Labelling Machine Web Acceleration for Precise Label Positioning
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Solution Overview
Problem
Existing labelling machines face challenges in accurately controlling the advancement and positioning of label webs, particularly in print and apply labelling machines where printing is done while the label moves relative to the printhead, leading to difficulties in ensuring correct information reproduction and label placement.
Innovation Solution
A labelling machine with a controller that provides control signals to a motive apparatus to accelerate and decelerate the label web through intermediate speeds, using an encoder to monitor and adjust the web's position and speed, ensuring precise placement and reducing oscillations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the label web is accelerated directly from a first speed to a second speed without intermediate speeds, then the acceleration process is simpler and faster, but speed oscillations occur leading to inaccurate label positioning and poor print quality
Solution Approach 1:
The acceleration process is segmented into multiple stages with intermediate speeds. The controller commands the motive apparatus to accelerate through a series of predetermined intermediate speeds between the first and second speeds, breaking down the single acceleration step into multiple controlled transitions. This segmentation reduces speed oscillations and improves label positioning accuracy while maintaining manageable control complexity.
2Manufacturing precision
If the label web tension is increased to prevent oscillations during acceleration, then positioning accuracy improves, but the web may become damaged or the printing quality deteriorates due to excessive tension
Solution Approach 1:
The system dynamically adjusts the acceleration profile by commanding the motive apparatus to pass through multiple intermediate speeds rather than applying a single high acceleration. This dynamic approach allows the web tension to vary smoothly throughout the acceleration process, preventing both oscillations and excessive tension that could damage the web or degrade printing quality.
3Productivity
If the acceleration time is reduced to increase productivity, then more labels can be applied per hour, but positioning accuracy decreases due to insufficient time for stable speed transition
Solution Approach 1:
The acceleration process maintains continuous useful action by smoothly transitioning through intermediate speeds without interruption. The controller continuously commands the motive apparatus to progress through the predetermined intermediate speeds, ensuring both rapid acceleration for productivity and stable speed transitions for positioning accuracy.
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
A labelling machine comprises a supply spool support for supporting a spool of label carrying web, a take up spool support adapted to take up a portion of web, and a first motive apparatus for transporting web along a web path between the supply spool support to the take up spool support, and a controller. The controller is configured to provide a control signal to the first motive apparatus, wherein the controller is further configured such that the controller provides a control signal to the first motive apparatus to accelerate the first motive apparatus between a first speed and a second speed by providing a control signal to the first motive apparatus to command the first motive apparatus to accelerate to a predetermined first intermediate speed intermediate the first and second speeds, then a control signal to command the first motive apparatus to accelerate to a second predetermined intermediate speed intermediate the first intermediate speed and the second speed, and then a control signal to command the first motive apparatus to accelerate to the second speed.