Label Rewinder Backfeed Control for Constant Carrier Tension
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Solution Overview
Problem
Industrial label printers face challenges in maintaining consistent tension in the backing paper during high-speed operations, leading to potential slippage and errors in label printing and feeding, especially when complex tensioner mechanisms are absent or torque control is insufficient.
Innovation Solution
Implementing a method where the label rewinder operates in the opposite direction during backfeed to create an extension, controlling the rewinder speed to manage tension, and adjusting the rewinder speed and torque to match the drive roller's surface speed, ensuring a constant tension is maintained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate backing paper tensioner unit is used to maintain constant tension, then label feeding reliability is improved, but device complexity and time for label changing increase
Solution Approach 1:
The patent combines the tensioning function with the existing rewinder mechanism. The rewinder is configured to both rewind the backing paper and maintain constant tension on it, eliminating the need for a separate tensioner unit. This merging of functions reduces device complexity while preserving reliability.
Solution Approach 2:
The rewinder is designed to perform multiple functions: it rewinds the backing paper, maintains constant tension on the backing paper, and controls the tension during backfeed operations. This multi-functionality eliminates the need for dedicated separate components for each function.
2Ease of operation
If torque control is used to manage tension during backfeed, then ease of operation is improved, but reliability during high-speed operation deteriorates due to insufficient tension
Solution Approach 1:
The patent implements dynamic tension control where the rewinder's torque is automatically adjusted based on real-time conditions. During backfeed, the rewinder creates controlled slack, and during normal operation, it maintains constant tension. This dynamic adjustment ensures both ease of operation and reliability across different operating conditions.
Solution Approach 2:
The system uses feedback from the drive roller speed and rewinder position to automatically adjust the rewinder's torque. The control mechanism ensures that tension is maintained appropriately during both backfeed and normal high-speed operation, preventing both excessive tension and insufficient tension conditions.
3Ease of operation
If the rewinder runs in reverse during backfeed to create slack, then ease of operation is improved, but the risk of bouncing effect and insufficient tension increases
Solution Approach 1:
The patent applies preliminary anti-action by controlling the rewinder's reverse rotation during backfeed to create only the necessary amount of slack, preventing excessive bouncing. The system anticipates the potential harmful effect and applies just enough counter-action to prevent it while maintaining operational simplicity.
Solution Approach 2:
The system changes the rewinder's operational parameters (speed, direction, torque) dynamically during backfeed. By controlling the reverse rotation speed and torque, the system creates controlled slack without causing harmful bouncing effects. The parameters are adjusted to maintain the balance between creating necessary slack and preventing excessive movement.
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
This approach enhances the reliability and efficiency of label printing by reducing slippage and wear on the drive roller, allowing for faster and more consistent label dispensing without the need for complex tensioner mechanisms.
Implementation Method 1
controlling the rewinder speed to manage tension
Implementation Method 2
reducing slippage and wear on the drive roller
Implementation Method 3
The label stock may be pressed against the drive roller by a nip roller, in order to mitigate risk of slip between the drive roller and the label stock
Implementation Method 4
The label stock may be pressed against the drive roller by a nip roller, in order to mitigate risk of slip between the drive roller and the label stock
Implementation Method 5
Labels are removed from the moving backing paper by passing the label stock under tension around a labelling peel beak
Data Source
AI summary
The specification relates to a method in a label printer (100), the label printer at least comprising: a label supply spool (120) configured to supply a label web comprising a label (191) and a carrier (191); a label rewinder (130) configured to rewind at least the carrier; a drive roller (172). The method comprises: operating the label rewinder in an opposite direction to a rewind direction and building or continue to build an extension (195) on the carrier between the drive roller (172) and the carrier rewinder (130) during a backfeed operation of the label web; performing a backfeed operation by rotating the drive roller (172) in a direction opposite to the print operation direction until a next label is displaced back to a start print position; stopping the drive roller after backfeed when a length of the extension (195) is reduced; and rewind with the rewinder (130) in rewinder operation direction causing the carrier to tense.