling 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 effectively discards defective labels with high accuracy, reducing product wastage and operational costs, while ensuring proper labeling of products, thus enhancing packaging efficiency and consumer safety.
Implementation Method 1
The motorized roll winder material is selected on the basis of sticking properties of self-adhesive labels in the label web
Data Source
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AI summary
In accordance with an aspect of the present invention, an apparatus to discard defective label form a labeling machine is provided. The invention includes a label path to move a label web containing a plurality of labels from an origin station to a destination station. The invention then includes an inspection unit to detect the defective labels from the plurality of labels in the label path. The invention also includes a defective label discarding unit configured to discard the defective labels from the label path. The invention further includes, a collecting unit to collect the plurality of defective labels. The invention then includes, a labeling unit configured to label the good label in a required product and a processor to synchronize the label path, the inspection unit, the defective label discarding unit, the collecting unit and the labeling unit.