Abstract:
An apparatus and method for wrapping adhesive backed labels around elongate articles, such as electrical wires including a rotatable puck assembly having an interrupted circumferential surface defining an opening for receiving an elongate object to be labeled and wing members for applying the label during rotation.

Description:
RELATED APPLICATIONS 
   This application claims the benefit of co-pending provisional patent application Ser. No. 60/464,508, filed 22 Apr. 2003. 

   BACKGROUND OF THE INVENTION 
   This invention relates to an automatic bench tool for automatic application of labels to wires, cables, or other elongate articles. 
   In the past, labels have been applied to elongate articles such as wires and cables by way of applicators requiring cumbersome, noisy hydraulic or high-pressure air lines. Further, several problems have burdened the efficiency of such applicators. For example, previous label applicators have required the operator to manually handle the labels during application. This results in skin oil and dirt contamination of labels. Label contamination also may cause flagging and an end product having an unfinished appearance. The present applicator requires no such manual handling and therefore produces a clean, finished product. Additionally manufacturers using prior art applicators typically allocate more than fifteen seconds to manually apply one standard label. The applicator of the present invention can complete the process in less than half the time, thus providing an increase in productivity and reduction in labor costs. 
   It is an object of the present invention to provide a new method and apparatus for wrapping labels around elongate objects and the like. 
   Another object of the present invention is to provide a method and apparatus that quickly and efficiently wraps labels around elongate objects such as wires, cables and the like. 
   Still another object of the present invention is to provide an apparatus that is easy to use. 
   Yet another object of the present invention is to provide an apparatus that may be used with elongate articles of various diameters. 
   Still yet another object of the present invention is to provide and apparatus and method that produces a finished product having minimal flagging or other undesirable characteristics. 
   SUMMARY OF THE INVENTION 
   Briefly, to achieve the desired objects of the instant invention, and in accordance with a preferred embodiment thereof, provided is an apparatus and a method for applying labels around elongate articles such as wire, cable, or the like. Additionally, this invention may be used in conjunction with other tools as for instance an external wire-cutting machine, or a thermal transfer printer for printing labels on demand. 
   In a preferred embodiment of the present invention, the apparatus includes a means for receiving labels, at least one label sensor, at least one guide roller to guide at least one label toward a label stripper assembly, a gripper assembly carried on a gripper arm assembly for grasping an elongate object, means for driving the gripper arm assembly, a puck assembly having an article receiving opening, and means for driving the puck assembly. 
   The preferred labels to be used in accordance with the present invention are preferably continuous sheets of a suitable label material carried on continuous sheets of releasable liner material. The labels may be preprinted and supplied in a spindled roll, or may be printed at need by an optionally attached printing system, thus allowing labels to be easily kitted for each label job. Further, the labels may preferably include datum marks printed on the liner material. 
   A method according to the present invention includes the steps of: 
   1. Providing at least one label having an adhesive backing and liner. 
   2. Introducing the label to a label applicator apparatus. 
   3. Moving the label toward a label stripping assembly. 
   4. Partially removing the liner from the label so as to expose a portion of the label adhesive backing. 
   5. Providing an elongate object to be labeled. 
   6. Moving the elongate object toward the exposed portion of the label adhesive backing. 
   7. Engaging a surface of the elongate object with the exposed portion of the label adhesive backing. 
   8. Providing a puck assembly having a cavity; said cavity including a pair of wing members, said wing members being normally biased towards one another. 
   9. Moving the engaged surface of the elongate article and attached label into the puck cavity and between the normally biased wing members. 
   10. Rotating the puck assembly and wing members around the elongate article and attached label, thereby securing the label entirely around the diameter of the elongate article. 
   11. Removing the elongate article and secured label from the puck cavity. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of one side of the present invention and including a partially broken away portion. 
       FIG. 2  is a side plan view of the side illustrated in  FIG. 1 , and including a partially broken away portion. 
       FIG. 3  is a side plan view of the present invention and showing the side opposite that shown in  FIGS. 1 and 2 , and further illustrating a partially broken away portion. 
       FIG. 4  is a side plan view similar to that of  FIG. 3 , but with the circuit board removed for ease of viewing. 
       FIG. 5  is a front plan view of the present invention. 
       FIG. 6  is an exploded view of the puck assembly and drive belt of the present invention. 
       FIG. 7  is a perspective view of the puck assembly according to the present invention. 
       FIG. 8  is a front plan view of the puck member with affixed puck plate. 
       FIG. 9  is a front plan view of the puck member affixed to the puck guide members and puck mount plate. 
       FIG. 10  is a perspective view of the label peeler assembly and showing a label partially peeled away from the backing and in position to be applied. 
       FIG. 11  is a fragmentary perspective view of the present invention and showing an elongate object in place in the gripper arms and ready to be inserted into the puck member. 
       FIG. 12  is a fragmentary perspective view similar to that of  FIG. 11 , but showing the gripper arms closed around an elongate object and moving toward a presented label. 
       FIG. 13  is a fragmentary perspective view similar to those of  FIGS. 11 and 12 , but showing an elongate article engaging an adhesive surface of a presented label. 
       FIG. 14  is a fragmentary perspective view similar to those of  FIGS. 11-13 , inclusive, but showing the gripper arms pushing the elongate object and engaged label against the puck door and toward the puck cavity. 
       FIG. 15  is a fragmentary perspective view similar to those of  FIGS. 11-14 , inclusive, but showing the gripper arms pushing the elongate object and engaged label into the puck cavity. 
       FIG. 16  is a fragmentary perspective view similar to those of  FIGS. 11-15 , inclusive, but showing the elongate object and engaged label in the puck cavity and the puck rotating thereabout thereby securing the label around an elongate object. 
       FIG. 17  is a fragmentary perspective view similar to those of  FIGS. 11-16 , inclusive, but showing the puck member in finished position with a label wrapped around an elongate object. 
       FIG. 18  is a fragmentary perspective view similar to those of  FIGS. 11-17 , inclusive, but showing the gripper arms moving an elongate object with wrapped label from the puck cavity and past the puck door. 
       FIG. 19  is a fragmentary perspective view similar to those of  FIGS. 11-18 , inclusive, but showing the finished, wrapped elongate object removed from the puck cavity. 
       FIG. 20  is a fragmentary perspective view similar to those of  FIGS. 11-19 , inclusive, but showing the gripper arms in open position to release the finished, wrapped elongate object. 
   

   DETAILED DESCRIPTION 
   Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
   Turning now to the drawings, in which like reference numerals refer to corresponding elements throughout the views, attention is first directed to  FIG. 1  illustrating a perspective view of the apparatus  10  with a portion of the side panel  12  broken away so that the various components of the apparatus  10  may be seen. 
   The label assembly  10  preferably includes two independently operated motors, the first of which will be identified herein as a drive motor  14 , the second of which will be identified as a gripper arm motor  16 . As may be seen particularly in  FIGS. 3 and 4 , the drive motor  14  is preferably arranged to provide power to a continuous chain drive belt  18  under tension supplied by a conventional take up tensioner  19 . The continuous drive belt  18  engages spaced sprockets  20  extending from axially extending spindles  22 . 
   As may be seen in  FIGS. 1-4 , the apparatus  10  preferably includes a label roller assembly  24  for carrying spooled labels  26  of the type to be used with the present invention, and a label take-up roll structure  28 . The label roller assembly  24  being arranged to facilitate label feed from a roll of labels  26  into the apparatus  10  and the take-up roll structure  28  being arranged to receive and wind up backing material  27  once the labels have been removed (see particularly  FIG. 2 ). 
   As seen in the Figures and particularly  FIGS. 6-9 , the present invention further includes a novel puck assembly  30 . The puck assembly  30  is adapted to receive an elongate object  5  for wrapping labels  26  thereon. As seen, the puck assembly  30  preferably includes a c-shaped puck element  32  having an interrupted circumferential surface  34 . The interrupted circumferential surface  34  includes a marginal edge portion  36  preferably having a toothed configuration. Seen particularly in  FIG. 8 , the marginal edge  36  further includes an axially extending marginal support shelf  38 . 
   As may be seen particularly in the exploded view of  FIG. 6 , the puck assembly  30  further includes a c-shaped puck plate  40 . The puck plate  40  is affixed to the puck element  30  on the outer edge  42 , by way of screws  44  or other conventional manner and preferably includes a circumferential surface  46  in rotational contact with a plurality of circumferentially spaced roller bearings  48  located in a puck mount plate  50 . The puck plate  40 , when affixed to the puck element  32  on its outer edge  42  and in conjunction with the axially extending marginal support shelf  38 , provides a circumferential trough  54 . 
   As mentioned earlier and seen particularly in the view of  FIG. 6 , the puck assembly  30  further includes a puck mount plate  50 . The puck mount plate  50  defines a relatively flat planar surface having a first side  51 A, a second side  51 B, and oppositely disposed arm portions  52 . The oppositely disposed arm portions  52  define a generally c-shaped central aperture  53 . The first side  51 A of the puck mount plate further includes a plurality of circular countersunk apertures  56  through apertures  58 , and a coaxial countersunk groove  60 . The countersunk apertures  56  are each preferably arranged to receive a supporting roller bearing  48 . The countersunk groove  60  is preferably coextensive with the marginal edge  62  of the generally c-shaped central aperture  53  and is interrupted to allow a portion of each bearing  48  to extend through a respective interruption  64  for rotational support of the circumferential surface  46  of the puck plate  40 . The through apertures  58  are adapted to receive mounting bolts or screws (not shown) for mounting to a stationary supporting structure  66  (shown in  FIG. 2 ). The countersunk groove  60  is preferably adapted to receive the outer circumferential surface  46  of the puck plate  40 . 
   The puck assembly  30  further includes an upper puck guide member  68  having a radially inwardly extending curb surface  70 , a plurality of countersunk apertures  56  to receive roller bearings  48 , and a plurality of apertures with countersunk areas  57  for receiving mounting bolts or screws  44  which are in turn received by the puck mount plate  50 . The radially inwardly extending curb surface  70  is preferably received in the aforementioned circumferential trough  54 . 
   The puck assembly  30  further includes a lower puck guide member  72 . The lower puck guide member  72 , similarly to the upper puck guide member  68 , includes an arcuate, coaxial, radially extending curb surface  70 , a plurality of apertures with countersunk areas  57  for receiving mounting bolts or screws  44 , and a plurality of countersunk apertures  56  for receiving additional roller bearings  48 . The arcuate, coaxial radially extending curb  70  of the lower puck guide  72  is preferably arranged to be received in the circumferential trough  54  formed by the puck plate  40  and support shelf  38  of puck member  32  (see particularly  FIG. 8 ). 
   As seen in  FIGS. 6 and 7 , the puck mount plate  50  includes at least one aperture  58 A for receiving a drive sprocket  74 . An idler pulley  76  is preferably provided and rotatably coupled to the puck mount plate  50 . The drive sprocket  74  and the idler pulley  76  being spaced and arranged to support a preferably notched drive belt  78 . The notched surface  78 A of the drive belt  78  is adapted to engage the toothed marginal edge  36  of the puck member  32 . The relationship of the components will be hereinafter discussed. 
   As mentioned earlier, the c-shaped puck member  32  includes an interrupted circumferential surface  34 . The interrupted surface  34  defines an opening  80  for receiving an elongate object  5  (see  FIGS. 2-4 , inclusive) to be labeled in accordance with this invention. The opening  80  is preferably provided with a spring-loaded entrance door  82 , which is arranged to provide entrance to the cavity  84  of the c-shaped puck  32  upon inward pressure exerted by the elongate object  5 . A double leaf torsion spring  86  is mounted on an upstanding pin  88  located at the entrance. One leaf  86 A of the spring  86  bears against the inner face  81 A of the door  82  such that the door  82  is normally closed. 
   As seen particularly in the exploded view of  FIG. 6 , the puck member  32  is further provided with a pair of complementary, pivotally mounted, wing members  90 A,  90 B. Each wing member  90 A,  90 B preferably has a general configuration defining two oppositely disposed arm members  92 A,  92 B and defining an obtuse angle  94  therebetween. Arm members  92 A each include an end  96 , which is pivotally mounted at its extremity to the puck member  32  by means of respective pivot pins  89 . Arm members  92 B each preferably include an opposite end  98  extending inwardly of the cavity  84  and having an obverse side  100  in contact with a complementary side  102  of the second one of the pair of wing members  90 A,  90 B. Each of the wing members  90 A,  90 B is preferably normally biased toward one another by means of a respective spring loaded pin  104  bearing on the respective pivoted arm  92 A, the bias of which directs the wings  90 A,  90 B towards one another. In this way, when an elongate object  5  is introduced past the door  82  and into the cavity  84  of the puck member  32 , the inward pressure of the outer surface  145  of the elongate object  5  causes the wings  90 A,  90 B to separate relative to one another and thereby allow the elongate object  5  to be held between the normally contacting wing arms  92 B. While the elongate object  5  is held in this position, the rotational movement of the puck element  32  causes the label  26  to be secured around the elongate object  5 . While the drawings show pivoted wing members  90 A,  90 B including pivot pins  89 , and spring loaded pin  104 , it is to be understood that the present invention may be practiced using wing members  90 A,  90 B having an inherent bias toward one another and being rigidly suspended from the puck member  32  (not shown). 
   Prior to placement into the apparatus  10 , the labels  26  may be conjoined by way of a releasable liner material  27  (as seen particularly in  FIG. 10 ). When the labels  26  are conjoined in this way, they may be spooled on a label roller assembly  24  (see  FIG. 1 ) for facile dispensation into the apparatus  10 . As seen in  FIG. 2 , the spooled labels  26  may be manually threaded through the apparatus  10  prior to commencement of labeling process. The labels  26  and releasable liner material  27  are positioned in the apparatus  10  such that they are guided by rollers  106  past a sensor assembly  108 , a tensioner arm  110 , and a label stripping assembly  112  (all of which will be hereinafter discussed). Thereafter, the liner material  27 , having been stripped of the labels  26  by label stripping assembly  112 , continues past rollers  106  and into a nip  114 . The nip  114  is preferably provided by a drive roller  116  and a cooperating idler roller  118 . The idler roller  118  is mounted at the distal end  119  of a pivoted lever arm  120  that is pivotally supported intermediate its ends  119 ,  119 A and which the free end  119 A is supported by an adjustable, spring biased tensioner  122 . The drive roller  116  is designed to pull the backing material  27  through the apparatus  10  and after labels  26  have been removed, onto a take-up roll  28 , as mentioned earlier. 
   As earlier mentioned, the labels  26  and backing material  27  are pulled through the apparatus  10  and past the sensor assembly  108 . The backing material  27  is preferably overprinted with a band of transparent UV ink, in order to define datum marks  124  (see particularly  FIG. 10 ). The sensor assembly  108 , such as an infrared sensor, is arranged to detect the datum marks  124  between successive labels  26 , SO that the apparatus  10  can determine label  26  presence and spacing as well as incremental movement of the labels through the apparatus  10 , and alternatively, determine where to form prints on successive labels  26 , if supplied with a printer (not shown) for on demand label printing. In order to achieve this, the sensor assembly  108  comprises a light source (not shown), which illuminates the backing material  27  with UV light. UV light is reflected from the backing material  27  onto a UV sensor (not shown) disposed adjacent the light source. The output of the sensor is connected to a control unit via a level detector. In use, a greater amount of UV light is reflected by the backing material  27  when the datum marks  124  pass the sensor. The level detector is arranged to detect the increased output level of the sensor and in this manner an assembly control circuit can control the position of successive labels  26  to correspond with the position of the successive marks  124  as the backing material  27  and attached labels  26  advance through the apparatus  10 . 
   As seen in the Figures, the labels  26  and backing material  27  are moved toward a label removal device, such as a label stripper assembly  112 , by way of the drive roller  116 , mentioned earlier. As is detailed in the view of  FIG. 10 , the label stripper assembly  112  includes a supporting table  126  having an edge  128  over which the labels  26  and attached backing  27 , pass, thereby peeling an edge  130  of a passing label  26  from the backing material  27  and exposing an adhesive surface  132  for initial contact with an elongate object  5  (not seen in this view) prior to entry into the cavity  84  of the puck element  32  (see  FIGS. 12-14 , for example). The label stripping assembly  112  further preferably includes a label sensor  134  arranged to detect the presence of a label  26  in the proximity of the puck member  32 . 
   The apparatus  10  further preferably includes a gripper assembly  136  for alternatively grasping and positioning an elongate article  5  to be labeled. The gripper assembly  136  is preferably independently operated by a gripper motor  16 , as mentioned earlier. As shown in  FIG. 4 , the gripper motor  16  drives an eccentric rotor  138 , which is pivotally attached to one end  139 A of a linkage  140 . The opposite end  139 B of the linkage  140  provides rotative motion to gripper elements  142 , thereby allowing grasping and ungrasping of an object, such as the elongate article  5  shown in these views. As seen, the gripper elements  142  each preferably include a pair of spaced apart, openable jaw members  144 . As may be seen particularly in  FIGS. 11-20 , inclusive, the jaw members  144  are adapted to receive, grasp, and position an elongate object  5  relative the puck member  32 . While the gripper elements  142  are shown as being spaced apart a predetermined distance to one another it is to be understood that the predetermined distance may be varied according to need, or alternatively may be adapted to put longitudinal tension on a grasped elongate object  5 , thereby holding the object  5  taut for the labeling process. 
   The operation of the present assembly  10  will be next described in connection with  FIGS. 11-20 , inclusive. As seen in  FIG. 11 , an elongate object  5  is placed in the spaced apart open jaw members  144  of the gripper assembly  136  prior to movement of the closed jaws  144 . As mentioned earlier, it is to be noted that while the Figures show the pair of jaws  144  spaced apart a predetermined distance, this apparatus  10  may also be adapted to vary the distance between the jaws  144 . 
     FIG. 12  illustrates the jaws  144  closed about an elongate object  5  and moved inwardly in the direction of arrows A. A label  26  with an exposed adhesive portion  132  is presented and ready for contact with the outer surface  145  of an elongate object  5 . Further, spent liner material  27  is illustrated as being moved over the supporting table  126  of label stripping assembly  112  and toward the take-up roll  28  (see  FIG. 2 ) in the direction of arrow B. With reference to  FIG. 2 , it may be seen that the spent liner material  27  moves through the aforementioned nip  114  and onto the take-up roll  28 . 
   As seen in  FIG. 13 , the gripper elements  142 , jaw members  144  and the elongate object  5  further travel in the direction arrows A and toward the outer face  81 B of the door  82  of puck member  32 , as discussed earlier. This movement further engages the exposed adhesive surface  132  of label  26  with the outer surface  145  of the elongate object  5 . 
   As further seen in  FIG. 14 , the elongate object  5  and partially adhered label  26  are further moved in the direction of arrows A and pushed against the outer face  81 B of the door  82 . As seen, this movement partially opens the door  82  into the cavity  84  (not seen in this view) of the puck member  32 . The apparatus  10  is adapted to allow for varying dwell times of the elongate object  5  against the outer face  81 B of the door  82 , thereby allowing greater or lesser adhesive surface portions  132  to be engaged prior to puck rotation.  FIG. 15  depicts the elongate object  5  and partially attached label  26  further moved in the direction of arrow A into the cavity  84  of the puck member  32  and against the biased wing members  90 A,  90 B in readiment for rotational movement of the puck member  32 .  FIG. 16  illustrates the puck member  32  rotating in the direction of arrow C, thereby securing the label  26  around the elongate object  5 . The puck member  32  rotates at a predetermined speed for a predetermined number of revolutions, which depend on the type and size of elongate article  5  and label  26  to be utilized. 
   As seen in  FIG. 17 , and after completion of a predetermined revolution cycle, the puck element  32  returns to a finished position. The label  26  may be seen as fully secured about the elongate object  5  while remaining in the puck cavity  84 .  FIG. 18  illustrates the gripper elements  142 , jaw members  144 , and elongate article  5  with label  26  attached, moving in the direction of arrows D. This movement pushes the elongate object  5  against the inner face  81 A of door  82 , thereby opening the door  82  for removal of the object  5  and attached label  26  from the puck cavity  84 , as seen in  FIG. 19 .  FIG. 20  shows the elongate article  5  with label  26  applied thereabout, and jaw members  144  in the open position for removal of elongate article  5 . 
   The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.