Labelling Machine Web Speed Control via Multi-Stage Acceleration
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Solution Overview
Problem
Existing labelling machines face challenges in accurately controlling the speed and positioning of label webs, leading to potential overshooting and oscillations, which can result in inaccurate label placement and compromised print quality.
Innovation Solution
A labelling machine with a controller that accelerates the motive apparatus between two speeds via intermediate speeds, and includes a method to decelerate the label web to rest at a desired position, allowing for correction to ensure precise positioning, and accounts for label web lag by advancing a predetermined distance followed by relaxation to achieve accurate placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the motive apparatus accelerates the label web quickly to reach the desired speed, then the productivity is improved, but the speed overshoot and oscillations occur leading to manufacturing precision deterioration
Solution Approach 1:
The acceleration process is segmented into multiple discrete stages with intermediate speed targets. The controller divides the single acceleration phase into several smaller acceleration phases, each with its own target speed and duration, preventing overshoot by breaking down the continuous acceleration into manageable segments.
Solution Approach 2:
The controller performs preliminary actions by pre-calculating and implementing deceleration before the label web reaches the desired position. The system anticipates the need to slow down and begins decelerating in advance, accounting for the web's momentum and preventing overshoot of the target position.
2Productivity
If the motive apparatus uses high acceleration to maintain speed, then the productivity is improved, but the label web tension control deteriorates affecting manufacturing precision
Solution Approach 1:
The system dynamically adjusts the acceleration and deceleration rates based on real-time feedback from encoders and position sensors. The controller continuously modifies the motive apparatus operation to maintain optimal web tension while achieving the desired transport speed, rather than using fixed high acceleration values.
Solution Approach 2:
The controller changes operational parameters including acceleration rate, deceleration rate, and intermediate speed targets based on the specific labelling requirements and web properties. This allows optimization of both productivity and tension control for different labelling scenarios.
3Measurement precision
If the label web is decelerated abruptly to stop at the desired position, then the positioning accuracy is improved, but the web tension spikes causing manufacturing precision deterioration
Solution Approach 1:
The controller performs preliminary deceleration actions before the label web reaches the desired stopping position. By beginning to slow down the web in advance and using multi-stage deceleration with intermediate speed reductions, the system prevents abrupt stopping that would cause tension spikes, while still achieving accurate positioning.
Solution Approach 2:
The system provides beforehand cushioning by implementing gradual deceleration phases that act as a buffer before the final stop. The controller reduces speed through intermediate stages, cushioning the momentum build-up and preventing sudden tension spikes that would occur with abrupt deceleration.
4Manufacturing precision
If the controller implements multi-stage acceleration with intermediate speeds, then the manufacturing precision is improved, but the acceleration time increases reducing productivity
Solution Approach 1:
The controller dynamically adjusts the number and values of intermediate speed targets based on the specific labelling task requirements. For high-precision applications, more intermediate stages are used, while for routine labelling, fewer stages are implemented, optimizing the balance between precision and productivity for each scenario.
Solution Approach 2:
The system dynamically adapts the acceleration profile by adjusting intermediate speed targets and transition durations based on real-time feedback from encoders and position sensors. This allows the controller to optimize the balance between precision and speed, making the acceleration process as efficient as possible while maintaining required accuracy.
Data Source
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.