Rewind Reel Label Applicator Motor Control

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Solution Overview

Problem

Existing label applicators face issues with drive rollers sticking to labels, adhesive accumulation, motor cost inefficiencies, and speed control inaccuracies, leading to misfeeding, waste, and deformation of labels.

Innovation Solution

A label applicator design using a rotary encoder and motor on the rewind reel to maintain constant linear speed, eliminating drive and nip rollers, and employing a controller to manage speed and tension through label feed, positioning, and idle modes, with Hall-effect sensors for precise speed control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If drive rollers and nip rollers are used to move the carrier strip, then the web can be transported through the applicator, but the rollers tend to stick to labels and accumulate adhesive, causing misfeeding and requiring large motors to maintain constant speed

Engineering Contradiction:

Improveweb transport reliabilityVSAvoidroller system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the drive roller and nip roller from the system entirely. Instead of using rollers to transport the carrier strip, the invention uses a rewind reel driven by a motor that directly pulls the web through the applicator. This extraction of the problematic roller components eliminates adhesive accumulation and sticking issues while simplifying the overall device structure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical roller-based web transport system with a motor-driven rewind reel system. The motor directly drives the rewind reel, which then pulls the carrier strip through the applicator, eliminating the need for separate drive and nip rollers. This substitution of mechanical systems resolves the issues of adhesive accumulation and maintains reliable web transport.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If larger motors are used to maintain constant web speed, then speed control accuracy improves, but cost increases significantly

Engineering Contradiction:

Improvespeed control accuracyVSAvoidmotor size and cost

Core Design Contradiction:

Measurement precisionVSPower

Solution Approach 1:

The patent incorporates a rotary encoder that provides feedback on the position and speed of the rewind reel. This feedback mechanism allows the motor to adjust its operation to maintain constant web speed through closed-loop control. The encoder enables precise speed control without requiring an oversized motor, as the system can compensate for speed variations through active feedback control.

Inventive Principle:

Principle #23Feedback

3Loss of time

If the leading labels are not removed before reloading, then reloading time is reduced, but the labels adhere to the drive roller and create waste

Engineering Contradiction:

Improvereloading timeVSAvoidlabel waste

Core Design Contradiction:

Loss of timeVSLoss of substance

Solution Approach 1:

By removing the drive roller from the system, the patent eliminates the surface that causes labels to adhere during reloading. The carrier strip is pulled through the applicator by the rewind reel mechanism rather than being pushed by a drive roller, so labels do not stick to a roller surface during the reloading process. This allows operators to reload without removing leading labels, reducing both time and waste.

Inventive Principle:

Principle #2Taking out (Extraction)

4Productivity

If drive and nip rollers are used, then web transport is achieved, but the rollers wear out and the carrier strip may slip, causing misfeeding

Engineering Contradiction:

Improvelabel application rateVSAvoidweb transport stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces the roller-based web transport system with a motor-driven rewind reel system. The motor directly drives the rewind reel, which pulls the carrier strip through the applicator without relying on separate drive and nip rollers. This substitution eliminates roller wear and slipping issues, maintaining stable web transport and preventing misfeeding while preserving high label application rates.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 simplifies web path re-threading, reduces component count and waste, maintains label accuracy, and ensures constant speed without large motors, addressing the drawbacks of existing systems.

Implementation Method 1

A rotary encoder is configured for monitoring and helping to control the linear speed of the carrier strip through the applicator

Methodology Applied

Scientific EffectRotary encoder:

Implementation Method 2

Hall-effect sensors for precise speed control

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS9090370B2Rewind-reel driven label applicator

Publication Date: 2015.07.28 ILLINOIS TOOL WORKS INC

AI summary

A label applicator for separating labels from a continuous carrier strip and applying the labels to an object positioned at the applicator includes a baseplate, a supply reel, a rewind reel, a motor and a rotary encoder. The supply reel is operably mounted to the baseplate and configured for supporting the carrier strip having labels thereon. The rewind reel is also operably mounted to the baseplate and rewinds the carrier strip after label disbursement. The motor is operably connected to the rewind reel and configured for moving or advancing the carrier strip through the applicator, while the rotary encoder controls a linear speed of the carrier strip through the applicator.