Tape Feeding Apparatus with Image Detection for Label Alignment
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Solution Overview
Problem
Existing apparatuses for forming labels from continuous tape struggle with centering images accurately, especially when pitch variations or printing errors occur, and lack precision in tape alignment and print quality monitoring.
Innovation Solution
The apparatus employs a system with multiple sensors and a control unit to detect images on the tape, compare them to a reference image, and adjust the tape's advancing speed to ensure precise cutting and alignment, using a combination of conveying rollers and cutting devices with motor control, along with feedback mechanisms for real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a band optical sensor is used to detect images on the advancing tape, then the risk of errors due to transverse movements of the tape is reduced, but the measurement precision deteriorates because the sensor provides only an average value over a preset portion of the surface
Solution Approach 1:
The patent divides the tape surface into multiple detection zones along the advancing direction, with each zone monitored by a corresponding sensor element. This segmentation allows the system to detect both transverse movements (improving reliability) and maintain precision by identifying the specific location of images along the tape length, rather than providing only an average value across the entire tape width.
2Productivity
If the cutting device operates at high speed to increase productivity, then the production output increases, but the manufacturing precision deteriorates due to programmed or not programmed variations in operating parameters during tape advancement
Solution Approach 1:
The patent implements a feedback control system where sensors continuously detect the position of images on the advancing tape, and the control unit adjusts the cutting device's operating parameters in real-time based on detected pitch variations. This allows high-speed operation to maintain precision by compensating for parameter variations dynamically, rather than requiring slow, constant-speed operation.
Solution Approach 2:
The system dynamically adapts the cutting device's operation to match the actual tape advancement characteristics. By making the cutting process dynamic rather than static, the system can operate at high speeds while maintaining precision through real-time adjustments to cutting timing and position based on actual tape movement detection.
3Manufacturing precision
If the tape advancing speed is adjusted frequently to compensate for pitch variations, then the manufacturing precision improves, but the loss of time increases due to continuous speed adjustments
Solution Approach 1:
The system performs preliminary detection of pitch variations and image positions before the cutting operation occurs. By detecting and calculating the necessary speed adjustments in advance, the control unit can smoothly implement corrections without interrupting the production flow, thus maintaining precision while minimizing time loss associated with adjustments.
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 minimizes errors due to tape movement and pitch variations, ensures precise label formation, and effectively monitors print quality and tape alignment, enabling reliable and adaptive operation.
Implementation Method 1
a sensor (9) configured for detecting an image on the advancing tape (3)
Data Source
AI summary
An apparatus (1) and a method for feeding a continuous tape (3) for forming labels (2) is disclosed, according to which a pair of rollers (5) advances the tape at an advancing speed that is calculated on the basis of the rotation speed of one cutting roller (6) that cuts the tape into labels, (2) at a signal that is indicative of the cut that occurred and at a positioning error of an actual image present on the tape with respect to a reference image. The real image is detected by a linear camera (9) or by a matrix camera.