Abstract:
A label dispensing apparatus is provided for applying labels to advancing articles. The label dispensing apparatus features a modular design that couples different types of label dispensing modules to one of several label applicators through a standard chassis. An apply-only label dispensing module for use in the apparatus includes a primary drive roller mechanism receptive of a label web being supplied from the label dispensing chassis and capable of advancing the label web along a web path; a peeler wedge positioned downstream in the web path from the primary drive mechanism, such that the label web traverses the peeler wedge to separate the labels from the label web; a secondary drive roller mechanism positioned downstream from the peeler wedge for advancing the label web along the web path and for maintaining tension on the label web; and a drive mechanism connected to the primary drive roller and the secondary drive roller for providing rotary motion to each of the primary drive roller and the secondary drive roller, thereby advancing the label web along the web path.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to a label dispensing apparatus and, more particularly, to an apply-only label dispensing module for use in a conventional print-and-apply label dispensing chassis. 
     2. Discussion 
     Label dispensing units for applying labels to advancing articles have come into widespread use in a variety of industries. Print-and-apply label dispensing systems are today&#39;s cost-effective solution for labeling products, cartons, cases and pallets. Generally, these types of systems feature a unique modular design that couples a variety of commercially available print engine modules to one of several label applicators through a standard chassis. In operation, the print-and-apply label dispensing system produces high quality, “on-demand” labels and applies them automatically in a single, easy operation to an advancing article. Exemplary print engine modules are commercially available from Sato America, Inc. of Sunnyvale, Calif., Zebra Technologies, Inc. of Vernon Hills, Ill. and Datamax Corporation of Orlando, Fla. 
     Despite the flexibility provided by a print-and-apply label dispensing system, some high speed operations are more suited for an “apply-only” labeling system. Apply-only systems utilize pre-printed labels, and thus are able to apply labels to advancing articles at higher rates than print-and-apply systems. Therefore, a need exists for an apply-only label dispensing module that can be easily integrated with the standard chassis of the conventional print-and-apply label dispensing system. By exploiting the modularity of the standard chassis, the apply-only module best fits certain high speed labeling applications of a specific production environment, while reducing costs of providing an overall label dispensing system. However, the present invention must also be designed to account for the slower rates associated with the standard chassis. 
     SUMMARY OF THE INVENTION 
     A label dispensing apparatus is provided for applying labels to advancing articles. The label dispensing apparatus features a modular design that couples different types of label dispensing modules to one of several label applicators through a standard chassis. In accordance with the present invention, an “apply-only” label dispensing module includes a primary drive roller mechanism receptive of a label web being supplied from the label dispensing chassis and capable of advancing the label web along a web path; a peeler wedge positioned downstream in the web path from the primary drive mechanism, such that the label web traverses the peeler wedge to separate the labels from the label web; a secondary drive roller mechanism positioned downstream from the peeler wedge for advancing the label web along the web path and for maintaining tension on the label web; and a drive mechanism connected to the primary drive roller and the secondary drive roller for providing rotary motion to each of the primary drive roller and the secondary drive roller, thereby advancing the label web along the web path. 
     Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from a reading of the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded perspective view of a label dispensing module and a label dispensing chassis in accordance with the present invention; 
     FIG. 2 is a side view of the label dispensing module mounting into the label dispensing chassis in accordance with the present invention; 
     FIG. 3 is a diagram showing the primary components of the label dispensing module of the present invention; 
     FIG. 4 is a front perspective view of the label dispensing module of the present invention; 
     FIGS. 5A and 5B are top and bottom perspective views, respectively, of a primary drive roller mechanism of the present invention; 
     FIGS. 6A and 6B are top and bottom perspective views, respectively, of a secondary drive roller mechanism of the present invention; 
     FIG. 7 is a rear view of the label dispensing module of the present invention; and 
     FIG. 8 is a diagram showing product detect sensors in conjunction with the label dispensing apparatus of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A label dispensing apparatus  10  in accordance with the present invention is depicted in FIG.  1 . The apparatus  10  includes an apply-only label dispensing module  12  and a label dispensing chassis  14 . The label dispensing chassis  14  provides a rectangular opening  16  that is used to house the label dispensing module  12 . As shown in FIG. 1, a mounting flange  13  the label dispensing module  12  is designed with a hole pattern  15  which facilitates it being bolted into an opening  16  via a similar hole pattern  17  on a face of the chassis  14 . One skilled in the art will readily recognize that other connector means may be used to releasably couple the module  12  to the chassis  14 . In this way, a conventional print engine or print-and-apply module can be easily replaced by the label dispensing module  12 . Although the Paragon system from Marprint, Inc. of White Bear Lake, Minn. is the presently preferred label dispensing chassis  14 , this is not intended as a limitation of the invention. On the contrary, the present invention is applicable to other commercially available label dispensing chassis. 
     In order to support a print-and-apply module, the chassis  14  includes a label supply hub  22 , a web rewind hub  24 , a drive mechanism  64  (shown in FIG. 7) and a label applicator  28 . As shown in FIG. 2, a roll of labels easily mounts onto the label supply hub  22 , whereby it provides a label web  30  for the label dispensing apparatus  10 . The label web  30  can then be threaded along a web path until it attaches to the web rewind hub  24 . The web rewind hub  24  is used to accumulate the label web  30 . To advance the label web  30 , a drive mechanism (not shown) provides rotary motion to the web rewind hub  24 . 
     A microcontroller (not shown) is typically used to control the drive mechanism as well as other various functions associated with the label dispensing apparatus  10 . A brake may also be used in conjunction with the label supply hub  22  to prevent unravel of the label web  30 . The chassis  14  further includes a power supply (not shown) which serves as a source of power for the microcontroller. 
     A standard tamp applicator  28  for applying labels to advancing articles is also controlled by the microcontroller. A label is dispensed from the label dispensing module  12  to the applicator  28  as will be more fully explained below. Thus, the label is positioned onto a vacuum pad of the applicator  28 . When an advancing article is detected, an air cylinder engages, causing the pad to come in momentary contact with the advancing article, thereby applying the label. The air cylinder may also engage at periodic time intervals which coincides with the speed of the conveyor being used to transport the advancing articles. The air cylinder then retracts and the next label is dispensed onto the pad. Depending on the configuration of the advancing article and the specific labeling requirements, it is envisioned that other types of applicators, including a dual tamp applicator, a vacuum blow applicator, a roll on applicator, and a corner wrap applicator, may also be used in conjunction with the chassis  14 . While the above description is provided with reference to a particular label dispensing chassis, it is readily  20  understood that this explanation is merely an overview of the basic chassis components. As will be apparent to one skilled in the art, additional components as well as other configurations for these components are within the scope of the present invention. 
     Referring to FIGS. 2,  3  and  4 , the apply-only label dispensing module  12  of the present invention includes a secondary dancer arm  40 , a primary drive roller mechanism  42 , a peeler wedge  44 , and a secondary drive roller mechanism  46 . The label web  30  from the label supply hub  22  is received on the module  12  by the secondary dancer arm  40 . The dancer arm  40  pivotally connects to the module  12  and moves within a range of positions based on the tension of the label web  30 . To do so, the dancer arm is spring loaded as shown in FIG.  7 . In this way, the dancer arm  40  supports the different operating speeds of module  12 . The primary drive roller mechanism  42  in turn receives the label web  30  from the secondary dancer arm  40 . The primary drive roller mechanism  42  is further defined as a primary drive roller  50  and a primary pinch roller  52  which operate collaboratively to advance the label web  30 . A first intermediate roller(s)  54  may also be disposed between the secondary dancer arm  40  and the primary roller mechanism  42  to guide the label web  30  along the web path  32 . The primary drive roller mechanism  42  is also shown in FIGS. 5A and 5B. 
     The secondary drive roller mechanism  46  receives the label web  30  from the primary roller mechanism  42  and is further defined as a secondary drive roller  56  and a secondary pinch roller  58 . Again, the secondary drive roller  56  and the secondary pinch roller  58  operate collaboratively to advance the label web  30  along the web path. The peeler wedge  44  is positioned in the web path between the primary drive roller mechanism  42  and the secondary drive roller mechanism  46 . Labels are separated from the webbing as the label web  30  traverses an edge  60  of the peeler wedge  44 . As is well known in the art, the edge  60  is formed with a radius on the order of 0.030 inches. The secondary drive roller mechanism  46  is also shown in FIGS. 6A and 6B. 
     To further guide the label web  30  along the web path  32 , a second intermediate or dampener roller(s)  62  may also be disposed between the secondary drive roller mechanism  46  and the web rewind roller  24 . The dampener roller  62  pivotally connects to the module  12  and moves within a range of positions based on the tension of the label web  30 . As the web rewind roller  24  pulls the label web  30 , the dampener roller  62  absorbs any “jerky” motion in the label web  30 . 
     A drive mechanism  64  is connected to each of the primary drive roller  50  and the secondary drive roller  56  as shown in FIG.  7 . In a preferred embodiment, the drive mechanism  64  comprises a stepper motor  66  connected via a timing belt  68  to each of the drive rollers. The timing belt passes over a timing pulley on the end of each roller and over a standing pulley on the stepper motor. In this way, the stepper motor  66  provides rotary motion to each of the primary drive roller  50  and the secondary drive roller  56 . 
     Thus, the primary drive roller mechanism  42  pulls the label web  30  from the label supply hub  22  and the secondary drive roller mechanism  46  provides a tension on the label web  30 . The labels are separated from the webbing as the label web  30  traverses an edge  60  of the peeler wedge  44 . To maintain the tension on the label web  30 , the diameter of the secondary drive roller  56  is designed slightly larger (e.g., 0.010″) than the diameter of the primary drive roller  50 . In effect, the secondary drive roller  56  is moving further than the primary drive roller  50 , even though they rotate at exactly the same revolutions per minute. As long as the tension is maintained on the label web  30 , the labels separate from the webbing and continue forward onto the suction pad of the applicator  28 . The label can then be applied by the applicator  28  to an advancing article. 
     In a conventional print-and-apply label dispensing system, the label web  30  can travel at a rate up to 10 inches per second. In this case, the web rewind hub  24  is driven by the drive mechanism associated with the chassis  14 . However, an apply-only label dispensing module advances the label web at much faster rates (e.g., as much as 24 inches per second). Thus, the web rewind hub  24  needs to be driven faster than the traditional 10″ per second. To accomplish this, a larger drive pulley is used on the drive mechanism of the chassis  14 . 
     In a preferred mode of operation, a microcontroller  70  residing on the label dispensing module  12  is used to control the operation of the drive mechanism  64 . A label detection sensor  72  may be placed on the label dispensing module  12 . As is well known in the art, the label detection sensor  72  is an optical-based sensor which detects the leading edge of a label based on the amount of light passing through the label web  30 . The label detection sensor  72  communicates with the microcontroller  70  which in turn drives the drive mechanism  64 . The label web  30  is advanced by the drive mechanism  64 , such that the leading edge of a label stops at the edge of the peeler wedge  44 . In this way, the label is properly positioned so that the next time the label web  30  advances, the label is dispensed onto the vacuum pad of the applicator  28 . In other words, the microcontroller  70  starts and stops the drive mechanism  64  based on the optical detection of the next label on the label web  30 , thereby dispensing labels to the applicator  28 . As will be apparent to one skilled in the art, how far the label web  30  advances between each label depends on the size of the labels and the position of the label detection sensor  72  in relation to the edge of the peeler wedge  44 . 
     To further coordinate the functions of the label dispensing apparatus  10 , a first product detection sensor  74  is electrically connected to the microcontroller  70 . As shown in FIG. 8, the first product detection sensor  74  is positioned upstream from the applicator  28 , so that it can detect an article  75  as it approaches the label dispensing apparatus  10 . Based on the information provided by the first product detection sensor  74 , the microcontroller  70  then coordinates the application of the label to the advancing article by the applicator  28 . In order to coordinate between the product detection sensor  74  and the applicator  28 , the microcontroller  70  associated with the label dispensing module  12  is designed to interface with the microcontroller of the chassis  14 . In this case, the microcontroller  70  assumes a constant speed for the conveyor being used to transport the advancing articles. 
     However, in an alternative embodiment, a second product detection sensor  76  may be used to dynamically control the operations of the label dispensing apparatus  10  for a variable speed conveyor. Again, the product detection sensor  76  is operative to detect the leading edge of an advancing article and communicate this information to the microcontroller  70 . Based on information from each of the two product detection sensors  74  and  76 , the microcontroller  70  can then determine the rate at which the advancing articles are approaching the label dispensing apparatus  10 . Accordingly, the operations of the drive mechanism  64  and the label applicator  28  are adjusted by the microcontroller  70 . 
     While the above description constitutes the preferred embodiment of the invention, it will be appreciated that the invention is susceptible to modification, variation, and change without departing from the proper scope or fair meaning of the accompanying claims.