A high-speed print-and-apply label applicator includes a conveyor system, a control and monitoring system, a label web feeding assembly, a label printer and encoder system, a tamp pad assembly driven by a linear motor having a shaft that is formed at least partially by a composite material.

BACKGROUND

1. Technical Field

The present application relates to a systems and methods for labeling packages.

2. Description of Related Art

High-speed print-and-apply label applicator systems have been around for many years. These systems allow for high-speed labelling of packages as the packages pass by on a continuous conveyer system. These label applicator systems generally consist of a control and monitoring system, a label printer and encoder system, a tamp assembly, and a conveyor system. The control and monitoring system monitors the system during the labeling of packages and allows the operator to input commands and other operational parameters into the label applicator system. The label printer and encoder system prints and encodes the labels as directed by the control and monitoring system. Packages are delivered to the tamp assembly by the conveyor system, so that the tamp assembly can apply the labels to the packages.

Currently the number of packages that can be processed in a given timeframe is restricted by the speed of the tamp assembly. These label applicator systems are typically driven by pneumatic cylinders, rotary stepper motors, and/or rotary servo motors, all of which limit the speed at which the packages can be labelled. Although there have been great strides in the area of high-speed print-and-apply label applicator systems, significant shortcomings remain.

While the system of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the method to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, combinations, and alternatives falling within the spirit and scope of the present application.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The use of the term “package” is meant to mean any article, such as, but not limited to, boxes, envelopes, containers, books, magazines, DVD's, CD's, and includes any item or article that can be placed on a conveyer system and/or under a label tamp assembly for labeling purposes.

Referring now toFIG. 1in the drawings, the preferred embodiment of a high-speed print-and-apply label applicator100according to the present application is illustrated. Label applicator100allows for the high-speed printing and application of labels102from a web of labels110onto packages104. Packages104may be of the same size and shape, or as is shown, may be of various sizes and shapes. Label applicator100includes a control and monitoring system170, a label web feeding assembly120, a label printer and encoder system130, a label rejection assembly160, a tamp pad assembly180, and a conveyor system150. However, it will be appreciated that other embodiments of label applicator100may have more or fewer components. The components for label applicator100are preferably mounted or secured in a frame assembly108. It will be appreciated that label applicator100may also be used in conjunction with a wide variety of package sorting machines, parcel management machines, and various other parcel encoding systems.

Control and monitoring system170of label applicator100allows for the monitoring and control of label applicator100, and in some embodiments, also allows for the control and monitoring conveyor system150, either directly or via communication with a system controller of conveyor system150. It will be appreciated that control and monitoring system170includes one or more monitors and/or displays, CPU's, ROM chips, RAM chips, USB ports, Ethernet and/or Internet connectivity, etc., and is conductively coupled to a user interface172and/or a system monitoring panel168. User interface172includes one or more switches, indicators, touch screens, keyboards, touchpads, and/or other input and/or output devices. It will be appreciated that user interface172may also be and/or include computers, tablet computers, remote controls, smart phones, and/or other personal handheld electronic devices. System monitoring panel168includes of one or more air pressure gauges and/or other operational indicators. In some embodiments, users may access control and monitoring system170remotely, which may be conducted through a computer network, another computer, smart phone, tablet, other label applicator systems, and/or other electronic devices.

Label web feeding assembly120preferably includes one or more supply rolls112, one or more guide rollers122, one or more joining guide rollers124, one or more drive and nip roller assemblies126, and one or more web rewind rolls114. In addition to the components mentioned above, other components may be used, depending upon the desired application. Any of the aforementioned parts are capable of motorization to facilitate the winding and unwinding of web110and/or the rewinding of scrap web110a. In the embodiment ofFIG. 1, drive and nip roller assembly126pulls scrap web110a, thereby causing web110, along with a joined label102c, to pass around a peel tip142of a peeler member140. In embodiments that have labels102that require cutting, label web feeding assembly120may include a cutting assembly operably associated with peeler member140.

As shown in the embodiment ofFIG. 1, label printer and encoder system130, also referred to herein as printer system130, is preferably an RFID encoder and a thermal printer. However, in other embodiments printer system130may be a thermal printer, ink printer, other type of printer, and/or applicator. As shown inFIG. 1, labels102are RFID labels. However, in other embodiments it should be appreciated that labels102may be formed of paper, plastic, nylon, vinyl, or any other type of suitable label materials. In the embodiment ofFIG. 1, labels102are discrete self-adhesive labels; however, other embodiments may use labels that require cutting and adhesive for fixation to the packaging.

In some applications, a secondary label102bmay be required. In such applications, secondary label102bis fed from a secondary label supply roller190that feeds secondary label102binto printer system130for printing and/or processing. A secondary label rewind roll192collects the secondary scrap web194. Secondary label102bmay be printed or non-printed, and may be made of paper, plastic, nylon, vinyl, or any other type of suitable label materials. In addition, secondary label102bmay include a printed or non-printed clear protective film. Printer system130can print secondary label102busing any means such as thermal printing, ink or other method. Secondary label102bjoins label102aat joining guide roller124, then joined label102cmoves through to an applicator system131.

Applicator system131generally consists of peeler member140and peel tip142, but may also include a label cutter, from which joined label102cis separated from web110. After separation, joined label102cwill either be taken up by label tamp assembly180, or be received by a label rejection assembly160. Label rejection assembly160includes an accumulation pad162and a label rejection driving mechanism164. Accumulation pad162is where defective joined labels102caccumulate. Label rejection driving mechanism164may also include one or more linear motors. Applicator system131may contain additional heat dissipating technology, either active or passive.

Tamp pad assembly180includes a specialized linear motor184, a slider shaft186, a tamp pad182, an applicator plate182a. Tamp pad assembly180is a high-speed label application assembly that extends and retracts tamp pad182. Tamp pad assembly180may include one or more air intake hoses and/or fans located near tamp pad assembly180to provide air suction as required to hold labels as needed. In the preferred embodiment, tamp pad182is formed from a polyurethane foam pad covered by and/or coated with a very thin sheet or layer of ultra-high-molecular-weight (UHMW) polyethylene material and/or coating to reduce friction and aid in the rapid transfer of label102cto package104.

Label applicator100includes a wide variety of sensors, probes, bar code readers, and/or scales to facilitate the processing and labeling of packages104. As packages104travel along conveyor system150, the weight, dimensions, and other physical parameters of each package104, including the label height D1, D2, and D3, are determined by various dimensioning sensors and other sensors. This package data is transmitted to control and monitoring system170, which in turn, sends appropriate control signals to linear motor184.

Linear motor184is selectively configured to have a reduced mass and is capable of moving shaft186at speeds of up to at least 7.3 meters per second and at accelerations of over 780 meters per second squared. The linear motor available from LinMot™ under Part No. 0150-2549 (PS01-37Sx60-HP-N-AGI) is particularly well suited for this application. Linear motor184slides along a high-performance slider. The slider available from LinMot™ under Part No. 0150-1510 (PL01-20x600/540-HP) is particularly well suited for this application. Specifically, shaft186is formed at least partially from a relatively lightweight, high-strength, composite material, preferably a carbon fiber material. This allows for very short positioning times and very high cycle rates. These performance characteristics far exceed those possible with prior-art systems. By utilizing linear motor184and selectively configured shaft186, the height D1, D2, D3of packages104may vary from 0″ to 18″. In addition, by utilizing linear motor184, packages104may be spaced more closely together than prior-art systems, primarily because of the speed, stroke capabilities, and other operational parameters of the linear motor184. By being able to space packages closer together, increased package throughput is achieved. It will be appreciated that multiple linear motors may be utilized by system100. Linear motor184may include various cooling and/or lubrication systems and ensure that linear motor184operates reliably and efficiently.

In addition, linear motor184and/or shaft186may include one or more magnetic springs and/or compression springs, such as a compression spring187, to assist in the deceleration of shaft186and applicator plate182aas shaft186and applicator plate182amove upward toward the resting position of shaft186, and to assist in the efficient operation of shaft186as shaft186moves through repeated stroke cycles. Compression springs187may be located adjacent the home (retracted) position of shaft186or the lower (extended) position of shaft186. In addition, it will be appreciated that either linear motor184or shaft186, or both, may serve as the moving component in tamp pad assembly180. Accordingly, compression springs187may be located adjacent the home (retracted) position of linear motor184or the lower (extended) position of linear motor184. Furthermore, compression springs187may be coupled directly to linear motor184and/or shaft186.

Referring now also toFIG. 2in the drawings, linear motor184is illustrated. In the preferred embodiment, linear motor184has four major components: a position and temperature sensors circuit board201, a stator203, a slider205, and a payload mounting shaft207. Tamp pad182is preferably connected to shaft207. Other embodiments might use linear motors having different components.

The circuit board201measures and monitors the current position of the linear motor184, not only when linear motor184is stopped, but also while linear motor184is in motion. Deviations in position are detected immediately and reported to the control and monitoring system170. Slider205is preferably made of neodymium magnets that are mounted in a high-precision stainless steel tube. Stator203contains the motor windings for slider205. Position capture sensors and a microprocessor circuit (not shown) for monitoring linear motor184are also part of linear motor184.

One unique feature of label applicator100is the configuration and manner of operation of tamp pad assembly180. Instead of moving shaft186at the same acceleration and velocity each stroke, linear motor184is configured such that the travel time of shaft186is the same for each stroke of shaft186. Thus, the acceleration and velocity of shaft186varies dependent upon the vertical travel distance between the start position of shaft186and the upper surface of each package104. In other words, tamp pad182moves from a start position, or first position, to the upper surface of each package104in the same amount of time, regardless of the height D1, D2, or D3, i.e., regardless of the vertical travel distance of tamp pad182. In the preferred embodiment, this selected travel time of shaft186, also referred to herein as the actuation profile of shaft186, is 150 ms. It will be appreciated, that the actuation profile may be varied from one operational session to another. Selectively setting the actuation profile helps ensure that label102cis placed onto each package104at a selected time and at a selected location.

In operation, the height D1, D2, and D3of each package104is measured. Then, tamp pad assembly180actuates linear motor184and shaft186according to the selected actuation profile. This results in each label102cbeing accurately placed on each package104in a set amount of time, preferably 150 ms.

The particular embodiments disclosed above are illustrative only, as the application may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered, combined, and/or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the claims below. It is apparent that a system with significant advantages has been described and illustrated. Although the system of the present application is shown in a limited number of forms, it is not limited to just these forms, but is amenable to various changes and modifications without departing from the spirit thereof.