MOVABLE LABEL PRINTER-APPLICATOR ASSEMBLY

Abstract: An improved package labeling apparatus of the type in which labeling information for a package (73) which is moving to a labeling station (51) is transmitted to the labeling station to control the application of the required label (191). The improvement comprises a carriage mounted printer-applicator assembly which responds to the labeling transmission, prints the label, moves to intercept the moving package and applies the label.

Description: MOVABLE LABEL PRINTER-APPLICATOR ASSEMBLY BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a movable label printer-applicator. More particularly, it relates to a label printer-applicator which is used in conjunction with a package conveyor system to print and apply labels to packages. Most particularly, the present application finds use in the application of bar coded shipping labels having one face coated with a pressure sensitive adhesive. Description of the Prior Art Label applicators for applying labels to conveyor borne packages while they are in motion are known in the shipping industry. Known applicator systems remove a printed label from its backing strip and retain it against an applicator grid until the article to be labeled reaches an appropriate position on the conveyor. At that point, a blast of gas, such as air, is used to transfer the label from the grid to the surface of the article. A variation on the known systems is disclosed in U.S. Patent 4,255,220. This patent discloses a label applicator in which a label receiver is mounted for movement on a supporting structure. A printed label received from a label dispenser is releasably retained on the label receiver. This receiver moves from a retracted position to an extended position in close proximity to the article to be labeled. A blast of air is used to transfer the label to the package. The label receiver returns to the retracted or home position where it receives the next label from the label dispensing means and the sequence is repeated. While the systems described above are dependable and satisfactory for many labeling operations they have several problems. First, packages have to be turned and aligned on the conveyor in order to pass under the fixed path. Second, the movable receiver had to travel from the extended position to the retracted or home position in order to pick up another label for every package on the conveyor. Finally, these requirements effectively limit the speed with which packages can be conveyed past the labeling station. SUMMARY OF THE INVENTION The present invention provides an apparatus for labeling moving packages in which a carriage mounted, integrated printer-applicator head prints and applies the package label. In the preferred application, labeling information is input for a package which is then placed on conveyor system for transport. Sensors check the package geometry or configuration and its location on the conveyor. An edge sensor signals when the package has reached a predetermined position on the conveyor. The package location and configuration data along with the labeling information are transmitted to a controller which receives and correlates the data. The controller produces a label control signal which is transmitted to the labeling station. Vertical and lateral drive motors position the carriage mounted, integrated printer-applicator assembly in response to the label control signal. The printer-applicator (P-A) assembly both prints and applies the required label to the package. The controller stores the P-A assembly position so that the P-A assembly moves directly to the next desired position as the sequence described above is repeated. To avoid impacts with packages that have shifted or turned as they traveled along the conveyor, sensors are provided to signal the P-A assembly to translate vertically. It is an object of this invention to provide a system that will quickly and accurately label moving packages. It is an object of this invention to provide a label applicator which does not require that it return to a fixed home position between labels. J. is an object of this invention to provide a label applicator that moves vertically and laterally in a fixed plane normal to the direction of package movement. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a package labeling system incorporating the present invention. Figure 2 is a perspective view of the labeling station assembly. Figure 3 is a front elevation of the labeling station assembly. Figure 4 is a side elevation of the labeling station assembly. Figure 5 is a perspective of the printer-applicator assembly. Figure 6 is an elevation of the printer-applicator assembly in the direction 6-6 on Figure 5. Figure 7 is an elevation of the printer-applicator assembly in the direction 7-7 on Figure 5. Figure 8 is a perspective view of a portion of the package labeling system which illustrates label application on a package. Figure 9 is a flow diagram for package sensing and labeling in accordance with the preferred embodiment. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to Figure 1, there is shown a label applicator system 1 that has been mounted over a conveyor system 2. At the beginning of the conveyor system 2 there is an operator's station 4 having a key pad 5 which is used to input shipping information for a given package. The package (not shown) is then placed on the conveyor belt 3 for transport through the label applicator system 1. At the first station, 10 in Figure 1, a sensor array 11, shown in phantom, is located in the housing 14 which is supported by framework 12 and straddles the conveyor belt 3. A primary controller 13 is located within the same housing 14. The sensor array 11 locates the leading and trailing edges of each package and transmits this data to the controller 13. The specific configuration of the sensor array 11 is not important to the present invention and there are a number of commercially available devices for this purpose. However, it is necessary to have some means of initial package identification. At the second station 20, a lateral location sensor 21 checks the lateral location of the package on the conveyor 3 and transmits a signal to the primary controller 13. Located at the third station 30 is a package profile sensor 31. This sensor 31 is comprised of light curtain emitter 32 and light curtain receiver 33. The emitter 32 and receiver 33 are mounted on opposing sides of the conveyor belt 3 in alignment with each other. As the package passes between the emitter 32 and receiver 33, it is profiled and the data transmitted to the primary controller 13. In the preferred embodiment, the light curtain emitter 32 and receiver 33 are Part No ' s . XPS60018X and XPS60018R from Scientific Technologies, Inc., Corporate Headquarters, 31069 Genstar Road, Hayward, CA 94544. At the fourth station 40, the sensor 41 detects the leading edge of the approaching package. This establishes the package's arrival at a predetermined point along the conveyor 3. The primary controller 13 receives and correlates the package location and configuration data, and transmits a printer control signal to the labeling station assembly 51. Signals are transmitted through signal and transmission cables (not shown) which are housed in cable through 6 that runs between the housing 14 and the labeling station assembly 51. Lighting supports 7 and lights 8 straddle the conveyor belt 3 at regular intervals and support the cable through 6. Figures 2, 3 and 4 show more detailed views of the labeling station assembly 51. Before describing the operation of the labeling station 52, it will be beneficial to describe the components which comprise the preferred assembly. The assembly 51 is comprised of an open framework 63 which straddles the conveyor belt 3. The framework 63 is comprised of four vertical frame members 133, 134, 135 and 136 which define the four corners of the framework support assembly 63. The vertical frame members 133-136 are fixed in position on the sides of the conveyor 3 at 137. The longitudinal frame members 139 and 140 are respectively affixed to the vertical frame members 133 and 134 at upper and lower positions. A second pair of longitudinal frame members 141 and 142 are affixed to the second pair of vertical frame members 136 and 137 in like fashion. Straddling the conveyor belt 3 are the cross members 144 and 145. The cross member 144 connects the top vertical frame members 133 and 135. The cross member 145 connects the tops of the vertical frame members 134 and 136. An intermediate cross member 143 also connects the vertical frame members 133 and 135 at an intermediate position which is above the maximum expected package height. As can be seen from the above, the framework 63 is essentially a box frame which straddles the conveyor 3. While the specific construction is not important, it must be remembered that the frame 63 has to withstand rapid movement of the P-A assembly and must be sturdy enough to permit positive location of the P-A assembly over the conveyor 3. The linear actuators 146 and 147 are affixed to the respective longitudinal frame members 139 and 140, and 141 and 142, on either side of the conveyor and in front of the respective vertical frame member 133 and 135. The linear actuator 172 is horizontally attached, via a pair of mounts 173, to the vertical linear actuators 146 and 147. In the preferred embodiment, the linear actuators 146, 147 and 172 are Part No. 1251001 from Macron Dynamics, Inc., 405 Caredean Drive, Horsham, PA. The carriage assembly 170, rides on the horizontal linear actuator 172 and is moved across the conveyor 3 by the lateral direction drive motor 178. Mounted on the lateral drive motor 178 is a rotary encoder or position sensor 179 which continually transmits the position of the carriage assembly 170 so it can be tracked by the secondary controller 160. In the preferred embodiment, the lateral drive motor 178 and the rotary encoder 179 are Part No. R34JENC-R2-NS-VS-00 from Pacific Scientific, Motor and Control Division, 4301 Kishwaukee Street, P.O. Box 106, Rockford, IL 61105-0106. The horizontal linear actuator 172 and the carriage assembly 170 are raised and lowered on the vertical linear actuators 146 and 147 by the vertical drive motor 150 which is attached to the support assembly 63 by a motor support bracket 148. The drive pulley 151 on the vertical drive motor is coupled to the shaft pulley 156 by belt 158. This combination drives a transverse shaft 154 which engages the upper ends of vertical linear actuators 146 and 147. Rotary encoder or position sensor 157 tracks the turning of the transverse shaft 154 for the secondary controller 160 which controls the vertical drive motor 150. An electric brake 153 is attached to the opposing end of the transverse shaft as a safety feature. In the preferred embodiment, the vertical drive motor 150 and rotary encoder 157 are Pacific Scientific, Motor and Control Division, Part No. R65HENA-R2-NS-VS-00. The vertical drive brake 153 is Part No. 1-055-541-006BF from Rexnord, Stearns Division, 120 N. Broadway, Milwaukee, WI 53202. The printer-applicator support bracket 174 is affixed to the carriage assembly and supports the printer-applicator assembly 200. The printer controller 202, Figure 4, is also attached to the carriage assembly 170. Mounted on the printer-applicator support bracket 174 above the P-A assembly 200 are a label supply reel 184, which supplies labels on a tape 190, and a take up spool 185. An external air supply line 164, extends from pneumatic line filter 163 to the head assembly 200. An external air supply is attached at connection 162. The following description will refer to Figures 5, 6 and 7 which are enlarged views of the P-A assembly 200. Contained inside the P-A housing 205 is a print head 204, which receives the labels on the tape 190, prints them and delivers printed labels 191 to the label dispenser 207. In the preferred embodiment, the printer 204 and the printer controller 202 are Part No's. 4524S-USPS from Sato America, Inc., 2761 Marine Way, Mountain View, CA 94043. Attached to the P-A housing 205 above the dispenser 207 is a support bracket 210. Depending from the support bracket 210 is a catch plate support 215 to which a catch plate 216 is pivotally mounted. An air cylinder 211, with a clevis 212 attached to its lower end, is pivotally attached to the catch plate 216 with pin 213. At its upper end, the air cylinder 211 is pivotally attached to the support bracket 210. An air supply line 220 supplies the air nozzle 221 which depends from the support bracket 210 over the label dispenser 207. Look-down sensor 222 and photo eye 224 are also mounted below the support bracket 210. Articulated cable carriers 188 and 189, see Figures 3 and 4, route cables and air lines (not shown) between the controller 160 and the P-A assembly 200. The printer control signal generated from the package configuration and location data is transmitted to the secondary controller 160 at the labeling station 50. This secondary controller 160 controls vertical drive motor 150 and lateral drive motor 178 to reposition the carriage assembly 170. In the preferred embodiment, the printer-applicator head assembly 200 is located one-half to one and one-half inches above the package surface. The look-down sensor 222 confirms the P-A assembly position. The primary controller 13 commands, through the printer controller 202, the print head 204 to print a shipping label based on the shipping data. With the preferred assembly, the printing can be done on the move, since a home base location is not needed, and the label can be applied almost simultaneously upon package arrival. The labeling dispenser 207 peels the label 191 off its backing 192, and a blast from air nozzle 221 blows the label onto the package. The package then proceeds under foam roller assembly 186 which rolls over the label to ensure that it is firmly seated on the package. Strike sensors 180 are mounted on the support brackets 182 to confirm that the arriving package has not tipped or shifted into a position that will cause it to strike the P-A assembly 200. If a package has shifted, the strike sensors signal the secondary controller to raise the P-A assembly 200 to avoid possible damage to the assembly and/or the package. If for any reason a label 191 cannot be applied to a package, such as strike sensors 180 indicating that the package has exceeded the height limitation, the controller 13 activates the air cylinder 211 to swing the catch plate 216 into position under the label dispenser 207. The label 191 is then blown onto the catch plate 216. If the catch plate 216 is full, photo eye 224 signals the controller that operator assistance is required. Because the P-A assembly 200 can both print and apply a shipping label, it is not necessary to have the P-A assembly 200 return to a retracted or home position before printing and applying a label to the next package on the conveyor 3. The P-A assembly 200 proceeds directly from its last position to the next desired position based on the location and configuration data collected for the next package on the conveyor. In the preferred embodiment, the P-A assembly prints the label as it travels to the next desired position. The P-A ass'embly 200 utilizes labels 191 as described in U.S. Patent No . 4,724,166. The label 191 can be peeled away from the clear adhesive layer that affixes it to the package without damage to or obstruction of any information which may be under the label. This makes the label position on the package inconsequential to other information on the package surface. Once the package has reached its destination, the label 191 can be removed, leaving only its clear adhesive layer behind. Referring to Figure 8, there is shown a portion of the conveyor system 2 and the labeling station assembly 51. Three packages are shown on the conveyor belt 3. These packages represent some of the types of packages that have been successfully labeled with the present invention. The first package 71 is an unevenly profiled soft pack envelope which simulates a sweater. It is shown on the conveyor belt 3 at a position past the labeling station assembly 51 with a bar code printed label 191 successfully applied. A second package 72, shown at the labeling station 51 under the P-A assembly 200 is a triangular prism with the label 191 applied. A third package 73 is shown between light curtain emitter 32 and receiver 33. The third package 173 is an over stuffed soft pack envelope. In the current embodiment, maximum package size is limited to 18 inches high and the 24 inch conveyor width. However, other configurations are possible. Due to the present package identification and tracking system, the label applicator assembly is sensitive to package geometry and location. Thus, each package is treated individually without the need for the P-A assembly 200 to return to some fixed home base. These features combine to provide both increased speed and increased flexibility. In the preferred embodiment, the conveyor system 2 is made up of a series of individually controllable belt segments which operate at speeds that increase along the conveyor from 240 to 400 feet per minute at the P-A assembly 200. The primary controller 13 regulates the flow of packages through the system 1 based on the time required for inputting of labeling information as well as its completeness, the translation and print time required by the P-A assembly, and the position of other packages preceding the current package on the conveyor. Figure 9 shows a information flow diagram for the preferred embodiment of the disclosed labeling apparatus system. By way of explanation, the diagram shows the operations performed in respect to the package flow along the conveyor path. It will be understood by those skilled in the art that some operations may occur simultaneously and that the sequence of events is not limited to this example. Box 5 shows the entry of labeling data and a secondary operation, designated box 5.1, shows the package being placed on the conveyor. Boxes 10, 20, 30 and 40 show the various package configuration and position detecting operations that occur at stations 10, 20, 30 and 40 respectively as previously discussed. The position and configuration data is transmitted to the primary controller 13, shown in box 70. The secondary controller 160 and the printer controller 202 are also shown in box 70 with the primary controller and are referred to collectively. The controller receives the package location and configuration data, correlates it and determines the required translation for the P-A assembly 200 to intercept the package. As the package proceeds to the labeling station 50, a strike sensor shown in box 50.1 checks that the package does not exceed maximum height and/or position requirements. If there is a problem, the sensor results in a signal to the controller box 70 which moves the P-A assembly to a maximum height, stops the conveyor to avoid a collision and activates the label catch plate to remove the unused label. If the package does not exceed maximum height, the controller signals the P-A assembly 200, as shown in box 50.2, to label the package as it proceeds down the conveyor. As will be appreciated by those skilled in the art, the present label printer-applicator apparatus allows for faster processing of packages than those label applicators previously known.

Claims: CLAIMS I claim: 1. An improved package labeling apparatus of the type in which labeling information for a package which is moving to a labeling station is transmitted to the labeling station to control the application of the required label, wherein the improvement comprises: a carriage mounted printer-applicator assembly which responds to the labeling transmission, prints the label, moves to intercept the moving package and applies the label. 2. A package labeling system of the type in which labeling information is input into a controller for a package which is transported on a conveyor to a labeling station which applies the required label, wherein the improvement comprises: means to determine the package configuration and its position on the conveyor, and to transmit that information to the controller; means within the controller which coordinates the labeling and package information and outputs a label information signal; and a carriage mounted printer-applicator assembly which responds to the label information signal, prints the label, moves to intercept the package and applies the label. 3. The system of claim 2, wherein the carriage mounted printer-applicator assembly moves both vertically and laterally in a fixed plane normal to the conveyor path. 4. The system of claim 3, wherein linear actuators move the carriage mountedprinter-applicator assembly into position to intercept the package. 5. The system of claim 2, wherein the carriage mounted printer-applicator assembly prints the package label as it moves into position to intercept the package. 6. The system of claim 2, wherein a label supply reel, mounted on the carriage assembly, supplies blank labels to the printer-applicator assembly and a take-up spool, mounted on the carriage assembly, collects the spent backing ribbon. 7. The system of claim 2, wherein a rotary encoded drive motor powers the vertically mounted linear actuators and a rotary encoded drive motor powers the horizontally mounted linear actuator; the encoded motors provide tracking data to the controller which receives and correlates the data, and outputs control signals to accurately position the printer-applicator assembly. 8. The system of claim 2, wherein the printer-applicator assembly moves to intercept successive packages without returning to a home base. 9. The system of claim 8, wherein the printer- applicator intercepts the package at a predetermined point based on the package configuration, conveyor speed, and a leading edge of the package. 10. The system of claim 2, wherein strike sensors are mounted in front of the printer-applicator assembly to detect if a package position will strike it and upon detection of such a package to transmit a signal to the controller which raises the printer-applicator assembly and stops the conveyor. 11. The system of claim 2, wherein a catch plate on the printer-applicator assembly is actuated by the controller to intercept any label which cannot be properly applied to the package. 12. A method for operating a package labeling system which comprises: (1) providing a package conveyor system with a means for inputting data, a plurality of package geometry and location sensors, a controller, a motor driven, carriage mounted, integrated label printer-applicator assembly along the conveyor path, and labels; (2) inputting labeling data for a package on the conveyor; (3) transmitting the labeling data to the controller; (4) sensing the package geometry and position on the conveyor; (5) transmitting the package geometry and position data to the controller; (6) correlating the package geometry and position data with the labeling data; (7) transmitting a label information signal to the printer-applicator; (8) moving the printer-applicator assembly to intercept the package without returning to a home base; and (9) printing and applying a label in accordance with the label information signal; 13. The method according to claim 12 wherein the printer-applicator assembly is further provided with both vertically and horizontally movement in a fixed plane normal to the conveyor path. 14. The method according to claim 12 wherein the steps of moving the printer-applicator assembly and printing the label are done concurrently. 15. The method according to claim 12 further comprising: providing a vertical drive means with an associated rotary encoder and a horizontal drive means with an associated rotary encoder for movement of the printer-applicator assembly; tracking the printer-applicator assembly position with the rotary encoders; transmitting position data to the controller; correlating position data in the controller; and controlling the vertical and horizontal position of the printer-applicator assembly based on the position data. 16. The method according to claim 12 further comprising: providing a catch plate associated with the printer-applicator assembly; and actuating the catch plate to intercept any label which cannot be properly applied to the package.

Inventors: OVERHOLT ROBERT S, OVERHOLT, ROBERT, S.
Applicants: ACCU SORT SYSTEMS INC, ACCU-SORT SYSTEMS, INC.
Application year: 1993
Main classification: B65C9
IPC codes: B65C1, B65C9