Label Roll Gripper With Sensor-Guided Core Clamping
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Solution Overview
Problem
Existing label roll handling systems face issues such as low clamping force, lack of precise centering, potential damage to label rolls, and inability to handle partially used rolls, leading to inefficient and unreliable handling processes.
Innovation Solution
A gripping system with internal and external clamping jaws, equipped with distance sensors and a pressure control valve, allows for secure, precise, and adaptable gripping of label rolls, ensuring reliable handling and minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a manipulator unit with small cylinders is used to grip label rolls, then the device size can be reduced, but the clamping force becomes relatively low and cannot be maintained
Solution Approach 1:
The patent employs a pneumatic gripping system with cylinders that generate clamping force through compressed air. The pneumatic actuation mechanism provides sufficient clamping force while maintaining a compact device structure, resolving the contradiction between device size and clamping force capability.
Solution Approach 2:
The gripping system incorporates adjustable and maintainable clamping force through pneumatic pressure control. The system can dynamically adjust the clamping force level and maintain it consistently during operation, overcoming the limitation of fixed, low clamping force in smaller manipulator designs.
2Device complexity
If gripper jaws are only locked in position without mechanical coupling, then the structure can be simpler, but precise centering of the label roll is not possible
Solution Approach 1:
The patent combines multiple gripper jaws into a mechanically coupled assembly that moves together as a unified structure. This mechanical coupling ensures that all jaws maintain consistent positioning relative to each other, enabling precise centering of the label roll while keeping the overall structure relatively simple through the integrated design.
3Volume of moving object
If the manipulator unit is very large in diameter, then it can accommodate larger label rolls, but the gripper must change clamping position from inner to outer gripper, negatively impacting cycle time and process reliability
Solution Approach 1:
The gripping system is segmented into multiple functional zones with both inner and outer gripper jaws that can operate independently or in coordination. This segmentation allows the system to handle label rolls of varying sizes without requiring physical repositioning of the entire manipulator, thereby maintaining short cycle times and high productivity.
Solution Approach 2:
The gripper system employs dynamic clamping where both inner and outer jaws can be actuated simultaneously or selectively based on the label roll size. This dynamic adaptation eliminates the need for manual or automated repositioning between inner and outer gripping positions, reducing cycle time and improving process reliability.
4Device complexity
If the label roll is clamped exclusively on its outer circumference, then the manipulator structure can be simpler, but the label tape could be damaged and the secure hold is questionable
Solution Approach 1:
The clamping structure is segmented into inner gripper jaws that contact the core and outer gripper jaws that contact the outer circumference. This segmentation allows the system to distribute clamping forces appropriately - the inner jaws provide secure holding on the core while the outer jaws provide stable support, preventing label tape damage while maintaining structural simplicity.
Solution Approach 2:
Different parts of the gripper system apply different clamping characteristics - the inner jaws provide concentrated clamping force on the core for secure holding, while the outer jaws provide distributed support on the outer circumference. This local differentiation of clamping quality ensures reliable label roll holding and protects the label tape from damage.
5Device complexity
If manual reloading is performed, then no complex automated gripping system is needed, but ergonomically problematic steps must be performed by the operator and process efficiency is reduced
Solution Approach 1:
The gripping system is designed to perform self-service functions including automatic positioning, centering, and clamping of label rolls. The integrated sensors and actuators enable the system to autonomously complete the reloading process without operator intervention, eliminating ergonomic issues and significantly improving reload efficiency and overall productivity.
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 system provides a safe and efficient method for handling label rolls of varying sizes and conditions, enhancing process reliability and reducing cycle time by preventing telescoping and damage, while enabling automated handling and changeovers.
Implementation Method 1
at least one distance sensor (e.g., ultrasonic sensor, reflective optical sensor, laser sensor, or capacitive sensor) arranged for detecting a distance between the gripping system and the label roll
Data Source
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AI summary
The invention relates, inter alia, to a gripping system (24) for gripping a label roll (12) with an annular core. The gripping system (24) has an internal gripper (26) which has several internal clamping jaws (28) that are arranged circumferentially around a central axis (M) of the gripping system (24) and are movable radially with respect to the central axis (M) for gripping the label roll (12) on an inner circumferential surface of the annular core. The gripping system (24) further has at least one distance sensor (34) which is arranged to detect a distance between the gripping system (24) and the label roll (12).