Labeling Device with Variable Speed Transfer for Crease-Free Application
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Solution Overview
Problem
Conventional labeling devices struggle to apply labels accurately and without creases to continuously moving material webs at high speeds, especially when large distances between labels are required, as they reach their limits in performance due to the need for large label supply rolls and frequent device replacements.
Innovation Solution
A labeling device with a transfer device that moves labels from a dispenser to a material web using holding means with variable circulating speed, allowing for precise application of elongated labels with their longitudinal axis transverse to the transport direction, featuring a rotating cylinder or driven endless belt with adjustable vacuum suction cups, enabling acceleration to match the web speed and maintaining label alignment without wrinkling or tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a continuously running label dispenser is used to maintain the same label speed as the material web, then label application accuracy is improved, but the distance between labels on the material web is limited to small values
Solution Approach 1:
The label dispenser operates cyclically with variable speed rather than continuously at constant speed. The drive mechanism accelerates and decelerates the label carrier tape dynamically, allowing labels to be dispensed at different speeds at different times during the cycle. This enables both small label spacing on the carrier tape and large spacing on the material web simultaneously.
Solution Approach 2:
The label dispenser uses periodic cyclic operation instead of continuous operation. The drive mechanism completes repeated cycles of acceleration and deceleration, with each cycle dispensing a fixed number of labels onto the carrier tape and then transferring them to the material web. This periodic action allows time for label accumulation on the tape while maintaining synchronization with the material web speed.
2Productivity
If a discontinuously operated label dispenser is used to achieve high material web speeds, then productivity is improved, but label application accuracy deteriorates due to acceleration limitations
Solution Approach 1:
The label dispenser employs dynamic speed variation with controlled acceleration and deceleration phases. The drive mechanism can rapidly change speed while maintaining precise control, allowing the system to operate at high speeds for productivity while ensuring smooth label transfer to the material web without creases or misalignment.
Solution Approach 2:
The system uses feedback control to monitor and adjust the label dispenser speed in real-time. Sensors detect the position of labels on the carrier tape and the speed of the material web, and the control system adjusts the dispenser acceleration and deceleration to maintain precise synchronization, ensuring accurate label application even at high production speeds.
3Length of moving object
If large distances between labels on the carrier tape are used to achieve large distances on the material web, then label spacing is improved, but the diameter of label supply rolls and carrier tape consumption increase significantly
Solution Approach 1:
The system dynamically varies the effective label spacing on the carrier tape through speed control. During the accumulation phase, labels are dispensed at high speed creating small spacing on the tape. During the transfer phase, the carrier tape slows down while the material web continues moving, effectively stretching the label spacing on the final product without requiring large physical spacing on the carrier tape itself.
Solution Approach 2:
The invention changes the speed parameter of the label carrier tape dynamically during operation. By varying the tape speed from high (during label accumulation) to low (during label transfer), the system achieves large effective label spacing on the material web while maintaining small actual label spacing on the carrier tape, thereby reducing carrier tape consumption and supply roll diameter requirements.
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
Enables precise and crease-free application of labels at high speeds with significantly larger distances between applied labels than stored on the carrier tape, improving operational efficiency and reducing the need for frequent device replacements or large supply rolls.
Implementation Method 1
rotating cylinder with an axis of rotation transverse to the direction of transport, the holding means being arranged on the lateral surface of the cylinder
Data Source
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AI summary
A labeling device for applying labels onto a material web, which is moved in a transport direction at a web speed, comprises a label dispenser and a transferring device, which takes over the labels from the label dispenser by means of holding means, moves the labels towards the material web and applies the labels onto the material web at a transfer location. The holding means of the transferring device can be moved in the transport direction and opposite the transport direction in a circulating path at a variable circulating speed, said holding means moving in the transport direction at the web speed when the holding means are located at the transfer location.