Patent Publication Number: US-7712509-B2

Title: Produce labeler with multiple cassettes at a single station

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a Continuation-in-Part of U.S. application Ser. No. 11/227,723 filed on Sep. 14, 2005 now abandoned. This application claims the benefit of and priority from U.S. provisional application Ser. No. 60/737,221 filed on Nov. 16, 2005. 

   BACKGROUND AND BRIEF SUMMARY OF INVENTION 
   This invention relates to produce labelers and, in particular, to selectively labeling a wide variety of fresh produce by size or grade at high speed. 
   Within the fruit packing industry it has become common practice for fruit to be labeled in large quantities at high speed on sizing/grading equipment. The demand for labeling is driven mainly by the retail industry, requiring product to be identified by variety and/or source and furthermore by size and quality. As a consequence, packers are commonly required to apply a number of different labels to fresh produce during the grading and packing operation. This is generally achieved by installing multiple labeling stations in sequence over the grading conveyors. Two major drawbacks exist with this arrangement: (a) the extended space required to accommodate multiple labeling stations, and (b) the resulting higher costs attached to such installations. 
   For example, if peaches are to be labeled “small, medium or large,” the peaches typically pass through sizing equipment where three banks of labeling equipment are used to apply the appropriate size labels to the sized peaches. The 3 labeling stations (including rotary bellows, etc.) all take up space and are all relatively expensive. 
   There is a clear need for labeling equipment that is more efficient and versatile than the prior art systems that use separate labeling stations for each separate size or grade of produce. 
   The closest prior art known to applicant includes the use of dual cassettes as shown in Rietheimer U.S. Pat. No. 5,645,680 (see  FIG. 6 ). However, Rietheimer has three major weaknesses. First, he uses a complex fixed cam surface housing (as opposed to rotary bellows). Secondly, his system uses conventional knife edge label stripping and is therefore limited to the use of relatively stiff labels. Thirdly, Rietheimer requires that the guide plate of each label cassette discharge each label tangentially to the rotary applicator and parallel to each transfer head as shown in  FIG. 6  herein. This geometry limits the number of cassettes usable to two (see  FIG. 6 ). The present invention is capable of using three or more label cassettes without the complex camming mechanism of Rietheimer. The present invention also uses thin and flexible labels, which are usable on more items than stiff labels. 
   The present invention provides, for the first time, a single automatic labeling station capable of applying 3 or more different labels to singulated produce passing through the station. The present invention also provides, for the first time, a single automatic labeling station wherein 3 or more label cassettes interact with a single rotary bellows applicator. 
   In the above example of “small, medium and large” peaches to be labeled, the present invention labels all 3 separate sizes in a single station with a single rotary bellows applicator. The invention reduces most of the prior art machinery required and the space necessary to house the machinery! 
   A primary object is to provide an automatic produce labeling apparatus capable of applying 3 or more different labels at a single labeling station and at high speed, i.e., more than 1000 labels per minute. 
   A further object is to provide an automatic labeling system which eliminates the need for multiple labeling stations otherwise required by the prior art in applying labels displaying different sizes or grades on produce. 
   A further object is to provide labeling apparatus wherein multiple label cassettes interact with a single rotary bellows applicator to apply multiple different labels to produce at speeds in excess of 1000 labels per minute. 
   Further objects and advantages will become apparent from the following description and drawings wherein: 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic illustration of the present invention showing three separate label cassettes being utilized in conjunction with a single rotary bellows applicator; 
       FIG. 2  is a schematic illustration of the system shown in  FIG. 1  wherein the system has been advanced one step from that shown in  FIG. 1 ; 
       FIG. 3  is a schematic representation of an alternate form of the invention wherein four separate label cassettes are utilized together with a single rotary bellows applicator; 
       FIG. 4  is a schematic representation of the system shown in  FIG. 3  after having been advanced one step from that shown in  FIG. 3 ; 
       FIG. 5  is a schematic representation of yet another form of the invention utilizing three separate label cassettes together with a print head in conjunction with a single rotary bellows applicator; 
       FIG. 6  is an illustration of a prior art system according to Rietheimer U.S. Pat. No. 5,645,680 utilizing two label cassettes together with an applicator that does not use bellows; 
       FIG. 7  is a reproduction of FIG. 3 from the parent U.S. application Ser. No. 11/222,723; and 
       FIG. 8  is a reproduction of FIG. 7 from the parent &#39;723 application. 
   

   DETAILED DESCRIPTION OF THE DRAWINGS 
     FIG. 1  illustrates one form of the present invention wherein three separate label cassettes  100 ,  200  and  300  are co-planar and are angularly displaced from each other around and above a single rotary bellows applicator shown generally as  400 . Cassettes  100 ,  200  and  300  form an arc of approximately 180°. A conveyor  500  moves in the direction of arrow  501  and carries produce shown generally as  600 . The produce  600  includes, in the example illustrated in  FIG. 1 , three different sized items including “large” items  601 , medium sized produce items shown as  602  and small items  603 . Label cassettes  100 ,  200  and  300  carry different sized labels, e.g. label cassette  100  carrying “large” size labels, cassette  200  carrying “medium” labels and cassette  300  carrying “small” labels. In  FIG. 1  a large produce item  601   a  is being labeled by the upper surface  401   a  of individual bellows  401 . The “large” label was applied to individual bellows  401  three steps earlier in the process by cassette  100  cooperating with sensors known in the art. As shown in  FIG. 1 , individual bellows  404  is in the process of having a “large” size label transferred to its upper surface  404   a  from label cassette  100 . That label will be applied in three successive steps to the “large” produce item  601   b . By situating each of the three label cassettes  100 ,  200  and  300  as shown in  FIG. 1 , a single multi-cassette labeling station is provided for applying different size or grading labels to either different sized or different graded produce moving past rotary bellows applicator  400 . 
   A significant feature of the invention is the orientation of the guide plates  102 ,  202  and  302 , respectively, relative to the outer or circumferential surface of rotary bellows applicator  400 . This angular relationship is illustrated by the axis X-X which is aligned with the guide plate  302  of label cassette  300  and the axis Y-Y which is tangential to the upper surface of rotary bellows applicator  400  adjacent the stripper edge or tip  305  of guide plate  302 . The angular relationship is shown as angle φ. The angle φ is preferably in the range of 30° to 60° but can range from 10° to 90°. This angular relationship is shown most clearly in  FIG. 8 , where guide plate  3202  forms angle φ with the upper surface  405   a  of rotary bellows applicator  405 , at a point in time when the upper surface  405   a  is adjacent the stripper edge  3305  as shown in  FIG. 8 . It is significant to note that prior art label cassettes known to the applicant must be aligned relative to a rotary bellows applicator so that the angle φ is zero degrees. This prior art design requirement would cause each of the label cassettes to be rotated approximately 30° clockwise in  FIG. 1  about the tips  105 ,  205  and  305  of the guide plates. Such realignment of the cassettes has the consequence that only two of the cassettes of  FIG. 1  could be arranged in the coplanar fashion above the rotary bellows applicator  400  if φ were zero. 
   The manner in which the labels are stripped from guide plates  102 ,  202  and  302  is shown and described in U.S. patent application Ser. No. 11/227,723 filed Sep. 14, 2005 (incorporated herein by reference) and is briefly described below in the interest of brevity. 
     FIG. 2  illustrates the system of  FIG. 1  wherein the conveyor  500  and rotary bellows applicator  400  have moved one step in the direction of arrows  501  for the conveyor and  412  for the applicator. In this step, the individual bellows  401  has rotated counterclockwise one step and has been retracted. Bellows  402  has expanded fully in order to apply a “small” label to produce item  603   a . The “small” label was transferred from label cassette  300  to rotary bellows  402  six steps earlier when sensors known in the art detected the “small” produce item  603   a.    
     FIGS. 3 and 4  illustrate a second embodiment of the invention wherein four label cassettes  1100 ,  1200 ,  1300  and  1400  are positioned in a coplanar fashion around and above rotary bellows applicator  1900 . The angle φ between guide plate  1402  and the outer circle described by the perimeter of rotary bellows applicator  1900  is approximately 50°. This angular relationship allows the use of four label cassettes as opposed to the three cassettes utilized in  FIGS. 1 and 2 . As the angle φ is increased, it becomes possible to use a greater number of cassettes, each of which is somewhat smaller than is the case when a lower number of cassettes is utilized. It is important that the cassettes be arranged in a coplanar fashion in order to apply the labels to the center of each individual bellows. It is also important that the cassettes form an arc not substantially more than 180° in order to remain comfortably above the conveyed produce. 
     FIG. 3  illustrates an “extra large” label being applied to produce item  1601   a  by individual bellows  1901 . 
     FIG. 4  illustrates the system of  FIG. 3  wherein the conveyor  1500  and the rotary bellows applicator have been moved in the direction of arrows  1501  and  1912  one step. The extra large produce item  1601   a  has moved one step to the right in  FIG. 4  from that illustrated in  FIG. 3 . The individual bellows  1901  has rotated one step in a counterclockwise direction from that shown in  FIG. 3 . In  FIG. 4  rotary bellows applicator  1902  is shown fully extended and applying a “small” label to produce item  1603   a.    
     FIG. 5  illustrates another aspect of the invention wherein three label cassettes  2100 ,  2200  and  2300  are aligned in a coplanar fashion and arranged angularly above rotary bellows applicator  2400 . In this embodiment, a print head  2800  is positioned below and adjacent to label cassette  2100 . The purpose of print head  2800  is to apply a printed legend on each label before the label is applied to a produce item. The printed legend, for example, may include a PLU (Product Look Up) code number or bar code. The three label cassettes  2100 ,  2200  and  2300  may carry the same labels or alternatively carry three different pre-printed labels, e.g. brand names such as “Sunkist” and other known brands, to be print coded on application. 
     FIG. 6  illustrates the prior art Rietheimer mechanism referred to at page  1  above. 
     FIGS. 7 and 8  herein are reproductions of FIGS. 3 and 7, respectively, from the parent U.S. application Ser. No. 11/227,723, and are included here along with the description below to describe the stripping edge used in conjunction with the present invention. For a more complete description, see the &#39;723 application. 
     FIG. 7  herein shows a produce labeler portion  3201  incorporating a guide plate used in a removable label cassette according to the present invention generally referenced  3202 . A two-part split style backing tape or carrier strip  3203  carrying a number of adhesive labels, such as those referenced  3204  and  3205 , respectively, is folded around the guide plate. The guide plate has, at its lower extremity, a stripping edge  3206  around which the tape is pulled causing it to be effectively folded back on itself. Stripping edge  3206  is unnotched when compared to LaMers U.S. Pat. No. 4,217,164. Stripping edge  3206  is square to or perpendicular to the axis of motion  3214  of the labels, and is essentially a straight edge bent upwardly at its center. Stripping edge  3206  forms a straight line perpendicular to the axis of motion  3214  of the labels. As the tape or carrier  3203  is pulled around the stripping edge  3206  of the guide plate  3202 , the label  3204 ,  3205  continues to move in a forward direction shown by arrows  3214 , i.e. the label  3205  remains substantially square to the run of the tape  3203  and the label&#39;s forward motion follows the direction of travel of the tape  3203  before having reached the stripping edge  3206 . Arrows  3214  also indicate the “axis of motion” of labels  3204 ,  3205 . 
   The underneath of the guide plate which is, in this embodiment, the region preceding the stripping edge  3206 , has a surface which is bent or bowed across the run of the tape (and across the axis of motion of the labels) and, because of the way the tape is strung around the edge, must encounter the underside of the plate as or before the tape reaches the stripping edge. Each of the backing tape halves  3208  and  3209  runs on one of the flat sides  3202   a  and  3202   b  of guide plate  3202 . In this configuration, the bent surface is essentially triangular or V-shaped in cross-section formed by two flat sides  3202   a  and  3202   b  of guide plate  3202 , with an apex angle of between 150° and 170°, and preferably approximately 160°. At this angle, advantageous separation occurs because the label  3205  is forced or bent about its axis of motion into a shallow ‘V’ formation, thus momentarily imparting sufficient stiffness into the label  3205  along its axis of motion to cause it to separate from the carrier as the carrier reverses direction at the stripping edge  3206 . As presented in  FIG. 7  herein, the top surface of the labels would be the adhesive side of the labels. 
   A fin  3207  is provided as a centering guide and separates the backing tape halves  3208  and  3209  from each other. Fin  3207  is located in close proximity to the edge  3206 , and is preferably formed as an integral part of the guide plate  3202 . The fin  3207  centers the split line between strips  3208  and  3209 , causing each strip to run on opposite sides  3202   a  and  3202   b  of the V-shaped guide plate  3206 , thereby centering the labels as well. The tension in each of the two parts  3208  and  3209  of the split, two part carrier strip, is kept uniform across the width of the carrier strip  3203 . Fin  3207  assures that the labels are bent in their middle to maximize the momentary stiffness of each label as it is stripped. 
   On the far side of the guide plate  3202  shown in  FIG. 7  herein, a spacer  3210  is provided which extends essentially parallel to the top surface of the guide plate and along one of the lateral edges in order to allow the guide plate to be fixed into a produce labeler. A spacer is commonly used in such circumstances to provide operational clearance and may take a number of forms. Such a spacer may also be attached to either side  3202   a ,  3202   b  of the guide plate  3202 . 
     FIG. 8  herein is a schematic representation of the present invention showing how guide plate  3202  and the axis of motion of labels, such as  3205 , forms an angle φ with respect to upper surface  405   a  of bellows  405  as shown, for example, in  FIG. 1 . Angle φ may range from 10° to 90°, but preferably is between 30° to 60°. 
   The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teaching. The embodiments were chosen and described to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best use the invention in various embodiments and with various modifications suited to the particular use contemplated. The scope of the invention is to be defined by the following claims.