This disclosure is related to a label application device, system and method that includes a media feed control solution for ensuring proper detachment of a label from its release liner so that the label may be placed onto its intended object.
Most label applicators rely on the column strength of a label substrate to overcome the bond strength of its pressure sensitive adhesive to a release liner, as the liner is pulled around a sharp bend (e.g., peeling plate). As the label travels with the liner, the bond is broken first, as the leading edge of the label reaches the location of the sharp bend. The column strength of the label substrate pushes the edge of the label straight, and the adhesive (which is bonded to the label substrate) is unable to maintain its bond to the liner.
However, the bond strength between the adhesive and the liner may vary, and there are instances where the label fails to peel off its liner with just a single pass over the sharp bend. Such “failure-to-peel” situations result in the label failing to attach onto its intended object, as the label remains on the liner and travels around and past the peeling plate. The conditions resulting in the failure-to-peel situation tend to increase in frequency as the label-substrate media ages due to the adhesive bond between the adhesive and the liner increases with age. The failure-to-peel situation may also tend to increase in frequency at slightly elevated temperatures, where the column strength of the substrate decrease.
This disclosure relates to a wire guide assembly for a label applicator that provides for the accurate labeling of objects by including a media feed control solution for properly breaking the adhesive bond of a label to its liner so that the label may be placed onto its intended object.
According to some embodiments, a label applicator is disclosed, wherein the label applicator comprises a label detection sensor, a memory configured to store machine-readable instructions, and a processor in communication with the memory. The processor is configured to execute the machine-readable instructions to control a media feeding mechanism to advance a media in a first direction, wherein the media includes a label adhered to a liner, receive a label signal from the label detection sensor, control the media feeding mechanism to retract the media in a second direction based on the label signal, wherein the second direction is a reverse direction from the first direction, and control the media feeding mechanism to advance the media in the first direction.
To understand the present disclosure, it will now be described by way of example, with reference to the accompanying drawings in which:
While the described features are provided for embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the features and is not intended to limit the broad aspect of the features to the embodiments illustrated.
As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the inventive features that may be embodied in various and alternative forms that include additional, or fewer, components and/or steps. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
The disclosed label applicator solves or improves upon one or more disadvantages with presently known label applicators. The present label applicator implements a media feed control solution that provides for the accurate labeling of objects when using a label media that includes a label adhered to a liner. In particular, the media feed control solution accounts for the unwanted situations where the label fails to break its adhesive bond to its liner and therefore fails to be attached to its intended object.
Referring generally to the figures, automated apparatuses for applying printed labels to wires, cables or other elongated objects of varying diameters are illustrated. The disclosure references an exemplary elongated object label application, where labels are wrapped around the objects without spinning the objects about their elongated longitudinal axes. The apparatuses are particularly useful for label types that require the label be wrapped around an object using more than one revolution. Self-laminating labels are one such type, requiring a transparent end of the label to be wrapped over top of a printed region to provide protection to the printed content. Once such example of a label applicator is disclosed in U.S. patent application Ser. No. 16/279,298, which is incorporated by reference here in its entirety. Another example of a label applicator is disclosed in U.S. patent application Ser. No. 17/121,957, which is incorporated by reference here in its entirety. Another example of a label applicator is disclosed in U.S. patent application Ser. No. 16/507,708, which is incorporated by reference here in its entirety.
While the present description is provided by referencing the label applicator system shown in
Turning to the drawings,
The label spool 110 is rotated, either in a forward feeding direction 10 or a reverse feed direction 20, via a motor that is controlled according to the media feed control solution described herein. Under a normal feeding operation, the label media 130 is fed out from the label spool 110 in the forward feed direction 10 and routed using a number of guide rollers 120 to a label application location (Area A). The label media 130 approaches the application location (Area A) along the media feed path, where the label 132 is intended to detach from the liner 131 and applied to its intended object at a detachment point within the application location (Area A). The detachment point may be at, or near, an edge of peeling plate 150, as shown in
The label detection sensor 160 is positioned at a sensor location that is downstream the media feed path, where the field of view 161 of the label detection sensor 160 is able to detect the presence of the label 132 when it has successfully detached from the liner 131, as shown, for example, in
In
Then in
Then in
Alternatively (not shown), the label detection sensor 160 may be positioned at a sensor location that is downstream the liner return path to detect when the label 132 has remained on the liner 131 past the detachment point.
The label detection sensor 160 may be an image sensor configured to capture an image within its field of view 161. Alternatively, the label detection sensor 160 may be a motion detection sensor configured to detect when the label 132 comes into its field of view 161, a break-beam sensor arrangement having two parts (e.g., one for emitting light and one for receiving the light) that detects when the label 132 breaks a plane of the light beam, as shown, for example, in
In the embodiments illustrated by
Further, according to the embodiments illustrated by
As shown in
Upon determining that the first label 132a has failed to detach from the liner 131, the label applicator 100 implements its media feed control solution by reversing the feeding direction of the label media 130 to re-run the first label 132a over the edge of the peeling plate 150.
After ceasing movement of the label media 130 in the reverse feed direction 20, the label applicator 100 reverts to moving the label media 130 in the forward feed direction 10. When successful, this jogging sequence will have the front of the first label 132a move over the edge of the peeling plate 150 a subsequent time and create enough breaking force to break the adhesive bond between the first label 132a and the liner 131 so that the first label 132a peels off the liner 131, as shown in
At 801, the label applicator 100 beings to feed the label media in the forward feed direction 10.
While the label media is being fed in the forward feed direction, at 802 a label is detected to be in a home position (e.g., label to be peeled), according to an embodiment described herein.
At 803, the label media is moved forward in the forward feed direction 10 for a first predetermined distance, where the first predetermined distance is selected to ensure the front portion of the label to be peeled passes over the edge 151 of the peeling plate 150 as it moves in the forward feed direction 10. Alternatively, the label media may be moved forward in the forward feed direction 10 for a first predetermined amount of time, where the first predetermined amount of time is selected to ensure the front portion of the label to be peeled passes over the edge 151 of the peeling plate 150 as it moves in the forward feed direction 10.
At 804, the label media is moved backward in the reverse feed direction 20 fora second predetermined distance, where the second predetermined distance is selected to ensure the front portion of the label to be peeled passes back behind the edge 151 of the peeling plate 150 as it moves in the reverse feed direction 20. Alternatively, the label media may be moved backward in the reverse feed direction 20 for a second predetermined amount of time, where the second predetermined amount of time is selected to ensure the front portion of the label to be peeled passes back behind the edge 151 of the peeling plate 150 as it moves in the reverse feed direction 20.
At 805, the label media 130 is moved forward in the forward feed direction 10 to address the next label to be peeled.
The remedial jogging process described by the flow chart 800 is applied quickly to each label 132 on the label media 130 to increase the probability that each label 132 will successfully peel of its liner 131 to be applied to its intended object. In other words, the media feed control solution described by the flow chart 800 does not inspect whether each label 132 has detached from its liner 131, but instead applies the remedial jogging steps to each label 132 on the label media 130. This solution may be more efficient and save resources, while still achieving the goal of increasing the probability that each label 132 will successfully peel of its liner to be applied to its intended object. Furthermore, the media feed control solution described by flow chart 800 is implemented to have a predictable execution time, which may be desired for some applications where sequential timing is needed for completion (e.g. having a known execution time for wrapping a label on sequential cable objects).
At 901, the label applicator beings to feed the label media in the forward feed direction 10.
While the label media is being fed in the forward feed direction, at 902 a label is detected to be in a home position (e.g., label to be peeled), according to an embodiment described herein.
At 903, the label media is moved forward in the forward feed direction 10 for a first predetermined distance, where the first predetermined distance is selected to ensure the front portion of the label to be peeled passes over the edge 151 of the peeling plate 150 as it moves in the forward feed direction 10. Alternatively, the label media may be moved forward in the forward feed direction 10 for a first predetermined amount of time, where the first predetermined amount of time is selected to ensure the front portion of the label to be peeled passes over the edge 151 of the peeling plate 150 as it moves in the forward feed direction 10.
At 904, the label applicator 100 determines whether the label detection sensor 160 has detected the label to be peeled at its position along the media feed path. If the label to be peeled is determined to have been detected by the label detection sensor 160, then at 906 the media feed control solution determines the label to be peeled has successfully peeled and the label media 130 continues to be fed in the forward feed direction 10 to address peeling of the next label 132.
However, if the label to be peeled is determined not to have been detected by label detection sensor 160, then at 905 a retry count is iterated higher by the label applicator 100, and then at 907 the label applicator 100 determines whether a maximum retry count has been exceeded.
If the maximum retry count has not been exceeded, then at 908 the label media is moved backward in the reverse feed direction 20 for a second predetermined distance, where the second predetermined distance is selected to ensure the front portion of the label to be peeled passes back behind the edge 151 of the peeling plate 150 as it moves in the reverse feed direction 20. Alternatively, the label media may be moved backward in the reverse feed direction 20 for a second predetermined amount of time, where the second predetermined amount of time is selected to ensure the front portion of the label to be peeled passes back behind the edge 151 of the peeling plate 150 as it moves in the reverse feed direction 20. Then following the reverse jogging process at 908, the label applicator 100 reverts to moving the label media 130 back in the forward feed direction 10 to re-run the label to peeled over the peeling plate 150.
The remedial jogging back and forth of the front portion of the label to be peeled over the edge of the peeling plate 150 continues until the label to be peeled is detected by the label detection sensor 160, thus indicating successful peeling of the label off its liner 131, or until the maximum retry count is exceed.
The remedial jogging process described by the flow chart 900 is applied when the label to be peeled is determined to have failed peeling of its liner 131, thus providing a more targeted media feed control solution than the one described in flow chart 800, although the execution time may be variable compared to the predictable execution time of the media feed control solution described in flow chart 800. Even so, both embodiments of the media feed control solution result in the increased probability that each label 132 will successfully peel of its liner 131 to be applied to its intended object.
The computing device system 1000 includes a processor 1010, a main memory 1020, a static memory 1030, an output device 1050 (e.g., a display or speaker), an input device 1060, and a storage device 1070, communicating via a bus 1001. The bus 1001 may represent one or more busses, e.g., USB, PCI, ISA (Industry Standard Architecture), X-Bus, EISA (Extended Industry Standard Architecture), or any other appropriate bus and/or bridge (also called a bus controller).
The processor 1010 represents a central processing unit of any type of architecture, such as a CISCO (Complex Instruction Set Computing), RISC (Reduced Instruction Set Computing), VLIW (Very Long Instruction Word), or a hybrid architecture, although any appropriate processor may be used. The processor 1010 may further be a microprocessor. The processor 1010 executes instructions 1021, 1031, 1072 stored on one or more of the main memory 1020, static memory 1030, or storage device 1070, respectively. The processor 1010 may also include portions of the computing device system 1000 that control the operation of the entire computing device system 1000. The processor 1010 may also represent a controller that organizes data and program storage in memory and transfers data and other information between the various parts of the computing device system 1000.
The processor 1010 is configured to receive input data and/or user commands through input device 1060 or received from a network 1002 through a network interface 1040. Input device 1060 may be a keyboard, mouse or other pointing device, trackball, scroll, button, touchpad, touch screen, keypad, microphone, speech recognition device, video recognition device, accelerometer, gyroscope, global positioning system (GPS) transceiver, or any other appropriate mechanism for the user to input data to computing device system 1000 and control operation of computing device system 1000 such as user input buttons on the label applicator 100.
The processor 1010 may also communicate with other computer systems via the network 1002 to receive control commands or instructions 1021, 1031, 1072, where processor 1010 may control the storage of such control commands or instructions 1021, 1031, 1072 into any one or more of the main memory 1020 (e.g., random access memory (RAM)), static memory 1030 (e.g., read only memory (ROM)), or the storage device 1070. The processor 1010 may then read and execute the instructions 1021, 1031, 1072 from any one or more of the main memory 1020, static memory 1030, or storage device 1070. The instructions 1021, 1031, 1072 may also be stored onto any one or more of the main memory 1020, static memory 1030, or storage device 1070 through other sources. The instructions 1021, 1031, 1072 may correspond to, for example, instructions for implementing the media feed control solution described herein.
Although the computing device system 1000 is represented in
The storage device 1070 represents one or more mechanisms for storing data. For example, the storage device 1070 may include a computer readable medium 1071 such as read-only memory (ROM), RAM, non-volatile storage media, optical storage media, flash memory devices, and/or other machine-readable media. In other embodiments, any appropriate type of storage device may be used. Although only one storage device 1070 is shown, multiple storage devices and multiple types of storage devices may be present. Further, although the computing device system 1000 is drawn to contain the storage device 1070, it may be distributed across other computer systems that are in communication with the computing device system 1000, such as a server in communication with the computing device system 1000. For example, when the computing device system 1000 is representative of a mobile device (e.g., smartphone), the storage device 1070 may be distributed across to include a cloud storage platform.
The storage device 1070 may include a controller (not shown) and a computer readable medium 1071 storing instructions 1072 capable of being executed by the processor 1010 to carry out control for feeding of the label media 130, as described herein. In another embodiment some, or all, the functions are carried out via hardware in lieu of a processor-based system. In some embodiments, the included controller is a web application browser, but in other embodiments the controller may be a database system, a file system, an electronic mail system, a media manager, an image manager, or may include any other functions capable of accessing data items.
The output device 1050 is configured to present information to the user. For example, the output device 1050 may be a display such as a liquid crystal display (LCD), a gas or plasma-based flat-panel display, or a traditional cathode-ray tube (CRT) display or other well-known type of display that may, or may not, also include a touch screen capability. Accordingly, the output device 1050 may function to display a graphical user interface (GUI), operational information, or messages to the user, as described herein. In other embodiments, the output device 1050 may be a speaker configured to output audible information to the user. In still other embodiments, any combination of output devices may be represented by the output device 1050.
Computing device system 1000 also includes the network interface 1040 that allows communication with other computers via the network 1002, where the network 1002 may be any suitable network and may support any appropriate protocol suitable for communication to/from computing device system 1000. In an embodiment, the network 1002 may support wireless communications. In another embodiment, the network 1002 may support hard-wired communications, such as a telephone line or cable. In another embodiment, the network 1002 may support the Ethernet IEEE (Institute of Electrical and Electronics Engineers) 802.3x specification. In another embodiment, the network 402 may be the Internet (e.g., the Internet 1 illustrated in
The network interface 1040 provides the computing device system 1000 with connectivity to the network 1002 through any compatible communications protocol. The network interface 1040 sends and/or receives data from the network 1002 via a wireless or wired transceiver 1041. The transceiver 1041 may be a cellular frequency, radio frequency (RF), infrared (IR), Bluetooth, or any of a number of known wireless or wired transmission systems capable of communicating with the network 1002 or other computer device having some or all of the features of the computing device system 1000. The network interface 1040 as illustrated in
The computing device system 1000 may be implemented using any suitable hardware and/or software, such as a personal computer or other electronic computing device. In addition, the computing device system 1000 may also be a smartphone, portable computer, laptop, tablet or notebook computer, PDA, appliance, IP telephone, server computer device, AV gateway, MQTT broker, or mainframe computer.
While the specific embodiments have been illustrated and described, other modifications may be applied without significantly departing from the spirit of the disclosure, and the scope of protection is only limited by the scope of the accompanying claims.
This application claims benefit to U.S. Provisional Patent Application No. 63/167,327, filed on Mar. 29, 2021, the entirety of which is hereby incorporated by reference herein.
Number | Date | Country | |
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63167327 | Mar 2021 | US |