Labelling Machine Print Ribbon Acceleration Control
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Solution Overview
Problem
Existing labelling machines face inefficiencies in accelerating the print ribbon to match the speed of the label web, leading to reduced throughput and difficulty in accurately positioning labels, particularly in print and apply labelling machines where printing is done while the label moves relative to the printhead.
Innovation Solution
A labelling machine with a controller that receives sensor signals from an encoder indicating the label web's movement rate and adjusts the pulsed control signals to the print ribbon's motive apparatus, allowing for immediate re-timing of pulses to accelerate the print ribbon more quickly and match the label web's speed, thereby enhancing throughput and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the print ribbon is advanced at a controlled rate using conventional pulse timing, then the positioning accuracy is maintained, but the acceleration rate is slower than desired
Solution Approach 1:
The control system dynamically adjusts the pulse timing intervals to the second motive apparatus based on real-time encoder feedback. When the label web speed changes, the controller retimes the pulses to achieve faster acceleration while maintaining positioning accuracy through continuous feedback adjustment.
Solution Approach 2:
The encoder provides continuous feedback on the label web's rate of movement, which the controller uses to dynamically retim e the control pulses to the second motive apparatus. This feedback loop enables the system to accelerate the print ribbon faster while maintaining accurate positioning by adjusting pulse intervals in real-time based on actual motion conditions.
2Productivity
If the print ribbon accelerates slower to match label web speed, then the system is simpler to control, but the throughput of the labelling machine is reduced
Solution Approach 1:
The encoder feedback system provides real-time information on label web speed, enabling the controller to dynamically adjust pulse timing to the second motive apparatus. This feedback mechanism allows faster print ribbon acceleration and improved throughput while keeping the control approach relatively simple through automatic retiming based on encoder signals.
Solution Approach 2:
The controller is pre-configured with the capability to retim e pulses when encoder feedback indicates a mismatch between print ribbon speed and label web speed. This preliminary preparation of the control system enables rapid response to speed changes, improving throughput without requiring complex real-time control algorithms.
3Productivity
If the print ribbon speed is quickly adjusted to match label web speed, then the throughput increases, but the positioning accuracy may be compromised
Solution Approach 1:
The encoder continuously monitors label web speed and provides feedback to the controller, which adjusts the pulse timing to the second motive apparatus in real-time. This feedback ensures that even during rapid acceleration to improve throughput, the print positioning accuracy is maintained through continuous speed matching and dynamic pulse retiming.
Solution Approach 2:
The control system dynamically retimes pulses based on real-time encoder feedback, allowing the print ribbon to accelerate quickly for improved throughput while maintaining positioning accuracy through continuous adaptive adjustment of pulse intervals rather than fixed timing.
Data Source
Figure 1
Figure 1A
Figure 2a~2b
AI summary
A labelling machine comprises a first motive apparatus configured to advance a label web along a label web path; an encoder arranged to output a sensor signal which is indicative of a rate of movement of said label web along said label web path; and a printer configured to print on said label web, the printer including a second motive apparatus configured to advance a print ribbon along a ribbon path. The labelling machine further comprises a controller configured to receive said sensor signal and control the second motive apparatus based on the sensor signal. The controller is configured to supply a pulsed control signal to the second motive apparatus, the intervals between pulses of the pulsed control signal being a function of a desired rate of movement of the print ribbon along the ribbon path. The controller is configured such that if the controller is controlling the second motive apparatus to advance the print ribbon at a first rate of movement having a first series of intervals between pulses, and the controller receives said sensor signal being indicative of the label web moving along label web path at a second rate of movement greater than the first, then the controller supplies a re-timed pulse to the second motive apparatus at a time which is before a next pulse defined by the first series of intervals.