Movable Label Applicator Assembly for Conveyor Packaging
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Solution Overview
Problem
Conventional package labeling systems suffer from reduced throughput due to the need for the label applicator to return to a fixed position after each label application, resulting in excessive movement distance and time, which is inefficient for varying package heights and lengths.
Innovation Solution
A movable label applicator assembly that adjusts its vertical height based on package height differences and controls conveyor speed to minimize the gap between packages, allowing for efficient cyclic motion and reduced stroke distance, combined with a linerless label material system for ergonomic loading and reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the label applicator is positioned at a fixed location above the conveyor, then the labeling position is stable, but the applicator must travel a long distance to return to the home position after labeling, reducing throughput
Solution Approach 1:
The label applicator assembly is made dynamically repositionable along the conveyor using a motorized carriage system. The applicator can move to different positions corresponding to different package locations, eliminating the need to return to a fixed home position after each labeling operation. This dynamic positioning capability allows the applicator to be optimally positioned for each package, thereby increasing throughput while maintaining labeling accuracy.
2Adaptability or versatility
If the applicator stroke distance is increased to accommodate taller packages, then all packages can be labeled, but the time required for each labeling cycle increases significantly
Solution Approach 1:
The system performs preliminary measurement of package height and position using sensors and imaging systems before the labeling operation. Based on these measurements, the applicator pre-positions itself at the optimal location for the specific package height, minimizing the stroke distance required. This preliminary action allows the system to adapt to varying package dimensions without incurring the time penalty of full-stroke movements for each cycle.
Solution Approach 2:
The applicator assembly is designed with dynamic repositioning capability along the conveyor, allowing it to adjust its position based on the actual package dimensions and location. This eliminates the need to accommodate the maximum possible package height through a fixed long-stroke design, instead optimizing the stroke distance for each specific packaging scenario, thereby reducing cycle time.
3Adaptability or versatility
If the label applicator assembly is mounted high above the conveyor to accommodate tallest packages, then all package heights can be reached, but the assembly becomes difficult to load and service
Solution Approach 1:
The label applicator assembly is mounted on a motorized carriage that can dynamically reposition along the conveyor at various heights. This allows the assembly to reach tall packages when needed while maintaining a lower, more accessible position during loading and servicing operations. The dynamic positioning capability decouples the relationship between package height accommodation and operator accessibility, as the system can adapt its vertical position based on operational requirements.
4Productivity
If the conveyor speed is increased to improve throughput, then more packages are labeled per unit time, but the gap control between packages becomes more difficult
Solution Approach 1:
The system incorporates feedback mechanisms including sensors and imaging systems that continuously monitor package position, dimensions, and spacing on the conveyor. This real-time feedback information is used by the control system to dynamically adjust the applicator positioning and conveyor speed to maintain optimal gap control between packages, even at higher throughput speeds. The feedback loop ensures that increased productivity does not compromise labeling precision.
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
This solution significantly increases labeling throughput by minimizing the gap between packages and reducing the need for extensive label applicator movement, while also simplifying the loading process and minimizing downtime due to fewer label changes.
Implementation Method 1
A supply of labeling material is fed or withdrawn into or from a vacuum system during the vertical height adjustment of the label applicator assembly
Data Source
AI summary
The present application relates to a method and system for labeling one or more products such as packages transported along a conveyer, and more specifically to applying a label on a respective package by way of a vertically adjustable assembly positioned above the conveyor. The adjustable assembly includes at least a label printer and an applicator for printing and applying the label on a surface of the package on the conveyor.