Labelling Machine Dual Reel Splicing Mechanism
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Solution Overview
Problem
Existing labelling machines experience a significant decrease in productivity when switching between different types or formats of labels, as they are not efficiently equipped to handle the transition between webs with distinct label types or formats.
Innovation Solution
A labelling machine with two rotatable reels, a splicing mechanism, and a control unit that allows for seamless switching between webs with different label types or formats by splicing and extracting labels, ensuring continuous operation and efficient application of various label dimensions and patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the labelling machine uses a single web of labels, then the structure is simple, but the machine cannot switch between different types or formats of labels
Solution Approach 1:
The system divides the label supply into multiple independent webs (first web from first reel, second web from second reel), each capable of being processed separately. This segmentation allows the machine to handle different label types simultaneously and switch between them by selecting which web to use, resolving the contradiction between versatility and structural simplicity.
Solution Approach 2:
The labelling machine is designed with universal components that can handle multiple web types. The splicing mechanism, cutting means, and application station are configured to work with both the first web and second web, enabling the same apparatus to process different label types without requiring complete reconfiguration, thus maintaining structural simplicity while achieving versatility.
2Adaptability or versatility
If the labelling machine switches between first and second webs of different types or formats, then versatility is improved, but productivity drastically decreases
Solution Approach 1:
The system prepares both the first web and second web in advance by positioning them on their respective reels and pre-configuring the splicing mechanism. The cutting means are positioned to make boundary line cuts at appropriate moments, and the splicing mechanism is ready to connect webs before the switching point is reached. This preliminary preparation eliminates delays during actual web switching, maintaining high productivity while enabling versatility.
Solution Approach 2:
The labelling machine maintains continuous operation by ensuring that while one web is being used, the other web is being prepared for immediate succession. The splicing mechanism operates continuously to join web segments without interruption, and the cutting means continuously prepare boundary line cuts. This continuous action ensures that the transition between different label types does not interrupt the labelling process, preserving productivity while achieving versatility.
3Manufacturing precision
If the cutting means are selectively activated at boundary lines, then precision in label separation is improved, but the complexity of control increases
Solution Approach 1:
The control system uses feedback from the web advancement position and label pattern recognition to determine when boundary lines are reached. The cutting means are selectively activated based on this feedback, ensuring precise cutting at the correct location. This feedback mechanism automates the control process, reducing the perceived complexity while maintaining high precision in label separation.
Solution Approach 2:
The selective activation of cutting means is achieved by replacing complex mechanical control mechanisms with electronic or optical detection systems. The control system uses sensors or vision systems to identify boundary lines and automatically triggers the cutting means, substituting mechanical complexity with simpler electronic control while achieving precise label separation.
Data Source
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AI summary
There is described a labelling machine (1) for applying different types or formats of labels (2) onto items (3); the machine (1) comprises: a first reel (4) and a second reel (5), which are wound by respective first, second webs (6, 7), different from each other and each consisting of a single respective type or format of repeated labels (2); an application station (8), at which the labels (2) are applied onto respective items (3); cutting means (9), which are selectively activated to cut the first web (6) and/or the second web (7) at a boundary line (10) between two successive labels (2); a conveyor (11), configured to receive, at its own receiving surface (12), the cut labels (2) from at least one of reels (4, 5) and to advance the labels (2) on the receiving surface (12) towards the application station (8); and splicing means (19) for splicing the first web (6) to the second web (7), which are formed of different types or formats of labels (2), so as to form a splicing section (30); the machine (1) further comprises extracting means (21), which are positioned adjacent to conveyor (11) and adapted to extract labels (2) from receiving surface (12); and a control unit (20), configured to activate extracting means (21) to extract at least the labels (2) of the first web (6) and splicing section (30) after splicing means (19) have spliced the first and second web (6, 7). (Figure 1)