Turntable Control Method for Labeling Machines
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Solution Overview
Problem
Existing turntable control systems in labeling machines lack flexibility, leading to inefficient and slow operations due to limited ability to change rotation sequences quickly, resulting in unnecessary movements and increased wear and energy consumption, especially in complex scenarios with varying bottle types or occupancy.
Innovation Solution
A method for controlling turntables that allows for flexible rotary movements by defining multiple nodes and rotation courses, enabling dynamic sequence changes based on predefined criteria such as bottle type or transport speed, with locally stored rotation profiles for rapid access and activation, reducing unnecessary movements and optimizing energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the turntable follows a fixed movement pattern with simple control options, then the control system is simple and reliable, but the system lacks flexibility and cannot adapt quickly to complex situations such as varying bottle types or occupancy
Solution Approach 1:
The control system transitions from a static, fixed movement pattern to a dynamic system where rotation sequences can be changed in real-time. The turntable control now adapts its rotation behavior based on detected conditions (bottle presence, bottle type, labeling module status), allowing the system to optimize its movement pattern dynamically rather than following a predetermined sequence.
Solution Approach 2:
The system incorporates feedback mechanisms that detect the current state (bottle occupancy, bottle type identification) and use this information to adjust the rotation sequence. The control system receives information about the turntable's current state and external conditions, then modifies its rotation behavior accordingly, creating a closed-loop control system that responds to actual operating conditions.
2Productivity
If the system performs unnecessary rotary movements to maintain fixed sequences, then the control logic remains simple, but productivity decreases and energy consumption increases
Solution Approach 1:
The system changes its operational parameters (rotation sequence, rotation speed, or idle state) based on detected conditions. When no labeling is required, the turntable can remain stationary or reduce rotation, rather than maintaining a fixed rotation sequence. This dynamic parameter adjustment eliminates unnecessary movements and reduces energy consumption while maintaining labeling productivity when needed.
Solution Approach 2:
Instead of performing complete rotation sequences in all cases, the system applies partial action by rotating the turntable only when and to the extent necessary for labeling operations. The control system activates rotation selectively based on whether bottles are present and whether labeling modules require service, avoiding excessive rotation movements that would waste energy and reduce overall system efficiency.
3Reliability
If the turntable rotates continuously according to fixed patterns, then the system operates smoothly, but wear on mechanical components increases due to unnecessary movements
Solution Approach 1:
The turntable rotation is changed from continuous operation to periodic action, where rotation occurs only during necessary labeling operations. The system activates rotation in periodic intervals corresponding to actual labeling needs, with idle periods where the turntable remains stationary. This reduces the cumulative wear on mechanical components while maintaining operational smoothness during active labeling cycles.
Data Source
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AI summary
The method involves defining node points (K1, K2, K3a, K3b, K4, K5) that are spatially and/or temporally passed by a rotary disk, where the disk is attached to a transport element e.g. rotary table or conveyor belt. Rotational plots are defined between the node points, where the rotational plots define a rotational movement of the disk using a drive element i.e. servomotor. One of the rotational plots is activated in periodic intervals during passing one of the node points, and is deactivated during passing the other node point. The rotational plots are stored at the drive element. Independent claims are also included for the following: (1) a control program for controlling a rotary disk (2) a machine readable storage medium comprising a control program with instructions to perform a method for controlling a rotary disk.