Web Feeding Alignment for Accurate Label Reel Splicing

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Solution Overview

Problem

Existing labelling machines face challenges in accurately positioning the free end flap of a new web during the splicing operation, leading to potential errors, increased manual intervention, and reduced automation in the splicing process.

Innovation Solution

A web feeding system with a gripper and positioning device that automatically aligns and loads the new web reel, minimizing human error by using magnetic engagement and robotic assistance to achieve precise splicing positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual positioning of the free end flap is used during splicing operation, then the operator can directly handle the web, but positioning accuracy deteriorates leading to errors and increased manual intervention

Engineering Contradiction:

Improvemanual handling of webVSAvoidpositioning accuracy of free end flap

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

A robotic arm acts as an intermediary between the operator and the web reel. The robotic arm grasps the free end flap and positions it with high precision, eliminating direct manual handling while maintaining ease of operation. The robotic system includes sensors and control mechanisms that enable accurate positioning of the web during splicing operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Manual mechanical positioning is replaced with an automated robotic system. The robotic arm uses controlled motion and positioning mechanisms to place the free end flap at the correct location, replacing the operator's manual dexterity with automated precision control through sensors and programmable movement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If automated positioning system with robotic arm is used, then positioning accuracy improves, but device complexity increases

Engineering Contradiction:

Improvepositioning accuracy of free end flapVSAvoidcomplexity of splicing system

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The robotic arm is designed to perform multiple functions: grasping the free end flap, positioning it accurately, and releasing it at the correct location. This multi-functional design reduces the need for separate specialized components, thereby managing system complexity while maintaining high positioning accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The robotic positioning system is equipped with sensors and control mechanisms that enable it to autonomously locate and position the free end flap without requiring complex external guidance systems. The system self-regulates its positioning through feedback from sensors, reducing the overall complexity of the control architecture.

Inventive Principle:

Principle #25Self-service

3Loss of substance

If precise splicing positioning is achieved through automated system, then labelling material waste is reduced, but production time increases due to automation setup

Engineering Contradiction:

Improvelabelling material wasteVSAvoidsplicing preparation time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The robotic arm is pre-programmed with the correct positioning parameters and splicing procedures. Before the actual splicing operation, the system performs preliminary positioning actions to ensure the free end flap is correctly placed, which prevents material waste during the actual splicing process and reduces the need for corrective actions.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Sensors in the robotic system provide real-time feedback on the position of the free end flap and the alignment with the splicing point. This feedback mechanism allows the system to make real-time adjustments to achieve precise positioning, minimizing material waste while optimizing the time required for splicing preparation.

Inventive Principle:

Principle #23Feedback

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

Enhances the accuracy and automation of the splicing process, reducing errors, saving labelling material, avoiding machine stops, and decreasing production time and costs.

Implementation Method 1

using magnetic engagement and robotic assistance to achieve precise splicing positioning

Methodology Applied

Scientific EffectMagnetic engagement: Magnetism

Data Source

PatentUS20250353636A1Web feeding system for a labelling module for preparing the splicing operation

Publication Date: 2025.11.20 SIDEL PARTICIPATIONS SAS

AI summary

Described is a web feeding system for feeding a web of labelling material to a labelling module that includes a splicing device. The feeding system includes a positioning device for automatically positioning the web leading portion of the web in a splicing position with respect to the splicing device.