Brevet 1

USO10988276B2
( 12) United States Patent ( 10 ) Patent No.: US 10,988,276 B2

McNestry et al. (45) Date of Patent : Apr. 27, 2021
( 54 ) MACHINE AND METHOD FOR ITS ( 58 ) Field of Classification Search
OPERATION CPC B65C 9/0006 ; B65C 9/18 ; B65C 9/1803 ;
B65C 9/1865 ; B65C 9/1892 ; B65C 9/40 ;
( 71 ) Applicant: VIDEOJET TECHNOLOGIES INC . , (Continued )
Wood Dale , IL (US )
( 72 ) Inventors : Martin McNestry, Derbyshire (GB ); ( 56 ) References Cited
Gary Pfeffer, Northamptonshire ( GB ) ;
Philip Hart , Nottinghamshire ( GB ) ; U.S. PATENT DOCUMENTS
James Butcher , Nottinghamshire (GB ); 4,288,272 A * 9/1981 Pfeffer B65C 9/1869
Steven Buckby , Nottinghamshire ( GB ) 156/361
(73 ) Assignee : VIDEOJET TECHNOLOGIES INC . , 2011/0132544 A1 * 6/2011 MeNestry B65C 9/1865
156/361
Wood Dale , IL (US )
* cited by examiner
( * ) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 Primary Examiner George R Koch
U.S.C. 154 ( b ) by 102 days.
(74 ) Attorney, Agent, or Firm Wolter Van Dyke Davis ,
( 21 ) Appl . No .: 16 /059,809 PLLC ; Robert L. Wolter
( 22 ) Filed : Aug. 9 , 2018 ( 57) ABSTRACT
( 65 ) Prior Publication Data A labelling machine comprises a supply spool support for
US 2019/0039771 A1 Feb. 7, 2019 supporting a supply spool comprising label stock compris
Related U.S. Application Data ing a web and a plurality of labels attached to the web and
which are separable from the web ; a take -up spool support
( 62 ) Division of application No. 14/ 438,549 , filed as adapted to take up a portion of web ; a motive means
application No. PCT/GB2013 /052934 on Nov. 7 , configured to propel the web along a web path from the
2013 , now Pat . No. 10,065,760 . supply spool support towards the take up spool support. A
sensor has a transmitter portion and a receiver portion , the
( 30 ) Foreign Application Priority Data receiver portion comprising a plurality of receivers, the
transmitter portion and receiver portion are configured to
Nov. 7 , 2012 (GB ) 1220059 receive a portion of the label stock therebetween , and the
Nov. 7 , 2012 ( GB ) 1220060 plurality of receivers are each configured to produce a
( Continued ) respective sensor signal which is a function of a property of
portion of label stock at a plurality of positions spaced
( 51 ) Int . Cl. from one another in a direction non -parallel to the web path .
B65C 9/42 ( 2006.01 ) In addition, a controller is configured to monitor each of the
B65C 9/18 (2006.01 ) sensor signals produced by the receivers and to select one of
( Continued ) the sensor signals produced by the receivers based on said
( 52 ) U.S. CI . monitoring of each of the sensor signals produced by the
CPC B65C 9/42 ( 2013.01 ) ; B65C 970006 receivers .
(2013.01 ) ; B65C 9/1865 ( 2013.01 ) ;
( Continued ) 16 Claims , 31 Drawing Sheets
10 ? 28 32 12
©
O
30 22 24 26 14
US 10,988,276 B2
Page 2
( 30 ) Foreign Application Priority Data

Nov. 7 , 2012 ( GB ) 1220063
Nov. 7 , 2012 ( GB ) 1220067
Nov. 7 , 2012 ( GB ) 1220070
Oct. 11 , 2013 (GB ) 1318068
(51 ) Int. Ci.
B65C 9/00 ( 2006.01 )
B65C 9/26 ( 2006.01 )
B65C 9/40 ( 2006.01 )
( 52 ) U.S. CI .
CPC B65C 9/1892 ( 2013.01 ) ; B65C 9/26
(2013.01 ) ; B65C 2009/0087 (2013.01 ) ; B65C
2009/0096 (2013.01 ) ; B65C 2009/404
( 2013.01 )
( 58 ) Field of Classification Search
CPC B65C 9/42 ; B65C 9/46 ; B65C 9/2009 ;
B65C 9/0087 ; B65C 2009/0096 ; B65C
2009/402 , B65C 2009/404 ; B21C 47/30
USPC 156/361 , 378 , 538 , 542 , DIG . 44 ,
156 /DIG . 45 , DIG . 46 ; 242/586 , 586.4 ,
242 / 587.2
See application file for complete search history.
U.S. Patent Apr. 27, 2021 Sheet 1 of 31 US 10,988,276 B2
10 A 28 32 12
30
Case 22 24 26 14
B
Fig . 1
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U.S. Patent Apr 27, 2021 Sheet 21 of 31 US 10,988,276 B2
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S1
Determine
dancing arm
position
S2
Brake under
PID control
S3
Tension label
web
S4
Determine
take up spool
diameter
S5
Fig . 31
Determine label
pitch length
S6
Position S8
leading edge Determine /
at beak update supply
spool diameter
S7
Ready to S9
operate Update take
up spool
diameter
400
410a 414 426 30 408

412 12
14 40
406
416 418
410
4105 424 422 404 420 h
403 402
Fig . 32
Speed /step rate

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Target
No Steps/distance
PosN sensor
edge detect No
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Fig . 33
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triggered ? No Ng?N ? deceleration
Yes Yes step rate
No
Count line S29 S41 Calculate S42
encoder pulses Too fast? deceleration
Yes step rate
S30 No
Count = Rd No S43
Yes Too slow ?
No
Time S26 Yes
registration delay No S44
Set to target
Yes rate
Start timer S27 S45
Acceleration Constant step S46
S28 possible ? No rate
Time = Rtd
No Yes
Yes S47 Calculate S48
S31 Too slow ? acceleration
Set feed profile Yes step rate
No
S49
Start feed S33
Too fast?
No
Ng= Nafif known) Yes
Cr = 0 S50
Set to target
rate
Calculate No S34
S36 Step motor S52 Step motor at S51
Edge S35 target rate determined rate
detected and No not Ng = No
known ? Yes
No S38
S37 Decrease steps S53
Ng = 0 ?
No
Yes
END FEED to feed Fig . 34
E1
Monitor
encoder
E2
Encoder
update No
available
Yes
E3 E4
Moved Yes Ng = Ng - Ed
forwards
No
E5
Ng = Ng + Ed
Fig . 35
US 10,988,276 B2
1 2
MACHINE AND METHOD FOR ITS roller. The label stock is often pressed against the capstan
OPERATION roller by a nip roller, in order to mitigate risk of slip between
the capstan roller and the label stock . For the reliable
CROSS - REFERENCE TO RELATED running of such machines the nip /capstan mechanical
APPLICATIONS 5 arrangement is designed so as to ensure respective axes of
the two rollers are substantially parallel to one another and
This application is a divisional of application Ser. No. that the pressure exerted by the nip roller (which is typically
14 /438,549 , filed on Apr. 24 , 2015 , now U.S. Pat . No. sprung loaded ) is generally even across the width of the label
10,065,760 . Application Ser. No. 14 /438,549 is a National carrying web . This often results in relatively expensive and
Stage entry (“ a 371 of international ” ) of Application No. 10 complex mechanical arrangements , and it is often a time
PCT/GB2013 /052934 , filed Nov. 7 , 2013 , both of which are consuming process to load the machine with a supply spool
hereby incorporated in their entirety. of label stock and feed the label stock from the supply spool
The present invention relates to a labelling machine and support to the take -up spool support, through the nip /capstan
particularly to a labelling machine for use with label stock rollers, before the labelling machine is operated. This is
comprising a web and a plurality of labels attached to the 15 because the nip roller has to be temporarily disengaged or
web and which are separable from the web . Such machines removed to allow the web of the label stock to be positioned
are sometimes referred to as “ roll - fed self - adhesive labelling along the web path between the supply spool support and the
machines " . take up spool support. The nip roller is then repositioned
A label stock comprising a web carrying labels is usually such that the label stock is pressed against the capstan roller
manufactured and supplied as a wound roll ( hereinafter 20 by the nip roller and the web of the label stock can be moved
referred to as a spool ) . For a given spool , all the labels are between the spool supports by rotation of the capstan roller.
typically the same size , within manufacturing tolerances . Furthermore, in such labelling machines, the take -up
However, in some instances, this is not the case . spool (and hence the take up spool support) itself typically
Labels are commonly used to display information relating needs to be driven in order to maintain adequate tension in
to an article and are commonly disposed on the article such 25 the web , between the nip /capstan roller and the take - up
that the information is easily readable either manually or spool support. If the tension is too low , the web can become
automatically . Such labels may, for example, display prod- wrapped around the capstan roller, causing the machine to
uct information , barcodes , stock information or the like. fail, and if the tension is too high , the capstan roller can be
Labels may be adhered to a product or to a container in “ over -driven ” by the take -up spool support, resulting in the
which the product is packaged . 30 web being fed at the wrong speed , or indeed the web
In the manufacturing industry, where such labels are read snapping. The drive for the take -up spool support must also
automatically, it is important for the information to be deal with the changing diameter of the take -up spool which
printed such that it is clear and positioned accurately so that carries the web from which labels have been removed . This
an automated reader can consistently and correctly read the is because the diameter of the take - up spool increases from
information . 35 an initial value where the take - up spool is empty , to a value
Some known labelling machines apply pre -printed labels many times greater than the initial value , when the supply
to an article. Other known labelling machines print infor- spool is exhausted.
mation onto labels immediately before printed labels are Known tape drives of labelling machines have mecha
applied to an article . Such labelling machines may be nisms for achieving appropriate drive of the take -up spool
referred to as print and apply labelling machines . 40 including so - called slipping clutch arrangements. The take
It is desirable to be able to advance a web of labels to be up spool support may either driven by an independent drive
applied to an article accurately, so as to ensure that print is means, such as a variable torque motor, or driven via a
accurately positioned on the label and / or to ensure that the pulley belt and gears from a motor driving the capstan roller.
label is accurately positioned on the article. This may be Tape drive mechanisms which rely upon capstan rollers
particularly important in print and apply labelling machines 45 add cost and complexity to the labelling machine , and have
in which printing is typically carried out while the label the disadvantages referred to above.
moves relative to the printhead , making accurate control of Another known problem associated with nip / capstan
the label ( and hence the label stock ) important if printing is roller arrangements of the type described above is that the
to be properly carried out such that the desired information pressure exerted by the nip roller onto the web and against
is correctly reproduced on the label . 50 the capstan roller can cause label adhesive to “ bleed ” out,
Given that labels are often removed from the moving web over time , from the edges of the label . This adhesive can
by passing the label stock under tension around a labelling eventually build up on the capstan or nip rollers. This
peel beak ( sometimes referred to as a peel beak , a peel blade adhesive can then cause the label stock to stick to the rollers
or a label separating beak) , it is sometimes desirable to such that it is not transported properly along the desired web
ensure that a predetermined optimum tension in the web of 55 path. Furthermore, it is common for labels to be accidentally
the label stock is maintained . In some applications, it is also removed from the web and become attached to the capstan
desirable that the label stock can be moved at a predeter- roller or nip roller, impeding proper operation of the label
mined speed of travel along a defined web path , so as to ling machine.
ensure that the speed at which labels are dispensed is It is therefore desirable in the manufacturing industry for
compatible with the speed at which products or containers 60 there to be means and a method for transporting a label stock
move along a path adjacent the device. and applying labels from the web of the label stock to a
A known labelling machine comprises a tape drive which product or container, which is accurate , reliable, simple to
advances the label stock from a supply spool support to a use and adaptable to different applications .
take up spool support. The tape drive has a capstan roller of A further problem with known labelling machines is that
known diameter which is accurately driven to achieve 65 certain components of the labelling machine may operate at
desired linear movement of the label stock along the web different speeds. For example , a labelling peel beak may
path . This capstan roller is also often referred to as a drive operate at a faster speed than a printer. That is to say, label
US 10,988,276 B2
3 4
stock can pass the labelling peak beak at a speed which is applied to an article, thereby reducing the throughput of the
greater than the speed at which the label stock can pass the labelling machine and /or conveyor.
printer. In labelling machines in which components of the Another problem with known print and apply labelling
labelling machine operate at different speeds , the operating machines of a “ last label out' configuration is that it may not
speed of the slower component may dictate the speed at 5 be possible to locate such a machine adjacent a conveyor of
which the label stock is advanced along the entire web path . a production line such that the labelling machine can apply
Consequently, the operating speed of the slower component labels beneath a certain height on an article conveyed by the
may limit the throughput of the labelling machine. conveyor.
Some embodiments of labelling machine which incorpo Known tape drives of labelling machines have mecha
rate a printer
machines . A may be referred
known type ofto print
as printandandapply
apply labelling
labelling 10 including
nisms for achieving appropriate drive of the take -up spool
machine is a ' last label out ' labelling machine. ' Last label up spool support so - called slipping clutch arrangements. The take
out’labelling machines function so as to print a specific label drive means , suchmay be either driven by an independent
for a specific article and then apply that label to the specific a pulley belt and gearsvariable
as a
from a
torque motor, or driven via
motor driving the capstan
article . For example, a ‘ Last label out ’ labelling machine 15
may operate such that for each article that passes the roller.
labelling machine a unique label is printed and then applied Some known labelling machines include a braking assem
to the article . In some ‘ last label out' machines the printed bly. The braking assembly may include at least one com
label differs for each article, whereas in other “ last label out ponent that is subject to wear over time . Once said at least
machines the printed label may differ during the course of 20 one component of the braking assembly has worn to the
a production batch passing the labelling machine . extent that performance of the labelling machine is unac
Due to the fact that “ Last label out ' labelling machines ceptably adversely affected then said at least one component
may print a unique label for each article before it is applied may require replacement. In order to replace said at least one
to the article, it is common for the printer of the labelling component it may require that the labelling machine is shut
machine to be located in close proximity to the labelling peel 25 down at an inconvenient time which results in down time of
beak . The location of the printer adjacent the labelling peel a production line of which the labelling machine forms part.
beak may make the portion of the labelling machine which A further problem with known labelling machines is that
includes the labelling peel beak bulky. it is difficult for an operator of the labelling machine to
Certain known label and / or barcode positioning standards assess the amount of label stock that remains on the supply
require that labels incorporating a barcode are applied by the 30 spool support at any given time and to act appropriately on
labelling machine at a particular position on an article . For the basis of diminishing label stock remaining on the supply
example, if the labelling machine is configured to apply spool support.
labels to articles which pass the labelling machine on a A further problem with known tape drives is that it may
conveyor, then known label positioning standards may not be possible to determine the width of the tape ( in the case
necessitate that the labelling machine is configured to apply 35 of a labelling machine , the label stock) moved by the tape
labels to each article on the conveyor at less than a prede- drive . The ability to determine the width of the tape may be
termined height from the conveyor and at a less than a useful in determining at least one operating characteristic of
predetermined distance from a front edge of the article. the tape drive , for example the tension required in the tape .
In cases where known print and apply labelling machines Given that known tape drives are not capable of determining
of the ‘ last label out type are required to apply labels to 40 the width of the tape , they may require a user to manually
articles at a relatively low height from a conveyor, due to the supply information as to the width of the tape . The supply of
fact that the portion of the labelling machine which includes such information is susceptible to human error and incorrect
the labelling peel beak is bulky, it may not be possible to information as to the width of the tape may result in
position such a known print and apply labelling machine of sub - optimal performance of the tape drive .
the ‘ last label out' type adjacent the conveyor such that 45 It is an object of embodiments of the present invention to
labels can be printed and subsequently applied to an article obviate or mitigate one or more of the problems of known
at a position adjacent the labelling peel beak and printer of labelling machines whether set out above or otherwise,
the labelling machine . and / or to provide an alternative labelling machine .
In order to solve this problem , known print and apply According to an aspect of the present invention there is
labelling machines of the “ last label out ' type may be located 50 provided a labelling machine comprising a supply spool
at a position such that the labelling peel beak and printer are support for supporting a supply spool comprising label
remote from the conveyor ( and hence articles on the con- stock ; a take - up spool support adapted to take up a portion
veyor). The labelling machine may also incorporate a tamp of web ; a motive means configured to propel the web along
( or any other appropriate label transfer device ) which is a web path from the supply spool support towards the take
controllably moved so as to transfer each label from the 55 up spool support, a printer for printing on the labels, the
labelling peel beak of the labelling machine and subse- printer being configured to perform a printing operation at a
quently apply it to the required position on each article . first linear speed as labels pass along the web path ; a
However, the use of a tamp (or any other appropriate label labelling component configured to perform a labelling
transfer device ) in this manner may be disadvantageous. operation at a second linear speed ; and a path length adjuster
For example, the label transfer means will increase the 60 comprising a movable member configured to contact a
complexity and cost of the labelling machine . In addition , portion of the label stock and define a portion of the web
the label transfer device is an additional component of the path between the printer and the labelling component; an
labelling machine which may fail, thus causing the labelling actuator configured to move the movable member so as to
machine to become inoperable. Furthermore, the time it modify a length of the web path between the printer and the
takes for a printed label to be transferred by the label transfer 65 labelling component; and a controller configured to control
device from the labelling machine to the desired article on the actuator and motive means so as to permit a first portion
the conveyor may increase the time it take for labels to be of the label stock to pass the printer at the first linear speed
US 10,988,276 B2
5 6
and a second portion of the label stock to pass the labelling where S , is the first linear speed and S2 is the second linear
component at the second linear speed . speed.
By enabling a first portion of the label stock to pass the The label stock may comprise a region to be printed on
printer at the first linear speed and a second portion of the and an adjacent region which is not to be printed upon ; and
label stock to pass the labelling component at the second 5 the controller may be configured to control the actuator and
linear speed, both the printer and labelling component can motive means so as to advance the region to be printed on
operate at their own speed and it is not necessary for both to
operate at the same speed, which may be the slower of the past the printer at the first linear speed , and simultaneously
printing speed and labelling component speed . This may decreasethetheactuator
control
length
to move the movable member so as to
of the web path between the printer and
leadTheto first
an increase in throughput
linear speed may be lessof the
thanlabelling machine
the second linear. 10 the labelling
speed . In other cases , the first linear speed may be greater not to be printed on past; and
component the advance
printer atthea region which isis
speed which
than the second linear speed . greater than the second linear speed , and simultaneously
control the actuator to move the movable member so as to
The motive means may comprise a motor configured to increase
rotate the take up spool support. the length of the web path between the printer and
The motor may be selected from the group consisting of 15 theThelabelling component.
a DC motor, an open - loop position controlled motor (e.g. a ber movable member may oscillate . The movable mem
stepper motor) and an closed loop position controlled motor maybe configured to increase the length of the web path
( e.g. a torque controller motor, such as a DC motor, together between the printer and labelling component and subse
with an appropriate positional sensor and feedback control quently decrease the length of the path between the printer
circuit ) . However any suitable motor may be used . Those 20 and the labelling component. This may occur repetitively.
skilled in the art will be aware of control schemes which are The labelling component may comprise a label applicator
suitable to control rotation of the motors to achieve the located in a location along said web path between said take
methods described herein , depending upon the type of motor up and supply supports and arranged to separate labels from
selected for use . Those skilled in the art will further be aware the web for application to a receiving surface .
of the relative merits of various motor types and will be able 25 The labelling machine may be arranged to apply pre
to select a suitable motor type on that basis . printed labels to packages in a product packaging facility.
The printer may be a thermal printer. The printer may be The printer may be arranged to print onto labels prior to
a thermal transfer printer. application of labels onto the receiving surface. The labels
The printer may be upstream , having regard to the direc- printed upon may be pre -printed.
tion of movement of the label stock from the supply spool 30 The label stock may comprise labels which are spaced
support to the take up spool support, of the labelling from one another along the web .
component. In other cases , the printer may be downstream , Within the description , label stock may be used to refer to
having regard to the direction of movement of the label stock the web with attached labels . Label stock may also be used
from the supply spool support to the take up spool support, to refer to a portion of web from which labels have been
of the labelling component. 35 separated.
The label stock may comprise a web and a plurality of According to another aspect of the present invention there
spaced labels attached to the web and which are separable is provided a method of operating a labelling machine, the
from the web, and the labelling component may be a labelling machine comprising a supply spool support for
labelling peel beak . The labelling component may be any supporting a supply spool comprising label stock ; a take- up
other appropriate labelling component. 40 spool support adapted to take up a portion of web ; a motive
The actuator and movable member may be configured means ; a printer for printing on the labels ; a labelling
such that the actuator moves the movable member in a component; a path length adjuster comprising a movable
generally linear manner . The actuator and movable member member; an actuator; and a controller; wherein the method
may be configured such that the actuator moves the movable comprises the motive means propelling the web along a web
member in any appropriate manner, for example , in an 45 path from the supply spool support towards the take up spool
arcuate manner . support; the printer performing a printing operation on a
The labelling machine may further comprise a generally portion of the label stock at a first linear speed ; the labelling
linear guide configured to guide the generally linear move- component performing a labelling operation on a portion of
ment of the movable member. The labelling machine may the label stock at a second linear speed ; the movable member
further comprise a generally arcuate guide configured to 50 contacting a portion of the label stock and defining a portion
guide the generally arcuate movement of the movable mem- of the web path between the printer and the labelling
ber. component; the actuator moving the movable member so as
The movable member may comprise a roller and a portion to modify a length of the web path between the printer and
which is mechanically linked to the actuator. the labelling component; and the controller controlling the
The actuator may comprise a stepper motor. Any other 55 actuator and motive means so that a first portion of the label
appropriate actuator may be used to control the position of stock passes the printer at the first linear speed and a second
the movable member. portion of the label stock passes the labelling component at
The controller may be configured, for a given time t , to the second linear speed .
control the actuator to move the movable member so as to Any of the features described in relation to the labelling
change a length of the web path between the printer and the 60 machine above may be applied to the method above .
labelling component by an amount LPL given by : According to another aspect of the invention , there is
provided a labelling machine comprising a supply spool
support for supporting a supply spool comprising label stock
LPL =
Si - S2 comprising a web and a plurality of labels attached to the
t 65 web and which are separable from the web ; a take-up spool
support adapted to take up a portion of web ; a first motive
means configured to propel the web along a web path from
US 10,988,276 B2
7 8
the supply spool support towards the take up spool support, spool support, and a flexible elongate member which
the first motive means comprising a first motor including a extends between the first and second pulleys.
first stator and a first rotor ; a labelling peel beak located The labelling machine may further comprise a linkage
along the web path and configured to peel the labels from which links the first rotor and one of the supply spool
label web as the label stock passes the labelling peel beak ; 5 support and the take -up spool support, such that rotation of
and a printer for printing on the labels, the printer including the first rotor is transmitted to said one of the supply spool
a ribbon supply spool support for supporting a ribbon supply support and take -up spool support via said linkage, and
spool comprising printer ribbon for the printer, a ribbon wherein the linkage is located on said one side of the first
take -up spool support adapted to take up a portion of the surface of the base plate .
printer ribbon , and a second motive means configured to 10 Although the above -described aspects of the invention
propel the printer ribbon from the supply spool support relate to a labelling machine and a method of controlling a
towards the take up spool support, the second motive means labelling machine , it will be appreciated that the invention
comprising a second motor including a second stator and a may also be applied to a tape drive and method of control
second rotor; wherein the labelling machine further com- ling a tape drive . The tape drive may form part of a labelling
prises a base plate; wherein the following list of components 15 machine or a printer ( such as a thermal transfer printer ).
are mounted to the base plate such that the majority of each Whereas the tape in the labelling machine is label stock , the
component is located on one side of a first surface of the base tape in a printer may be a print ribbon .
plate , the list including: supply spool support, take-up spool According to a another aspect of the invention there is
support, first stator, labelling peel beak , ribbon supply spool provided a labelling machine comprising a supply spool
support, ribbon take- up spool support and second stator. In 20 support for supporting a supply spool comprising label
other embodiments, any of the components in the list may be stock ; a take -up spool support adapted to take up a portion
removed from the list . of the label stock ; a movable element which defines a
If the first surface of the base plate is an upper surface, portion of a web path between the supply spool and the
then mounting all of the listed components to the base plate take -up spool support; a sensor configured to produce a
such that the majority of each component is located on one 25 sensor signal indicative of the position of the movable
side of a first surface of the base plate means that very little element; a controller configured to receive the sensor signal
( if any of each of the components extends beyond a lower and output a brake assembly control signal based upon the
surface of the base plate . Consequently, the lower surface of sensor signal ; a brake assembly configured to apply a
the base plate may be located close to a conveyor of a braking force to one of said spool supports based upon the
production line, thereby reducing the minimum height above 30 brake assembly control signal, the braking force resisting
the conveyor at which the labelling machine can apply a rotation of said one of said spool supports ; wherein the
label . This may help the labelling machine to apply labels controller is configured to control the brake assembly based
which meet certain standards relating to the positioning of upon the sensor signal so as to cause the moveable element
labels . to move towards a desired position . In other words the
In some embodiments, at least one of the supply spool 35 controller is configured to control the brake assembly based
support, take-up spool support, first rotor, ribbon supply upon the sensor signal so as to urge the moveable element
spool support, ribbon take -up spool support and second rotor towards a desired position .
may include a shaft which extends through an aperture In some embodiments it may be desirable to urge the
between the first surface of the base plate and a second moveable element towards a desired position so that a path
surface of the base plate . 40 length of the web path between the supply spool and take - up
The first rotor and one of the supply spool support and spool (which is defined in part by the movable element) is
take - up spool support may each include a shaft which maintained substantially constant. In other embodiments it
extends through an aperture between the first surface of the may be desirable to urge the moveable element towards a
base plate and the second surface of the base plate , the desired position so as to reduce the likelihood that relative
labelling machine further comprising a linkage which links 45 movement between the take -up spool and the supply spool
the shaft of the first rotor and the shaft of said one of the will result in the movable element reaching a limit of its
supply spool support and take -up spool support, such that movement.
rotation of the shaft of the first rotor is transmitted to the Tension in the label stock may change based upon the
shaft of said one of the supply spool support and take - up position of the movable element and wherein the desired
spool support via said linkage, and wherein the second 50 position of the movable element may correspond to a desired
surface is between the first surface and the linkage. tension within the label stock .
The second rotor and one of the ribbon supply spool The labelling machine may further comprise a motive
support and ribbon take -up spool support may each include means configured to propel the web along the web path from
a shaft which extends through an aperture between the first the supply spool support towards the take up spool support;
surface of the base plate and the second surface of the base 55 and the controller may be configured to control the brake
plate , the labelling machine further comprising a ribbon assembly and the motive means based upon the sensor signal
drive linkage which links the shaft of the second rotor and so as to urge the moveable element towards a desired
the shaft of said one of the ribbon supply spool support and position .
ribbon take -up spool support, such that rotation of the shaft The desired position may be defined in any convenient
of the second rotor is transmitted to the shaft of said one of 60 way. For example a single position or a range of positions
the ribbon supply spool support and ribbon take -up spool may be specified. The controller may implement a control
support via said ribbon drive linkage, and wherein the algorithm to determine a control signal to be applied to the
second surface is between the first surface and the ribbon brake assembly ( and optionally the motive means) to cause
drive linkage . the moveable element to be urged towards the desired
The linkage may comprise a first pulley mounted to the 65 position . The control algorithm may be a PID ( proportional,
shaft of the first rotor and a second pulley mounted to the integral, derivative ) algorithm . The control algorithm may
shaft of said one of the supply spool support and take - up process data indicating a current position of the moveable
US 10,988,276 B2
9 10
element and data indicating the desired position and deter- ing surface and the first braking surface together to produce
mine the control signal based upon the processed data . said braking force. In other words , the motor may be
According to a further aspect of the invention there is configured to selectively urge the second braking surface
provided a labelling machine comprising a supply spool into contact with (or towards) the first braking surface to
support for supporting a supply spool comprising label 5 produce said braking force.
stock ; a take -up spool support adapted to take up a portion The motor may be a torque controlled motor. For
of the label stock ; a movable element which defines a example , the motor may be a DC motor in which the torque
portion of a web path between the supply spool and the applied by the motor is related to the current supplied to the
take - up spool support; a sensor configured to produce a motor, as is well known in the art.
sensor signal indicative of the position of the movable 10 The motor may be a position controlled motor. The
element ; and a brake assembly configured to apply a braking position controlled motor may be a stepper motor.
force to one of said spool supports based upon the sensor The brake assembly may comprise a brake disc mechani
signal, the braking force resisting rotation of said one of said cally linked to said one of said spool supports , the brake disc
spool supports; and wherein the brake assembly comprises having said first braking surface (which may be a circum
a frictional brake comprising a first braking surface 15 ferential surface of the brake disc ) ; and a belt passing around
mechanically linked to said one of said spool supports and at least part of the brake disc , the belt having said second
a second braking surface, the first and second braking braking surface. The motor may be mechanically linked to
surfaces being configured such that when the first and the belt .
second braking surfaces are urged together, friction between The motor may be mechanically linked to the belt via a
the first and second braking surfaces produces said braking 20 cam , wherein the motor and cam are configured such that
force . In other words, the first and second braking surfaces rotation of the motor produces rotation of the cam .
may be configured such that when the first and second The cam may be linked to a first portion of the belt , and
braking surfaces are urged into contact, friction between the a second portion of the belt is fixed against movement; and
first and second braking surfaces produces said braking wherein the cam is configured such that when it is rotated in
force 25 a first direction by the motor, the cam urges at least a portion
According to another aspect of the invention there is of the second braking surface towards the first portion of the
provided a labelling machine comprising a supply spool belt , thereby urging the second braking surface towards (e.g.
support for supporting a supply spool comprising label into contact with ) the first braking surface . In other words ,
stock ; a take - up spool support adapted to take up a portion the cam may urge at least a portion of the second braking
of the label stock ; a movable element which defines a 30 surface and the first portion of the belt together, thereby
portion of a web path between the supply spool and the urging the second braking surface and the first braking
take - up spool ; a sensor configured to produce a sensor signal surface together.
indicative of the position of the movable element; a con- The brake assembly may further comprise a controller and
troller configured to receive the sensor signal and output a a solenoid , wherein the controller is configured to receive
brake assembly control signal based upon the sensor signal ; 35 said sensor signal indicative of the position of the movable
and a brake assembly configured to apply a braking force to element, and configured to supply a control signal to the
one of said spool supports based upon the brake assembly solenoid to thereby apply said braking force to one of said
control signal, the braking force resisting rotation of said one spool supports based upon the sensor signal.
of said spool supports. The brake assembly may further comprise a solenoid ,
The label stock may comprise the web and a plurality of 40 wherein the controller may be configured to supply the brake
labels attached to the web and which are separable from the assembly control signal to the solenoid to thereby apply said
web . The web may be referred to as a backing. braking force to one of said spool supports based upon the
The label stock may comprise labels which are spaced brake assembly control signal.
from one another along the web . The solenoid may comprise a coil and an armature having
Within the description , label stock may be used to refer to 45 an extent of movement relative to the coil defined by first
the web with attached labels. Label stock may also be used and second end positions. The brake assembly may further
to refer to a portion of web from which labels have been comprise an armature position sensor configured to output
separated . an armature position signal which is indicative of the
The brake assembly may be controlled independently of position of the armature relative to the coil .
movement of the moveable element (which may be a 50 The controller may be configured to control current
dancing arm ), thereby allowing for greater control of the supplied to the coil based upon the armature position signal
labelling machine . In particular, movement of the moveable so as to urge the armature towards a desired position relative
element may cause tension in the label web to vary. This is to the coil which is intermediate the first and second end
the case where the movable element is biased by a spring positions . The desired position may be a desired rest posi
which generally obeys Hooke's law such that movement of 55 tion . That is to say , the controller may be configured to
the moveable member against that biasing force requires an control the current of the coil so as to attempt to position the
increasing force to be applied to the moveable element and armature at a desired position intermediate the first and
therefore increasing tension in the label web . In such a case second end positions . The armature may be biased towards
the relationship between movement of the moveable element one of the first and second end positions .
( and therefore tension in the label web ) and operation of the 60 One of the first and second braking surfaces may be
brake creates a potentially undesirable relationship between associated with the coil or the armature of the solenoid , and
web path length, web tension and braking force . Allowing the controller may be further configured to control the
independent control of the brake provides additionally flex- current supplied to the coil such that the solenoid urges the
ibility . second braking surface and first braking surface together (or
The labelling machine may further comprise a motor 65 into contact ).
mechanically linked to the second braking surface, the The armature position sensor may comprise a transmitter
motor being configured to selectively urge the second brak- configured to transmit electromagnetic radiation ; a reflective
US 10,988,276 B2
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element associated with one of the armature or coil and spool support rotation axis , and wherein the dancing arm
movable therewith during relative movement between the rotation axis is co - axial with one of the spool support
armature and the coil , the reflective element being config- rotation axes.
ured to reflect at least part of the electromagnetic radiation The dancing arm rotation axis may be co - axial with the
transmitted by the transmitter, and a receiver configured 5 spool support rotation axis of the spool support to which the
such that electromagnetic radiation transmitted by the trans- brake assembly is configured to apply said braking force .
mitter and reflected by the reflective element is incident on The sensor configured to produce a sensor signal indica
the receiver. tive of the position of the movable element may comprise a
The brake assembly may comprise a motor. magnetic sensor attached to one of the moveable element or
The motor may be a DC motor mechanically linked to 10 a portion of labelling machine which is fixed relative to the
said one of said spool supports which is configured to apply movable element; and a magnet attached to the other of said
said braking force to said one of said spool supports. It will movable element or said portion of the labelling machine .
be appreciated, however, that in alternative embodiments The magnet may be selected from the group consisting of
other types of motor may be used and appropriately con- is a multi-pole magnet and a plurality of magnets.
trolled . The labelling machine may further comprise a motive
The brake assembly may further comprise a controller means configured to propel the web along the web path from
configured to receive said sensor signal indicative of the the supply spool support towards the take up spool support.
position of the movable element, and configured to supply a The motive means may comprise a motor configured to
control signal to the DC motor to thereby apply said braking 20 rotate the take up spool support.
force to one of said spool supports based upon the sensor The motor may be selected from the group consisting of
signal. a DC motor, an open loop position controlled motor (e.g. a
The controller may be configured to supply the brake stepper motor) and a closed loop position controlled motor
assembly control signal to the DC motor to thereby apply (e.g. a torque controller motor, such as a DC motor, together
said braking force to one of said spool supports based upon 25 with an appropriate positional sensor and feedback control
the brake assembly control signal . circuit ). However any suitable motor may be used . Those
The motor may be a stepper motor mechanically linked to skilled in the art will be aware of control schemes which are
said one of said spool supports , the stepper motor compris- suitable to control rotation of the motors to achieve the
ing a plurality of motor windings and the brake assembly 30
methods described herein , depending upon the type of motor
further comprises a variable electrical impedance device selected for use . Those skilled in the art will further be aware
connected across at least one of said windings, the variable of the relative merits of various motor types and will be able
electrical impedance device being configured to vary the to select a suitable motor type on that basis .
electrical impedance across said at least one winding to The labelling machine may further comprise a controller
thereby vary said braking force applied to said one of said 35 configured to control the motive means and the brake
spool supports . assembly based upon the sensor signal so as to urge the
The brake assembly may further comprise a controller moveable element towards a desired position or range of
configured to receive said sensor signal indicative of the positions.
position of the movable element, and configured to supply a A tension in the label stock may change based upon the
control signal to the variable electrical impedance device 40 position of the movable element and the desired position or
based upon the sensor signal , to thereby vary the electrical range of positions of the movable element may correspond
impedance across said at least one winding and hence vary to a desired tension or range of tensions within the label
said braking force applied to said one of said spool supports. stock .
The controller may be configured to supply the braking The controller may be configured to determine the desired
assembly control signal to the variable electrical impedance 45 tension or desired range of tensions based upon at least one
device, to thereby vary the electrical impedance across said characteristic of the label stock .
at least one winding and hence vary said braking force Said at least one characteristic of the label stock may be
applied toassembly
braking said onecontrol
of saidsignal
spool. supports based upon the at least one of width and breaking strain . The width and
The labelling machine may be configured such that in a 50 breaking strain may be that of the web ,
The controllermaybe configured to determine at least one
powered down state of the labelling machine, the brake of said at least one characteristic of the label stock based
assembly applies a braking force applied to said one of said upon user input to the controller.
spool supports . This ensures that when the labelling machine The controller may be configured such that at least one of
is switched off or when power is removed from the labelling said at least one characteristic of the label stock is deter
machine, the brake is applied . 55
The brake assembly may further comprise a resilient mined by the controller based upon the sensor signal.
biasing member, the resilient biasing member being The labelling machine may further comprise a biasing
mechanically linked to one of the first and second braking member, the biasing member being configured to bias the
surfaces and being configured to urge the first and second movable member towards a home position and to exert a
braking surfaces together (or into contact with one another) . 60 force on the label stock via the movable member.
The resilient biasing member may be a spring . The labelling machine may further comprise a label
The movable element may be a dancing arm . The dancing applicator located in a location along said web path between
arm may be mounted such that it moves along any prede- said take up and supply spool supports and arranged to
termined path . For example the movement of the dancing separate labels from the web for application to a receiving
arm may be linear or arcuate . 65 surface .
Each of the supply spool support and take up spool The labelling machine may be arranged to apply pre
support may be mounted for rotation about a respective printed labels to packages in a product packaging facility .
US 10,988,276 B2
13 14
The labelling machine may further comprise a printer operated using a first spool of label stock which is the first
arranged to print onto labels prior to application of labels spool of label stock which is used by the labelling machine .
onto the receiving surface. The labels printed upon may be The output signal may indicate degradation in braking
pre -printed performance or wear of a portion of the braking assembly.
The labelling machine may further comprise a memory, 5 Generating data based upon applied braking may com
and the controller may be configured to monitor at least one prise monitoring the position of a moveable element. The
of the sensor signal and brake assembly control signal and movable element may define a portion of a web path
periodically, based upon the at least one of the sensor signal between a label supply spool and a label take -up spool .
and brake assembly control signal , update a value stored in A control signal may be provided to control said applied
the memory which is indicative of the accumulated use of 10 braking and generating data based upon applied braking may
the braking assembly, the controller further being configured comprise monitoring said control signal .
such that, when the value stored in the memory falls within Said at least one of the data generated based upon applied
a predetermined range , the controller outputs a signal indica- braking and the predetermined threshold may be stored on a
tive that maintenance of the braking assembly may be memory of the labelling machine.
required . 15 According to another aspect of the invention there may be
Because the controller outputs a signal which is indicative provided a labelling machine arranged to transport label
that maintenance of the braking assembly may be required carrying web from a supply spool support to a take up spool
before the braking assembly fails, it is possible to perform support and comprising means for removing labels from the
maintenance on the braking assembly at a convenient time web between said supply spool support and said take up
and not at a potentially inconvenient time at which failure of 20 spool support, and a brake assembly arranged to resist
the braking assembly actually occurs . movement of one of the supply spool support and the take
The value stored in the memory may fall within a prede- up spool support, the labelling machine further comprising
termined range if it is above a predetermined amount. The a controller arranged to carry out a method according to the
value stored in the memory may fall within a predetermined previously discussed aspect of the invention .
range if it is below a predetermined amount. 25 Although the above -described aspects of the invention
According to another aspect of the present invention there relate to a labelling machine and a method of controlling a
is provided a method of operating a labelling machine, the labelling machine , it will be appreciated that the invention
labelling machine comprising a supply spool support for may also be applied to a tape drive and method of control
supporting a supply spool comprising label stock ; a take -up ling a tape drive . The tape drive may form part of a labelling
spool support adapted to take up a portion of the label stock ; 30 machine or a printer ( such as a thermal transfer printer ).
a movable element which defines a portion of a web path Whereas the tape in the labelling machine is label stock , the
between the supply spool and the take -up spool support; a tape in a printer may be a print ribbon .
sensor ; and a brake assembly comprising a frictional brake According to a further aspect of the present invention
comprising a first braking surface mechanically linked to there is provided a tape drive suitable for a labelling machine
said one of said spool supports and a second braking surface; 35 or printer, comprising a supply spool support for supporting
wherein the method comprises the sensor producing a sensor a supply spool of tape; a take -up spool support adapted to
signal indicative of the position of the movable element; and take up a portion of said tape ; and a brake assembly
the brake assembly applying a braking force to one of said configured to apply a braking force to one of said spool
spool supports based upon the sensor signal, the braking supports , the brake assembly comprising a solenoid com
force resisting rotation of said one of said spool supports, 40 prising a coil and an armature having an extent of movement
wherein the first and second braking surfaces are urged relative to the coil defined by first and second end positions ,
together and friction between the first and second braking an armature position sensor configured to output an armature
surfaces produces said braking force . In other words, the position signal which is indicative of the position of the
first and second braking surfaces may be urged into contact armature relative to the coil , and a controller configured to
and friction between the first and second braking surfaces 45 control current supplied to the coil based upon the armature
produces said braking force . position signal so as to urge the armature towards a desired
According to a further aspect of the invention there is position relative to the coil which is intermediate the first
provided a method of monitoring operation of a braking and second end positions, the desired position applying a
assembly in a labelling machine, the method comprising desired braking force to said one of said spool supports .
generating data based upon applied braking; and generating 50 The tape drive may further comprise a first braking
an output signal if said generated data has a predetermined surface ; and a second braking surface ; wherein the first
relationship with a predetermined threshold . braking surface is associated with one of said spool supports,
Generating data based upon applied braking may com- and the second braking surface is associated with the coil or
prise generating data indicating cumulative applied braking. the armature of the solenoid , and wherein the controller is
Said predetermined threshold may be based upon opera- 55 further configured such that in a braking mode the solenoid
tion of the braking assembly in a first condition . controller controls the current supplied to the coil so as to
Said predetermined old is based upon average operation urge the first braking surface and second braking surface into
of the braking assembly in said first condition over a contact. In other words , the controller is further configured
predetermined time period. such that in a braking mode the solenoid controller controls
The first condition may occur when the labelling machine 60 the current supplied to the coil so as to urge the first braking
is operated using a first spool of label stock . The first spool surface and second braking surface together.
of label stock may be the first spool of label stock which is The armature position sensor may comprise a transmitter
used by the labelling machine after a maintenance operation configured to transmit electromagnetic radiation ; a reflective
has been carried out on the braking assembly, for example, element associated with one of the armature or coil and
the first spool of label stock may be used by the labelling 65 movable therewith during relative movement between the
machine immediately after the maintenance operation. The armature and the coil , the reflective element being config
first condition may occur when the labelling machine is ured to reflect at least part of the electromagnetic radiation
US 10,988,276 B2
15 16
transmitted by the transmitter; and a receiver in a fixed The manual brake release assembly may comprise a
positional relationship with respect to the other of said movable element which defines a portion of a web path
armature or coil , the receiver also being configured such that between the supply spool and the take -up spool.
electromagnetic radiation transmitted by the transmitter and The manual brake release assembly may include a first
reflected by the reflective element is incident on the receiver. 5 engagement member attached to the cam , such that move
According to another aspect of the invention there is ment of the first engagement member causes movement of
provided a labelling machine comprising a supply spool braking the cam , thereby causing said movement of the second
support for supporting a supply spool comprising label surface .
The movable element may comprise a second engagement
stock ; a take -up spool support adapted to take up a portion 10 member
of the label stock ; and a brake assembly configured to apply be configured; and the first and second engagement members may
a braking force to one of said spool supports, the braking by a user such such that the movable element may be moved
that the first and second engagement members
force resisting rotation of said one of said spool supports; engage such that
wherein the brake assembly comprises a frictional brake movement of themovement of the movable element causes
engaged first and second engagement
comprising a first braking surface mechanically linked to 15 members thereby causing movement of the cam and hence
said one of said spool supports and a second braking surface , said movement of the second braking surface .
the first and second braking surfaces being configured such According to another aspect of the invention there is
that when the first and second braking surfaces are urged provided a labelling machine comprising a supply spool
into contact ( or together ), friction between the first and support for supporting a supply spool comprising label
second braking surfaces produces said braking force; and a 20 stock ; a take -up spool support adapted to take up a portion
motor mechanically linked to the second braking surface, of the label stock ; a movable element which defines a
the motor being configured to selectively urge the second portion of a web path between the supply spool and the
braking surface and first braking surface together to produce take -up spool support; and a brake assembly configured to
said braking force. In other words , the motor may be apply a braking force to one of said spool supports, the
configured to selectively urge the second braking surface 25 braking force resisting rotation of said one of said spool
into contact (or together) with the first braking surface to supports; wherein the brake assembly comprises a frictional
produce said braking force . brake comprising a first braking surface mechanically linked
The motor may be a torque controlled motor. For to said one of said spool supports and a second braking
example, the motor may be a DC motor in which the torque surface , the first and second braking surfaces being config
applied by the motor is related to the current supplied to the 30 ured such that when the first and second braking surfaces are
urged into contact (or together, or towards one another ),
motor, as is well known in the art.
The motor may be a position controlled motor. The duces friction between the first and second braking surfaces pro
position controlled motor may be a stepper motor. said braking force; and wherein the brake assembly
The brake assembly may comprise a brake disc mechani 35 brake releasea assembly
comprises manual brake release assembly, the manual
being configured to move the second
cally linked to said one of said spool supports, the brake disc braking surface in a direction so as to reduce the braking
having said first braking surface; and a belt passing around force .
at least part of the brake disc , the belt having said second The manual brake release assembly may include a first
braking surface . The motor may be mechanically linked to engagement member mechanically linked to the second
the belt . 40 braking surface, such that movement of the first engagement
The motor may be mechanically linked to the belt via a member causes said movement of the second braking sur
cam , wherein the motor and cam are configured such that face .
rotation of the motor produces rotation of the cam . The movable element may comprise a second engagement
The cam may be linked to a first portion of the belt , and member; the first and second engagement members may be
a second portion of the belt is fixed against movement; and 45 configured such that the movable element may be moved by
wherein the cam is configured such that when it is rotated in a user such that the first and second engagement members
a first direction by the motor, the cam urges at least a portion engage such that movement of the movable element causes
of the second braking surface towards the first portion of the movement of the engaged first and second engagement
belt , thereby urging the second braking surface into contact members thereby causing said movement of the second
with ( or towards) the first braking surface . In other words , 50 braking surface .
the cam may urge at least a portion of the second braking According to an aspect of the invention there is provided
surface towards the first portion of the belt , thereby urging a labelling machine comprising a supply spool support for
the second braking surface and the first braking surface supporting a supply spool comprising label stock compris
together. ing a web and a plurality of labels attached to the web and
The labelling machine may be configured such that in a 55 which are separable from the web ; a take - up spool support
powered down state of the labelling machine , the brake adapted to take up a portion of web ;
assembly applies a braking force applied to said one of said a sensor configured to produce a sensor signal indicative
spool supports. of a periodic property of at least a portion of the label stock ;
The brake assembly may further comprise a resilient and a controller configured to calculate a displacement of the
biasing member, the resilient biasing member being 60 web a web path defined between the supply spool and the
mechanically linked to the cam or the second braking take -up spool based upon the sensor signal and a length of
surface and being configured to urge the first and second a component of the label stock .
braking surfaces into contact with ( or towards) one another. By measuring displacement of the web along the web path
The brake assembly may comprise a manual brake release as a function of the sensor signal, and hence as a function of
assembly, the manual brake release assembly being config- 65 a periodic property of a portion of the label stock , the
ured to move the second braking surface in a direction so as controller can monitor movement and / or position of the
to reduce the braking force . web .
US 10,988,276 B2
17 18
The sensor may be configured such that it does not contact upon the calculated displacement of the web and the rotation
the label stock . This may be advantageous in some appli- signal. That is , if it is known that a particular ( linear)
cations because , in some applications, a component which displacement of the web corresponds to a particular number
contacts the label stock may be prone to wear or has the (which need not be an integer number) of rotations of one of
potential to impair movement of the label stock or misalign 5 the spools , it is a straightforward matter to determine spool
the label stock . diameter (or radius ) using the known relationship between
The sensor may comprise an electromagnetic radiation spool diameter and spool circumference .
detector. Any suitable electromagnetic radiation may be The displacement of the web calculated by the controller
used as a basis for sensing including, for example , visible may be used to cause movement of web along the web path
light, infrared radiation and ultraviolet radiation . Any appro- 10 such that a target portion of the label stock is moved to a
priate electromagnetic radiation detector may be used . An desired position along the web path .
example of a suitable electromagnetic radiation detector is a The target portion of the label stock may be a leading edge
photovoltaic cell. of a label and the desired position is adjacent an edge of a
The sensor may further comprise an electromagnetic labelling peel beak . Any appropriate portion of the label
radiation source. Any appropriate radiation source may be 15 stock may be the target portion . For example, the target
used. Likewise, any appropriate electromagnetic radiation portion may be a trailing edge of a label, or a portion of a
source may be used . Examples of suitable electromagnetic label which is spaced from the leading or trailing edge of a
radiation sources include a light emitting diode and a laser. label by a predetermined distance. The target portion may be
The label stock may comprise labels which are spaced a portion of the web . For example the target portion may be
from one another along the web . 20 a portion of the web between adjacent labels . The desired
Within the description, label stock may be used to refer to position may be spaced a predetermined distance from an
the web with attached labels. Label stock may also be used edge of a labelling beak . The desired position may be any
to refer to a portion of web from which labels have been appropriate position along the web path . For example , the
separated. desired position may be adjacent a printer or may be
The property of at least a portion of the label stock may 25 adjacent a component of the labelling machine .
be the electromagnetic transmittance or reflectance of at The labelling machine may further comprise motive
least a portion of the label stock . means for advancing the label stock along the web path from
The periodic property may arise from the spatial arrange- the supply spool support to the take up spool support.
ment of labels on the web . For example the periodic property The motive means may comprise a motor configured to
may arise from the label length and / or spacing between 30 rotate the take up spool support. The motor may be config
adjacent labels . This may be because the labels , the web ured to rotate the take up spool support in the direction of
and / or web with attached label may have different properties transport of the label web .
which give rise to the periodic nature of a property of the The motor may be selected from the group consisting of
label web . a DC motor, an open loop position controlled motor (e.g. a
The sensor may be arranged to sense differences between 35 stepper motor) and a closed loop position controlled motor
a property of the web and a label attached thereto and a (e.g. a torque controller motor, such as a DC motor, together
property of the web . For example, the electromagnetic with an appropriate positional sensor and feedback control
transmittance of the label web with a label attached thereto circuit ). However any suitable motor may be used . Those
may be lower than the electromagnetic transmittance of the skilled in the art will be aware of control schemes which are
web without a label attached thereto . 40 suitable to control rotation of the motors to achieve the
The portion of the label stock may comprise the web and methods described herein , depending upon the type of motor
attached labels . selected for use . Those skilled in the art will further be aware
The length of a component of the label stock may be of the relative merits of various motor types and will be able
selected from the group consisting of a length of a label , a to select a suitable motor type on that basis .
pitch length between adjacent labels and a gap length 45 The motive means may include a motor configured to
between adjacent labels . rotate the supply spool support and / or a capstan roller which
Where the periodic property arises from the spatial engages the label web . The motor may be configured to
arrangement of the labels on web , the described method rotate the supply spool support and / or capstan roller in the
allows displacement of the web to be determined based upon direction of transport of the label web .
a number of labels (which need not be an integer number) 50 The controller may be configured to control the motive
which pass the sensor and a distance related to label length means to advance the label stock such that the target portion
( or label lengths in the case of label stocks having labels of the label stock is moved to the desired position (e.g. such
with differing lengths) in the direction of label web move- that a particular part of the label stocksuch as a label
ment and / or label spacing. edge — is positioned in a predetermined spatial relationship
The labelling machine may further comprise a rotation 55 with a label peel beak) .
monitor configured to monitor the rotation of one of said The sensor may be further configured to measure the
spool supports, the rotation monitor being configured to length of the component of the label stock .
output a rotation signal indicative of the rotation of said one The controller may be configured to determine the length
of said spool supports . Any appropriate rotation monitor of the component of the label stock based upon monitored
may be used and any appropriate method may be used to 60 rotation one of said spool supports during sensing of an
produce a rotation signal indicative of the rotation of the integer number of periods of said sensor signal . For
spool support. Various rotation monitors are described example, the controller may count the number of steps that
throughout the specification, any of which may be used . For the take up motor is commanded to advance for a single
example, rotation monitors using optical or magnetic sen- period of the sensor signal. Based on the number of steps the
sors can be employed . 65 take up motor is commanded to advance for a single period
The controller may be configured to calculate a diameter of the sensor signal and the diameter of the take up spool , the
of a spool supported by one of said spool supports based controller may determine a pitch length of the label stock . It
US 10,988,276 B2
19 20
will be appreciated that other similar parameters of the label Whereas the tape in the labelling machine is label stock , the
stock may be similarly determined . tape in a printer may be a print ribbon .
The controller may be configured to determine the length According to an aspect of the invention there is provided
of the component of the label stock based upon a diameter a labelling machine comprising a supply spool support for
of a spool supported by the spool support the rotation of 5 supporting a supply spool comprising label stock compris
which is monitored . Various methods of determining the ing a web and a plurality of spaced labels attached to the web
diameter of a spool support are described within this speci and which are separable from the web ; a take -up spool
support adapted to take up a portion of web ; a motive means
fication. Any of these methods may be used to determine the configured
diameter of the spool support. to propel the web along a web path from the
The labelling machine may further comprise a further 10 troller
supply spool support to the take -up spool support; a con
, and a sensor having a transmitter portion and a
sensor configured to measure the length of the component of receiver portion, the transmitter portion and receiver portion
the label stock .
The labelling machine may further comprise a label therebetween , andtoto receive
being configured a portion of the label stock
applicator located in a location along said web path between 15 function of a property of a portiona ofsensor
produce signal which is a
said take up and supply spool supports and arranged to of positions spaced from one another instock label
a
at a plurality
direction non
separate labels from the web for application to a receiving parallel to the web path.
surface. The label applicator may include a labelling peel By having a sensor which produces a sensor signal which
beak . is a function of a property of a portion of label stock at a
The labelling machine may be arranged to apply pre- 20 plurality of positions spaced from one another in a direction
printed labels to packages in a product packaging facility . non -parallel to the web path the a labelling machine accord
The labelling machine may further comprise a printer ing to the invention is better able to handle label stock which
arranged to print onto labels prior to application of labels includes labels which have an irregular shape, for example,
onto the receiving surface. The labels printed upon may be labels having a leading and / or trailing edge which is non
pre -printed. The labelling machine may be a print and apply 25 perpendicular to the web path . In particular, in some known
labelling machine. labelling machines sensors are used which produce a sensor
According to another aspect of the invention there is signal which is a function of a property of a portion of the
provided a method of controlling a labelling machine, the label stock only at a single point in a direction non -parallel
labelling machine comprising a supply spool support for to the label web . It has been appreciated that such sensors are
supporting a supply spool comprising label stock compris- 30 disadvantageous as , where the property of the label web
ing a web and a plurality of labels attached to the web and varies in the non -parallel direction, such variations cannot
which are separable from the web ; a take - up spool support be sensed by the sensor although knowledge of such varia
adapted to take up a portion of web ; a sensor ; and a tions is useful in control of the labelling machine. This is
controller ; wherein the method comprises the sensor pro- particularly so when the sensor is used as a so - called " gap
ducing a sensor signal indicative of a periodic property of at 35 sensor ” as gaps between adjacent labels can be more readily
least a portion of the label stock ; providing the sensor signal detected than is the case when a single position sensor is
to the controller; and the controller calculating a displace- used .
ment of the web along a web path defined between the The controller may be configured to control the motive
supply spool and the take -up spool based upon the sensor means based upon a change in the sensor signal in order to
signal and a length of a component of the label stock . 40 position a target portion of the label stock at a desired
According to a further aspect of the invention there is location along the web path .
provided a labelling machine configured to carry out label- The label stock may comprise labels which are spaced
ling operations, the labelling machine comprising a supply from one another along the web .
spool support for supporting a replaceable supply spool ; a Within the description, label stock may be used to refer to
take-up spool support adapted to take up a portion of web , 45 the web with attached labels . Label stock may also be used
a web path being defined between the supply spool and the to refer to a portion of web from which labels have been
take - up spool ; and a controller configured to calculate a time separated.
indicative of when the supply spool requires replacement in The part of the label stock may be a leading edge of a label
order for the labelling machine to carry out further labelling and the desired location along the web path may be an edge
operations. 50 of a labelling peel beak . Any appropriate portion of the label
The time may be a time of day and / or date. stock may be the target portion . For example, the target
In this way an operator of the labelling machine may be portion may be a trailing edge of a label, or a portion of a
provided with an easy to understand indication of when label which is spaced from the leading or trailing edge of a
supply spool replacement is required. This allows operators label by a predetermined distance. The target portion may be
of the labelling machines to plan work accordingly. For 55 a portion of the web. For example the target portion may be
example it allows operators to ensure that they are ready to a portion of the web between adjacent labels. The desired
replace a supply spool at the relevant time thereby minimis- position may be spaced a predetermined distance from an
ing labelling machine downtime. edge of a labelling peak . The desired position may be any
The controller may be configured to calculate the time appropriate position along the web path . For example, the
indicative of when the supply spool requires replacement 60 desired position may be adjacent a printer or may be
based on a diameter of the supply spool . adjacent a component of the labelling machine .
Although the above -described aspects of the invention The controller may be configured to detect a feature of the
relate to a labelling machine and a method of controlling a label stock based upon a change in the sensor signal.
labelling machine , it will be appreciated that the invention The feature of the label stock may be selected from the
may also be applied to a tape drive and method of control- 65 group consisting of: a length of a portion of the label stock ,
ling a tape drive . The tape drive may form part of a labelling the presence of a label of the label stock , the absence of a
machine or a printer ( such as a thermal transfer printer ). label of the label stock , the leading edge of a label of the
US 10,988,276 B2
21 22
label stock and the trailing edge of a label of the label stock . receiver. The transmitter of each pair may be configured to
The feature of the label stock may be any appropriate portion transmit a signal to the receiver of the pair via the label
of the label stock . The detected feature may be the target stock .
portion of the label stock . The target portion may be a The property of a portion of label stock may be the
portion of a label which is spaced from the leading ortrailing 5 electromagnetic transmittance of the portion of label stock .
edge of a label by a predetermined distance . The target The property may be any other appropriate property of the
portion may be a portion of the web . For example the target label stock .
portion may be a portion of the web between adjacent labels . The portion of the label stock may comprise the web and
The feature of the label stock may be a length of a portion attached labels . The portion of the label stock may comprise
of the label stock and the length of the portion of the label 10 the web without an attached label .
stock may be selected from the group consisting of a length The sensor may be arranged to sense differences between
of a label , a pitch length between adjacent labels and a gap a property of the web
length between adjacent labels . The length of a label may be property of the web . and For
a label attached thereto and a
example, the electromagnetic
any appropriate length of a label . For example, the length of
a label maybe the length between two desired portions of a 15 transmittance of the label web with a label attached thereto
label . may be lower than the electromagnetic transmittance of the
The controller may be configured to control the motive web without a label attached thereto .
means based upon a change in the sensor signal in order to Said plurality of positions may be spaced from one
position the detected feature of the label stock at a desired another in a direction substantially perpendicular to the web
location along the web path . The detected feature may be the 20 path. Said plurality of positions may be spaced from one
target portion of the label stock . another in a direction which is angled with respect to the
The motive means may comprise a motor configured to web path .
rotate the take -up spool support. The plurality of positions may form a substantially linear
The motor may be selected from the group consisting of arrangement.
a DC motor, an open loop position controlled motor (e.g. a 25 The sensor may be configured such that the spacing
stepper motor) and a closed loop position controlled motor between an adjacent pair of said plurality of positions are
( e.g. a torque controller motor, such as a DC motor, together spaced by a distance which is greater than approximately
with an appropriate positional sensor and feedback control one twentieth of a width of a label of the label stock . The
circuit ) . However any suitable motor may be used . Those distance may be greater than at least one of one fiftieth , one
skilled in the art will be aware of control schemes which are 30 fortieth , one thirtieth, one tenth and one fifth of a width of
suitable to control rotation of the motors to achieve the a label of the label stock . The width of the label may be the
methods described herein , depending upon the type of motor width of the label perpendicular to the web path .
selected for use . Those skilled in the art will further be aware The sensor may be configured such that the spacing
of the relative merits of various motor types and will be able between two of said plurality of positions are spaced by a
to select a suitable motor type on that basis . 35 distance which is greater than approximately one fifth of a
The transmitter portion may comprise an electromagnetic width of a label of the label stock . The sensor may be
radiation source and the receiver portion may comprise an configured such that the spacing between two of said plu
electromagnetic radiation detector. Any suitable electromag- rality of positions are spaced by a distance which is greater
netic radiation may be used as a basis for sensing including , than at least one of approximately one tenth , one seventh ,
for example, visible light, infrared radiation and ultraviolet 40 one quarter, one third , one half of a width of a label of the
radiation . Any appropriate electromagnetic radiation detec- label stock . The spacing between two of said plurality of
tor may be used . An example of a suitable electromagnetic positions may be the spacing between the two outer posi
radiation detector is a photovoltaic cell . Any appropriate tions . The spacing between two of said plurality of positions
electromagnetic radiation source may be used . Examples of may be the spacing between the two positions which have
suitable electromagnetic radiation sources include a light 45 the greatest spacing .
emitting diode and a laser. The controller may be configured to control the motive
The transmitter portion may be configured to produce means and / or detect the feature of the label stock based upon
beam of electromagnetic radiation which has a power den- a first order or second order differential of the sensor signal .
sity or intensity which is substantially the same at said The controller may be configured to control the motive
plurality of positions . 50 means and / or detect the feature of the label stock based upon
The electromagnetic radiation source may comprise a a higher order differential of the sensor signal.
plurality of light emitting diodes arranged in a substantially The controller may be configured to control the motive
linear formation . means and /or detect a feature of the label stock based on
The receiver portion may comprise a photovoltaic device whether at least one of the sensor signal, a first order
which is configured to produce a sensor signal which is a 55 derivative of the sensor signal and a second order derivative
function of a property of a portion of label stock at said of the sensor signal, have a predetermined relationship with
plurality of positions . The photovoltaic device may receive a threshold value . For example, the at least one of the sensor
radiation which has passed through or reflected off said signal, a first order derivative of the sensor signal and a
plurality of positions . The photovoltaic device may output a second order derivative of the sensor signal may be greater
signal which is proportional to the total amount of radiation 60 than a thresh
which is incident upon it. The controller may be configured to control the motive
The receiver portion may comprise a plurality of receiv- means and / or detect a feature of the label stock based on
ers . whether at least one of the sensor signal, a first order
The transmitter portion may comprise a plurality of derivative of the sensor signal and a second order derivative
transmitters . 65 of the sensor signal exhibit a predetermined signature,
Each of the transmitters and receivers may form part of a wherein the signature is a predetermined temporal pattern in
sensor pair, each sensor pair having a transmitter and a the values of said at least one of the sensor signal, the first
US 10,988,276 B2
23 24
order derivative of the sensor signal and the second order The controller may select one of the sensor signals
derivative of the sensor signal. produced by the receivers based on a predetermined criteria
The labelling machine may further comprise a label and wherein the predetermined criteria is selected from the
applicator located in a location along said web path between group consisting of:
said take up and supply supports and arranged to separate 5 a sensor signal which exceeds a predetermined threshold
labels from the web for application to a receiving surface . for a greatest proportion of a monitoring time,
The labelling machine may be arranged to apply pre
printed labels to packages in a product packaging facility . olda for
sensor signal which is less than a predetermined thresh
a greatest proportion of a monitoring time,
The labelling machine may further comprise a printer a sensor signal which is the first sensor signal to exceed
arranged to print onto labels prior to application of labels 10 a predetermined threshold during a monitoring time ,
onto the receiving surface. The labels printed upon may be a sensor signal which is the last sensor signal to exceed a
pre -printed. predetermined threshold during a monitoring time ,
According to another aspect of the present invention there a sensor signal which is the first sensor signal to be less
is provided a method of operating a labelling machine , the
labelling machine comprising a supply spool support for 15 than
and
a predetermined threshold during a monitoring time,
supporting a supply spool comprising label stock compris
ing a web and a plurality of spaced labels attached to the web a sensor signal which is the last sensor signal to be less
and which are separable from the web ; than a predetermined threshold during a monitoring time .
a take -up spool support adapted to take up a portion of Any of the features described in relation to the labelling
web ; a motive means , a controller, and a sensor having a 20 machine above may be applied to the method above .
transmitter portion and a receiver portion ; Although the above -described aspects of the invention
the method comprising the motive means propelling the relate to a labelling machine and a method of controlling a
web along a web path from the supply spool support towards labelling machine , it will be appreciated that the invention
the take up spool support; the transmitter portion and may also be applied to a tape drive and method of control
receiver portion receiving a portion of the label stock 25 ling a tape drive . The tape drive may form part of a labelling
therebetween ; and the sensor producing a sensor signal machine or a printer ( such as a thermal transfer printer ).
which is a function of a property of a portion of label stock Whereas the tape in the labelling machine is label stock , the
at a plurality of positions spaced from one another in a tape in a printer may be a print ribbon .
direction non -parallel to the web path . According to another aspect of the invention there is
The controller may control the motive means based upon 30 provided a labelling machine comprising a supply spool
a change in the sensor signal in order to position a portion support for supporting a supply spool comprising label
of the label stock at a desired location along the web path . stock ; a take -up spool support adapted to take up a portion
The controller may detect a feature of the label stock of web , a web path being defined between the supply spool
based upon a change in the sensor signal . and the take -up spool ; a rotation monitor configured to
The receiver portion of the sensor may further comprise 35 monitor the rotation of one of said spool supports, the
a plurality of receivers, and the method may comprise the rotation monitor being configured to output a rotation signal
receivers each producing a respective sensor signal which is indicative of the rotation of said one of said spool supports ;
a function of a property of a portion of label stock ; the a torque application member configured to apply a torque to
controller monitoring each of the sensor signals produced by said one of said spool supports ; a controller configured to
the receivers; the controller selecting one of the sensor 40 determine a measure indicative of a width of the label stock
signals produced by the receivers based on said monitoring based on the rotation signal and the torque applied to said
of each of the sensor signals produced by the receivers. one of said spool supports.
Said selected signal may be used by the controller to By determining a measure indicative of a width of the
control the motive means based upon a change in the label stock the labelling machine does not require a user to
selected sensor signal in order to position a portion of the 45 manually supply the labelling machine with information
label stock at a desired location along the web path . relating to the width of the label stock . This eliminates the
The controller may detect a feature of the label stock possibility of human error contributing to the labelling
based upon a change in the selected sensor signal . machine being provided with incorrect information about
The controller may select one of the sensor signals the width of the label stock and hence enables optimal
produced by the receivers based on a predetermined criteria 50 performance of the labelling machine based on the measure
and wherein the predetermined criteria is selected from the indicative of a width of the label stock .
group consisting of the sensor signal which exceeds a The torque application member may be configured to
predetermined threshold for the greatest proportion of time ; apply the torque directly to said one of said spool supports.
the sensor signal which is less than a predetermined thresh- The torque application member may comprise a motor
old for the greatest proportion of time ; the sensor signal 55 mechanically linked to said one of said spool supports, the
which is the first sensor signal to exceed a predetermined motor being configured to rotate said spool support, and
threshold; the sensor signal which is the last sensor signal to thereby apply the torque to said spool support .
exceed a predetermined threshold ; the sensor signal which is The motor may be a DC motor and the controller may be
the first sensor signal to be less than a predetermined configured to monitor the current supplied to the motor to
threshold ; the sensor signal which is the last sensor signal to 60 thereby determine the torque applied to said spool support.
be less than a predetermined threshold . It will be appreciated , however, that in alternative embodi
Said selected signal may be used by the controller to ments other types of motor may be used and appropriately
control the motive means based upon a change in the controlled .
selected sensor signal in order to position a portion of the The torque application member may be configured to
label stock at a desired location along the web path . 65 apply the torque indirectly to said one of said spool supports.
The controller may detect a feature of the label stock For example, the torque may be applied to said one of said
based upon a change in the selected sensor signal . spool supports by the label stock.
US 10,988,276 B2
25 26
The torque application member may comprise a movable path being defined between the supply spool and the take -up
member which defines a portion of the web path and which spool ; a rotation monitor ; a torque application member; and
is configured to contact the label stock and apply a force a controller; wherein the method comprises the rotation
thereto , the force applied to the label stock being transmitted
monitor monitoring the rotation of one of said spool sup
to said one of said spool supports via the label stock and 5 ports, and outputting a rotation signal indicative of the
thereby applying a torque to said one of said spool supports. rotation of said one of said spool supports ; the torque
The labelling machine may comprise a biasing member application member applying a torque to said one of said
configured to bias the movable member towards a home spool supports; and the controller determining a measure
position . The biasing member may be a spring .
The force applied by the movable member to the label 10 indicative of a width of the label stock based on the rotation
stock may depend on the position of the movable member. supports . the torque applied to said one of said spool
signal and
For example, if the movable member is biased by a spring The labelling machine may further comprise a brake
that generally obeys Hooke's law, the greater the extension assembly
( or compression ) of the spring the greater the force applied a movable; and the torque application member may comprise
member which defines a portion of the web path ;
by the movable member to the label stock . 15
The labelling machine may further comprise a sensor and the method may further comprise the brake assembly
configured to produce a sensor signal indicative of the applying a braking force to said one of said spool supports
position of the movable member. which substantially prevents rotation of said one of said
The sensor configured to produce a sensor signal indica- spool supports; the movable member contacting the label
tive of the position of the movable element may comprise a 20 stock and applying a force thereto, the force applied to the
magnetic sensor attached to one of the moveable element or label stock being transmitted to said one of said spool
a portion of labelling machine which is fixed relative to the supports via the label stock and thereby applying a torque to
movable element; and a magnet attached to the other of said said one of said spool supports; and the brake assembly
movable element or said portion of the labelling machine. being released such that it allows rotation of said one of said
The magnet may be selected from the group consisting of 25 spool supports resulting from the torque applied to said one
a multipole magnet and a plurality of magnets. of said spool supports.
The labelling machine may further comprise a brake
assembly configured to apply a braking force to said one of theThe labelling machine may comprise a biasing member,
biasing member biasing the movable member towards a
said spool supports. home position .
The rotation monitor may comprise a Hall effect sensor or 30 The force applied by the movable member to the label
reed switch .
The controller may be configured to determine an angular stock may depend on the position of the movable member.
acceleration of said one of said spool supports based on the sensor producing a sensormay
The labelling machine further comprise a sensor, the
signal indicative of the position of
rotation signal. the movable member .
The controller may be configured to determine the mea- 35 Although the above -described aspects of the invention
sure indicative of a width of the label stock on based on said
angular acceleration of said one of said spool supports and relate to a labelling machine and a method of controlling a
the torque applied to said one of said spool supports. labelling machine , it will be appreciated that the invention
The controller may be configured to determine the mea- may also be applied to a tape drive and method of control
sure indicative of a width of the label stock based on a 40 ling a tape drive. The tape drive may form part of a labelling
moment of inertia of said one of said spool supports and any machine or a printer ( such as a thermal transfer printer ).
supported spool . Whereas the tape in the labelling machine is label stock , the
The controller may be configured to determine the mea- tape in a printer may be a print ribbon .
sure indicative of a width of the label stock based on the Where features have been described above in the context
outer diameter of the spool supported by said one of said 45 of one aspect of the invention, it will be appreciated that
spool supports. where appropriate such features may be applied to other
The controller may be configured to determine the mea aspects of the invention. Indeed, any of the features
sure indicative of a width of the label stock based on the described above and elsewhere herein can be combined in
average density of the spool supported by said one of said any operative combination and such combination is
spool supports . 50
expressly foreseen in the present disclosure .
The controller may be configured to determine a desired To the extent appropriate, control methods described
label stock tension based on the measure indicative of a herein may be implemented by way of suitable computer
width of the label stock .
The labelling machine may further comprise a label programs cessor
and as such computer programs comprising pro
readable instructions arranged to cause a processor to
applicator located at a location along said web path between 55 execute such control methods are provided. Such computer
said take up and supply supports and arranged to separate
labels from the web for application to a receiving surface . programs may be carried on any appropriate carrier medium
The labelling machine may be arranged to apply pre (which may be a tangible or non - tangible carrier medium ).
printed labels to packages in a product packaging facility. Specific embodiments of the present invention will now
The labelling machine may further comprise a printer 60 be described , by way of example only, with reference to the
arranged to print onto labels prior to application of labels accompanying drawings, in which :
onto the receiving surface . FIG . 1 shows a schematic side elevation of a portion of a
According to a further aspect of the invention there is labelling machine in accordance with an embodiment of the
provided a method of operating a labelling machine, the invention;
labelling machine comprising a supply spool support for 65 FIG . 2 shows a schematic side elevation of a portion of a
supporting a supply spool comprising label stock ; a take -up labelling machine in accordance with a second embodiment
spool support adapted to take up a portion of web ; a web of the invention ;
US 10,988,276 B2
27 28
FIG . 3 shows a schematic cross section through a portion FIGS . 24 and 25 show schematic plan views of a label
of a labelling peel beak which forms part of a labelling stock which is utilised in conjunction with labelling
machine in accordance with an embodiment of the inven- machines in accordance with two separate embodiments of
tion ; the invention ;
FIG . 4 shows a schematic plan view of a portion of label 5 FIG . 26 shows a schematic plan view of a label stock
stock which is utilised in conjunction with a labelling which is utilised in conjunction with a known labelling
machine in accordance with an embodiment of the inven machine ;
tion ; FIG . 27 shows a schematic plan view of the label stock
FIG . 4a shows a schematic graph of a sensor signal shown in FIG . 26 utilised in conjunction with a labelling
produced by a sensor which forms part of a labelling 10 machine tion ;
in accordance with an embodiment of the inven
machine in accordance with an embodiment of the present FIG . 28 shows a schematic side view of a labelling
invention , the sensor signal being produced when the por machine including a path length adjuster in accordance with
tion of label stock shown in FIG . 4 is utilised in conjunction an embodiment of the present invention ;
with the labelling machine ; 15 FIG . 29 shows a further schematic side view of a portion
FIG . 5 shows a schematic perspective view of a portion of of a labelling machine according to an embodiment of the
the labelling machine shown in FIG . 2 ; present invention including the path length adjuster shown
FIG . 6 shows a further schematic perspective view of a in FIG. 28 ;
portion of the labelling machine shown in FIG . 2 ; FIG . 30 shows a schematic plan view of a label stock
FIG . 7 shows a schematic side elevation of a portion of the 20 which is utilised in conjunction with a labelling machine in
labelling machine shown in FIG . 2 ; accordance with an embodiment of the invention ;
FIG . 8 shows a further schematic perspective view of the FIG . 31 is a flow chart showing operation of a labelling
portion of the labelling machine shown in FIG . 6 , with a first machine in accordance with an embodiment of the inven
mounting plate removed ; tion , including various features described herein ;
FIG . 9 shows a further schematic perspective view of a 25 FIG . 32 is a simplified schematic cross - sectional view of
portion of the labelling machine shown in FIG . 2 , with first a portion of a production line to which a labelling machine
and second mounting plates removed ; according to an embodiment of the present invention is
FIG . 10 shows a schematic end -on view of a portion of the mounted ;
FIG . 33 is a speed /distance graph for a typical label feed
labelling machine shown in FIG . 2 , with the first mounting 30 operation
plate removed ; ; and
FIG . 11 shows a further schematic end- on view of a FIG . 34 is a flow chart of processing carried out during the
portion of the labelling machine shown in FIG . 2 , with the label FIG
feed operation of FIG . 33 ; and
. 35 is a flow chart of processing carried out during an
second mounting plate removed;
FIG . 12 shows a schematic cross - sectional view of a 35 by someincrement
encoder / decrement routine which is implemented
embodiments of the present invention whilst car
portion of the labelling machine shown in FIG . 2 ; rying out the processing shown in FIG . 34 .
FIG . 13 shows a further schematic perspective cross
sectional view of a portion of the labelling machine shown twoFIGS . 1 and 2 show schematic side views of portions of
different types of labelling machine in accordance with
in FIG . 2 ; separate embodiments of the present invention. FIG . 1
FIG . 14 shows a schematic diagram illustrating a solenoid 40 shows a labelling machine with no integrated printer and
armature position control algorithm which is implemented FIG . 2 shows a labelling machine with an integrated printer.
by a controller which forms part of a labelling machine in The labelling machines shown in FIGS . 1 and 2 both
accordance with an embodiment of the invention; include a supply spool support 10 and a take up spool
FIG . 15 shows a schematic view of a multipole strip support 12. The supply spool support 10 and take up spool
magnet which forms part of a moving element position 45 support 12 are both mounted for rotation about respective
sensor which forms part of a labelling machine in accor- axes A and B. In the labelling machines shown in FIGS . 1
dance with an embodiment of the invention ; and 2 the axes A and B are substantially parallel to one
FIG . 16 shows a schematic view of a portion of the another; however, in some embodiments this may not be the
labelling machine shown in either of FIG . 1 or 2 ; case . The take up spool is connected to a motor 14 such that
FIG . 17 shows a schematic diagram illustrating a moving 50 the motor 14 can be powered in order to rotate the take up
element position control algorithm which is implemented by spool 12 about the axis B. In the labelling machines shown
a controller which forms part of a labelling machine in in FIGS . 1 and 2 , the motor 14 is connected to the take up
accordance with an embodiment of the invention ; spool support 12 via a belt (not shown ).
FIG . 18 shows a perspective view of a portion of an However, it will be appreciated that in other embodiments
alternative braking assembly which in some embodiments of 55 any appropriate linkage may be used to connect the motor 14
the present invention may take the place of the braking to the take up spool support 12. For example, while in the
assembly shown in FIGS . 5 to 11 ; described embodiment the belt will provide a fixed trans
FIG . 19 shows a further view of the alternative braking mission ratio between rotation of the motor shaft and
assembly shown in FIG . 18 ; rotation of the take up spool support, in other embodiments
FIG . 20 shows a further view of a portion of a labelling 60 a linkage providing a variable transmission ratio ( such as a
machine according to an embodiment of the present inven- gearbox ) may be provided . Indeed, in still alternative
tion including the alternative braking assembly shown in embodiments the take up spool support 12 may be directly
FIGS . 18 and 19 and further including a brake release driven by the motor 14. By directly driven it is meant that
mechanism ; the spool support may be mounted co - axially with the shaft
FIGS . 21 , 22 and 23 show schematic plan views of three 65 of the motor 14 , that is the shaft of the motor 14 may extend
separate label stocks which are utilised in conjunction with along the axis B. In the case where the take up spool support
a known labelling machine; 12 is directly driven by the motor 14 , the take up spool
US 10,988,276 B2
29 30
support may be mounted to a motor spindle of the motor 14 . which an error signal can be generated when the feedback
This arrangement is quite different from other arrangements signal is compared to a demanded output rotary position (or
which may use capstan rollers to contact the outside cir velocity ) , the error signal being used to drive the motor to
cumference of a spool or a spool support in order to rotate 5 minimise the error . A DC motor which is not provided with
the spool and / or spool support. an encoder is not a position -controlled motor.
In the labelling machine shown in FIGS . 1 and 2 the motor It will be appreciated that in embodiments of the labelling
14 is a stepper motor. An example of a suitable stepper motor machine other than those shown in FIGS . 1 and 2 , the motor
is a 34H318E50B stepper motor produced by Portescap , may any convenient form . For example, the motor may
USA . An example of a suitable belt which connects the be anytakeappropriate open or closed loop position - controlled
motor 14 to the take up spool support 12 is a synchroflex 10 motor.
timing belt . In this embodiment the gearing ratio for the belt When the labelling machines shown in FIGS . 1 and 2 are
drive is 4 : 1 whereby the motor revolves four times for every in use
revolution of the take up spool support. It will be appreciated supply, aspool
supply spool of label stock may be mounted to the
support such that the supply spool support 10
that in other embodiments any appropriate gearing ratio for supports the supply spool . The label machine shown in FIG .
the belt drive may be used . 15
In this case the stepper motor is capable of being con 1 does not have a supply spool mounted to the supply spool
trolled such that it can execute 1600 substantially equal support 10. However, the labelling machine shown in FIG .
angular movements per complete rotation of the stepper 2 does have a supply spool 16 mounted to the supply spool
motor. These substantially equal angular movements may be support 10. The supply spool 16 is mounted to the supply
referred to as micro -steps. Each micro -step is equivalent to 20 spool support 10 such that the supply spool 16 co -rotates
a rotation of about 0.225 ° or about 0.00392 radians. In this with the supply spool support 10 .
case , the stepper motor has 200 steps per revolution , but the As can be seen best in FIG . 2 , in use , label stock 18
stepper motor is controlled to produce 8 micro - steps per extends between the supply spool support 10 ( and in par
step , such that the number of micro - steps per revolution is ticular the supply spool 16 mounted to the supply spool
1600. Because the belt drive gearing ratio is 4 to 1 , the 25 support 10 ) and the take up spool support 12. A web path 20
number of micro steps of the motor per revolution of the take is defined between the supply spool support 10 and take up
up spool support is 6400. Stepper motors are generally spool support 12 by various components and, in use , the
driven by a stepper motor driver. In the case of the motor and label stock is transported along the web path 20. In the
control arrangement described above , if the stepper motor labelling machines shown in FIGS . 1 and 2 , first, second and
driver is commanded to advance one step , the stepper motor 30 third rollers ( 22 , 24 and 26 ) define the web path 20 between
driver will provide a signal to the stepper motor which the supply spool support 10 and take up spool support 12. It
causes the stepper motor to rotate by one micro - step ( i.e. will be appreciated that in other embodiments of the label
about) 0.225 ° . It will be appreciated that in other embodi- ling machine , components other than rollers may be used to
ments , the stepper motor may undertake any appropriate define the web path 20. Suitable components may be those
number of steps per complete rotation of the stepper motor, 35 which impart only a small friction force to label stock when
and the stepper motor may be controlled to produce any label stock contacts it .
appropriate number of micro - steps per step of the stepper The web path 20 is also defined by a dancing arm 28 and
motor. Furthermore , the belt drive gearing ratio may be a labelling peel beak 30. The dancing arm 28 includes a
chosen such that the number of micro steps of the motor per dancing arm roller 32 mounted at one end of the dancing arm
revolution of the take up spool support is any appropriate 40 28 .
desired number. In use , the label stock 18 extends along the web path 20
While the term ' step ' is sometimes used to denote a from the supply spool support 10 (and in particular from the
physical property of a stepper motor, in the present descrip- supply spool 16 ) around the first roller 22 , around the
tion, the term ' step ' is used to denote any desired angular dancing arm roller 32 , around the second roller 24 , around
movement of the stepper motor, for example a micro - step . 45 the labelling peel beak 30 , around the third roller 26 and is
Stepper motors are an example of a class of motors wound onto the take up spool support 12 to form a take up
referred to position -controlled motors . A position - controlled spool 34 .
motor is a motor controlled by a demanded output rotary It will be appreciated that in other embodiments of a
position . That is , the output position may be varied on labelling machine according to the invention any appropriate
demand , or the output rotational velocity may be varied by 50 number of rollers (or any other appropriate components)
control of the speed at which the demanded output rotary may be used to define a desired shape/ length of web path 20 .
position changes. A stepper motor is an open loop position- The dancing arm 28 is a movable element which is
controlled motor. That is , a stepper motor is supplied with an rotatable about axis A. That is to say, in the labelling
input signal relating to a demanded rotation position or machines shown in FIGS . 1 and 2 , the axis of rotation of the
rotational velocity and the stepper motor is driven to achieve 55 dancing arm 38 is coaxial with the axis of rotation of the
the demanded position or velocity . supply spool support 10 ( and the supply spool 16 ) . In other
Some position - controlled motors are provided with an embodiments this need not be the case . For example , the
encoder providing a feedback signal indicative of the actual dancing arm 28 may rotate about an axis which is spaced
position or velocity of the motor. The feedback signal may from the axis A of rotation of the supply spool support 10
be used to generate an error signal by comparison with the 60 (and supply spool 16 if attached ).
demanded output rotary position ( or velocity ), the error It will also be appreciated that in the labelling machine
signal being used to drive the motor to minimise the error. shown in FIGS . 1 and 2 , the dancing arm 28 is a movable
A stepper motor provided with an encoder in this manner element which defines the web path 20 and movement of the
may form part of a closed loop position - controlled motor . dancing arm 28 changes the length of the web path between
An alternative form of closed loop position - controlled 65 the supply spool support 10 and take up spool support 12. It
motor comprises a DC motor provided with an encoder. The will be appreciated that in other labelling machines any
output from the encoder provides a feedback signal from other appropriate movable element may be used , providing
US 10,988,276 B2
31 32
that movement of the movable element changes the length of roller such that it co -rotates with the print roller, and an
the web path between the supply spool support and take up encoder chip (part number AMS5040 , marketed by ams
spool support. R& D UK Ltd ) which measures rotation of the magnet and
The labelling machine shown in FIG . 2 includes a printer hence print roller, and outputs a signal which is represen
36 (however, as previously discussed , other embodiments of 5 tative thereof. This output can be used by the controller to
labelling machine according to the present invention need determine an amount of movement of the label web along
not include a printer ). The printer in this case is a thermal the label web path .
transfer printer. However, it will be appreciated that other In some embodiments the diameter of the print roller is
embodiments of labelling machine according to the present known to the controller. Because the diameter of the print
invention may include any appropriate type of printer, for 10 roller is known, and because the label web runs over the
example, an inkjet printer, a thermal printer or a laser print roller as the label web passes through the printer, the
marking system . The printer 36 includes a ribbon supply amount of rotation of the print roller is proportional to the
spool support 38 , a ribbon take up spool support 40 , a print displacement of the label web along the label web path .
head 42 and a ribbon guide member 44. In use , a spool of Consequently, a sensor signal output by the encoder, which
printer ribbon is mounted to the ribbon supply spool support 15 is indicative of the amount of rotation of the print roller, may
38 , such that said spool of printer ribbon constitutes a supply be supplied to a controller such that the controller can
spool 46 of printer ribbon which is supported by the ribbon determine the displacement of the label web along the label
supply spool support 38 . web path and, consequently, an amount of movement of the
In use , print ribbon from the supply spool 46 passes along label web along the label web path .
a print ribbon path past the print head 42 and is wound on 20 Although the encoder in this embodiment measures a
to the ribbon take up spool support 40 so as to form a take rotation of the printer roller in order to output a sensor signal
up spool 48. In order for print ribbon to be transported from which is indicative of an amount of movement of the label
the ribbon supply spool support 38 to the ribbon take up web along the label web path , in other embodiments this
spool support 40 , at least the ribbon take up spool support 40 need not be the case . Any appropriate encoder which is
is connected to a motor such that the motor can rotate the 25 capable of outputting a sensor signal which is indicative of
ribbon take up spool support 40 . an amount of movement of the label web along the label web
Because the printer 36 shown in FIG . 2 is a thermal path may be used . For example, an encoder which measures
transfer printer, the print ribbon is thermally sensitive such the rotation of a different roller which contacts the label web
that, as the print ribbon passes the print head 42 , at least a may be used.
portion of the print head 42 can be selectively energised to 30 In other embodiments a periodic property of the label
heat a desired portion of the print ribbon and transfer ink stock may be used to determine an amount of movement of
from that portion of the print ribbon to an adjacent substrate . the label web along the label web path . In such embodi
In this case the adjacent substrate is a label that forms part ments, the encoder may measure a property of the label
of the label stock 18. During operation of the printer 36 , the stock which is periodic in order to provide a sensor signal
guide block 44 comprises guide rollers which help to guide 35 which is indicative of an amount of movement of a label web
the print ribbon as it is transported from the ribbon supply along the label web path . For example, the encoder may use
spool support 38 to the ribbon take up spool support 40 . a gap sensor. As previously discussed , as the label web
In some embodiments the printhead of the printer may be advances along the label web path, the gap sensor will
configured to press the ribbon and label web against a print measure a periodic property of the label web (i.e. periodic
roller ( not shown) to effect printing. In some embodiments 40 electromagnetic transmission coefficient of the label web ) . If
the print roller comprises an aluminium shaft of diameter 8 a pitch length of the labels (i.e. the distance between
mm and is coated with a non - slip coating. In one embodi- equivalent portions of adjacent labels ) is known by the
ment, the non -slip coating is a silicon rubber coating having controller then the controller can use this information to
a Shore A hardness of 50-55 and a thickness of 2.75 mm calculate an amount of movement of the label web along the
Consequently, the print roller has a diameter of 13.5 mm . It 45 label web path based upon the periodic encoder signal.
is preferable that the print roller has as small a moment of The label stock which is used by either of the labelling
inertia as possible , and it is for this reason that the shaft is machines shown in FIGS . 1 and 2 comprises a web and a
made from aluminium . The primary purpose of the print plurality of labels attached to the web . The labels attached to
roller is to provide a backing support against which the the web are separable from the web . The labelling peel beak
printhead presses the ribbon and label web so as to effect 50 30 is configured such that, during operation of either of the
thermal transfer printing onto a label . As such , the print labelling machines shown in FIGS . 1 and 2 , as the label
roller acts as platen roller. The provision of a non -slip stock 18 is transported along the web path 20 past the
coating has the effect of ensuring that there is substantially labelling peel beak 30 , the labelling peel beak 30 separates
no slippage between the print roller and the label web . a passing label from the web .
Consequently, the print roller rotates consistently as the label 55 The separated label may then be attached to a desired
web moves along the web path . This means that the rotation article. An example of such a desired article is an item
of the print roller is an accurate indicator of label web passing on a conveyor ( not shown) of a production line .
movement. Rotation of the print roller may be used in However, it will be appreciated that the desired article may
processing carried out by a controller in order to determine be any appropriate article. In the case of the labelling
an amount of movement of the label web along the web path 60 machine shown in FIG . 2 , it will be appreciated that, prior
in the manner described below. to the label being attached to a desired article, the printer 36
In some embodiments the labelling machine may include may print a desired image on the label . In some embodi
an encoder which is configured to monitor rotation of the ments the printing may occur prior to the labelling peel beak
print roller. In one particular embodiment the encoder which 30 separating the label from the web of the label stock, and
measures the rotation of the print roller comprises a magnet 65 in other embodiments the printing of the image may occur
( part number BMN - 35H which is marketed by Bomatec , after the labelling peel beak 30 separates the label from the
Höri, Switzerland) which is mounted to the end of the print web of the label stock .
US 10,988,276 B2
33 34
During operation of the labelling machines shown in radiation detector 52. The electromagnetic radiation source
FIGS . 1 and 2 the motor 14 is energised to rotate the take up 50 is powered by a power source via a power line 54. The
spool support 12 about its axis B. As this is done, the take sensor, and in particular the electromagnetic radiation detec
up spool support 12 winds label stock 18 onto the take up tor 52 , is configured to produce a sensor signal 56. The
spool support 12 to form a take up spool 34. The take up 5 sensor may commonly be referred to as a gap sensor and is
spool 34 will include the web of the label stock . Any labels generally arranged to produce a sensor signal which differ
separated from the web of the label stock as they pass the entiates between portions of the web which carry labels and
labelling peel beak 30 will not form part of the take up spool portions of the web that do not . Although in this embodiment
34. In some embodiments the labelling peel beak 30 may be the labelling peel beak 30 includes the gap sensor, in other
configured to selectively separate labels from the web . In 10 embodiments, the gap sensor may be located remote to the
this case , any labels which are not separated from the web labelling peel beak at any appropriate position along the web
of the label stock by the labelling peel beak 30 will be wound path . In some embodiments it may be advantageous for the
onto the take up spool support 12 and therefore form part of gap sensor to be located close to the labelling peel beak .
the take up spool 34 . Locating the gap sensor close to the labelling peel beak may
The winding of the label stock 18 (and in particular the 15 reduce potential error in positioning a portion of the label
web of the label stock ) onto the take up spool support 12 will stock at the labelling peel beak based upon a signal produced
cause the label stock 18 to move along the web path 20 in by the gap sensor.
the direction indicated by arrows C (FIG . 2 ) . The winding of In use , the electromagnetic radiation source 50 produces
the web of the label stock onto the take up spool support 12 a beam 58 of electromagnetic radiation . Label stock 18
causes label stock to be paid out from the supply spool 16 20 comprising a web 60 and a plurality of labels 62 attached to
which is supported by the supply spool support 10 . the web (and which are separable from the web ) passes
This arrangement, whereby the take up spool support 12 between the electromagnetic radiation source 50 and elec
is driven so as to transport the label stock in the direction C tromagnetic radiation detector 52 as the label stock 18 is
of label stock transport, and where the supply spool support transported in a direction C along a web path past the
10 is not driven may be referred to as a pull -drag system . 25 labelling peel beak 30. The beam 58 of electromagnetic
This is because, in use , as discussed below, the supply spool radiation which is produced by the electromagnetic radiation
support 10 provides some resistance (or drag) to the move- source 50 passes through the label stock 18 and is incident
ment of label web so as to provide tension in the label web . on the electromagnetic radiation detector 52. The sensor
In this case friction within the system provides the drag. For signal 56 output by the electromagnetic radiation detector 52
example, the friction may include the friction between the 30 is a function of an amount of electromagnetic radiation
supply spool support and the means which supports the which is incident on the electromagnetic radiation detector
supply spool support for rotation . Drag may also be provided 52. That is to say , the sensor signal 56 output by the
by the inertia of the supply spool . In other embodiments the electromagnetic radiation detector 52 is a function of the
drag in a pull -drag system may be actively controlled . For amount of electromagnetic radiation which is produced by
example, in one embodiment a DC motor may be attached 35 the electromagnetic radiation source 50 and which passes
to the to the supply spool support and may be energised in through the label stock 18 .
a direction which is opposite to the direction in which the FIG . 4 shows a schematic plan view of a portion of label
supply spool support rotates due to label stock being wound stock 18. The portion of label stock 18 shown in FIG . 4 has
off the supply spool support and on to the take up spool labels which are all substantially the same size and shape.
support. In this case , the amount of drag that the DC motor 40 Other label stock which may be used by the labelling
provides to the system can be controlled by controlling the machine may have labels which are of a different size and / or
current supplied to the motor and therefore the torque which may have different spacing therebetween . For
applied by the motor. example, some label stock which may be used by the
In other embodiments of the labelling machine, the supply labelling machine includes two types of label, each type
spool support 10 may be driven so that, in use , it rotates the 45 having a different size and / or shape. The label stock may be
supported supply spool 16. In some embodiments the supply such that along the length of the label stock the labels
spool support 10 may be driven for rotation in a direction alternate between labels of a first type and labels of a second
which opposes movement of the label stock in the direction type . It can be seen from FIG . 3 that, when a portion of label
C of label stock transport (which is effected by the rotation stock 18 as shown in FIG . 4 passes between the electro
of the take up spool support 12 ) . This kind of arrangement 50 magnetic radiation source 50 and electromagnetic radiation
is also referred to as a pull -drag system . detector 52 , the beam 58 of electromagnetic radiation will
In other embodiments the supply spool support 10 may be propagate in a direction which is substantially out the page
driven such that it is rotated by a motor in a direction which in FIG . 4. The direction of propagation of the beam 58 of
is complementary to movement of the label stock in the electromagnetic radiation may be substantially perpendicu
direction C of label stock transport (which is effected by 55 lar to the plane of the substantially planar label stock 18 .
rotation of the take up spool support 12 ) . This type of The electromagnetic transmittance ( i.e. , what proportion
arrangement may be referred to as a push - pull system . It will of electromagnetic radiation incident on a material is trans
be appreciated that in embodiments of the labelling machine mitted through the material) of the web 60 of the label stock
which include a driven supply spool support 10 , the supply will commonly be different to the electromagnetic transmit
spool support 10 may be driven by any appropriate motor. 60 tance of the labels 52 of the label stock 18. Also the
Examples of such motors include a DC motor or a position- electromagnetic transmittance of two different thicknesses
controlled motor such as , for example , a stepper motor. of a material will also be different (i.e. , the electromagnetic
FIG . 3 shows a schematic cross - section through a label- transmittance through a relatively thick material will be less
ling peel beak 30 which forms part of a labelling machine in than the electromagnetic transmittance through a relatively
accordance with an embodiment of the present invention . 65 thin material). Either of these two factors , or a combination
The labelling peel beak 30 includes a sensor comprising an of the two, will result in the electromagnetic transmittance
electromagnetic radiation source 50 and an electromagnetic of a portion of the label stock 18 which includes only the
US 10,988,276 B2
35 36
web 60 ( for example at a position indicated by D , sometimes passes through a gap 64 , and then a label 62 affixed to the
referred to in the art as a ' gap ' ) will be different to (in this label web 60 in an alternating manner. The period of the
case greater than ) the electromagnetic transmittance of a periodic sensor signal 56 produced by the electromagnetic
portion of the label stock 18 which includes both the web 60 radiation detector 52 will be equal to the time taken for the
and a label 62 ( for example at a position indicated by E) . 5 label stock 18 to be transported in the transportation direc
When the beam 58 of electromagnetic radiation produced tion C by a distance equal to the pitch length Lp ( i.e. , the sum
by the electromagnetic radiation source 50 passes through a of the label length L, and the gap length LG . ) .
portion of the label stock with a relatively high electromag- In general terms, where a leading label edge passes the
netic transmittance ( such as through the label stock 18 at electromagnetic radiation detector 52 the sensor signal 56
position D within FIG . 4 ) , then the amount of electromag- 10 changes from having a relatively high value to a relatively
netic radiation which is incident on the electromagnetic low value . Similarly, where a trailing label edge passes the
radiation detector 52 will be greater than when compared to electromagnetic radiation detector 52 the sensor signal 56
the amount of electromagnetic radiation incident on the changes from having a relatively low value to a relatively
electromagnetic radiation detector 52 when the beam 58 of high value . The change in sensor signal 56 as the portion of
electromagnetic radiation produced by the electromagnetic 15 label web shown in FIG . 4 passes the electromagnetic
radiation source 50 passes through a portion of the label radiation detector is shown in FIG . 4a where the period of
stock 18 which includes both the web 60 and a label 62 ( for the signal p is marked . A transition from a gap to a leading
example at a position indicated by E in FIG . 4 ) . edge of a label is represented by a signal transition from a
Consequently, the sensor signal 56 output by the electro- relatively high value to a relatively low value . A transition
magnetic radiation detector 52 will be different depending 20 from a trailing edge of a label to a gap is represented by a
on whether the beam 58 of radiation produced by the signal transition from a relatively low value to a relatively
electromagnetic radiation source 50 passes through a portion high value .
of the label stock 18 which has a relatively high transmit- For some types of label stock the length of each label LL
tance ( for example at the position D ) or whether the beam 58 and the length of each gap Lg will be substantially constant.
of electromagnetic radiation produced by the electromag- 25 Consequently, the pitch length Lp for a given label stock 18
netic radiation source 50 passes through a portion of the will also be substantially constant. The pitch length Lp, label
label stock 18 which has a relatively low electromagnetic length L , and / or gap length Lg for a particular label length
transmittance ( for example at position E ) . For example, the may be provided by the supplier of the label stock 18 .
sensor signal 56 produced by the electromagnetic radiation Alternatively, the pitch length Lp, label length L , and / or gap
detector 52 of the sensor may be a voltage and the voltage 30 length LG may be measured using any appropriate known
may be greater when the beam of electromagnetic radiation way of measuring length . For example, an encoder may
58 passes through a portion of the label stock 18 has measure the rotation of a roller which contacts the label
relatively high electromagnetic transmittance compared to stock and this information may be used to determine dis
the voltage when the beam 58 of electromagnetic radiation placement of the label stock along the label web path . By
passes through a portion of the label stock 18 with relatively 35 measuring the displacement of the label stock along the web
low electromagnetic transmittance . path whilst the label stock passes the gap sensor, the gap
Because the label stock 18 will , in use , be transported sensor outputting the periodic sensor signal as discussed
along the web path in a transportation direction C , it will be above , the pitch length Lp, label length L , and / or gap length
appreciated that the beam 58 of radiation will alternate Lg can be measured .
between passing through a portion of the label stock 18 40 Information relating to the pitch length Lp of a particular
which includes only the web 60 (e.g. as indicated at position label stock 18 may be provided to a controller of the
D in FIG . 4 ) , and a portion of the label stock 18 which labelling machine. Alternatively, information relating to the
includes the web 60 and a label 62 (e.g. as indicated at label length and the gap length of a particular label stock
position E in FIG . 4 ) . For ease of reference, a portion of label may be provided to the controller of the labelling machine
web 60 which has no label attached to it and which is 45 such that the controller may use this information in order to
between two adjacent labels 62 may be referred to as a gap . calculate the pitch length of the label stock 18. In a further
Two such gaps are indicated by shading 64 in FIG . 4 . embodiment, the labelling machine may include a device
The label stock 18 includes a plurality of labels 62 which which measures the pitch length Lp ( or the label length LL
have a label width W , which is substantially perpendicular and gap length LG in order to calculate the pitch length Lp).
to the transportation direction C , and a label length L , which 50 It will be appreciated that any known measuring device may
is substantially parallel to the transportation direction C. The be used to measure such lengths.
labels 62 are substantially similar as is the gap 64 between In one embodiment the lengths Lp, L , and LG are mea
adjacent labels. The length of a gap is denoted LG . The pitch sured as follows. The motive means which advances the
length Lp between adjacent labels is the sum of the label label stock along the web path can be controlled by the
length L? and the gap length LG of the adjacent gap 64 . 55 controller such the controller can calculate the linear dis
As the label stock 18 moves in the transportation direction placement of the label stock in any given time . Referring to
C the electromagnetic radiation detector 52 of the sensor FIG . 4a , it can be seen that the sensor signal 56 varies with
will produce a sensor signal 56 which is indicative of a position of the label stock depending on whether there is a
periodic property of at least a portion of the label stock 18 . label or a gap adjacent to the sensor . Consequently , in order
In other words the sensor will produce a sensor signal 56 60 to determine the length L? the controller can calculate the
which is periodic given the nature of the label stock 18. In linear displacement of the label stock during the portion of
this case the electromagnetic transmittance of the label stock the periodic signal 57 (which in this case has a relatively low
18 can be said to be a periodic property of the label stock value ) measured by the sensor which is indicative of the
which varies along the length ( in a direction generally presence of label. Likewise , in order to determine the
parallel to the transportation direction C ) of the label stock 65 length Lg the controller can calculate the linear displace
18. That is to say, the sensor signal 56 will vary periodically ment of the label stock during the portion of the periodic
as the beam 58 of electromagnetic radiation periodically signal 59 (which in this case has a relatively high value )
US 10,988,276 B2
37 38
measured by the sensor which is indicative of the presence label stock relative to a known position . For example,
of a gap . In order to determine Lp the controller can either referring to FIG . 3 , the edge 66 of the labelling peel beak 30
add the linear displacements measured for L and LG , or the (at which the labels are separated from the web ) and the
controller can calculate the linear displacement of the label point at which the beam 58 of electromagnetic radiation
stock during a portion of the periodic signal p . 5 passes through the label stock are separated by a distance
The controller can calculate the linear displacement of the along the web path marked by DB. The controller may be
label web in various ways . One example is that the controller configured such that when an edge of a label 62 passes
may calculate the diameter of the spool supported by the through the beam 58 of electromagnetic radiation , the con
take up spool support . An example of how the controller troller then energises the take up motor such that the take up
may calculate the diameter of the spool supported by the 10 motor takes up a length of web which is equal to the distance
take up spool support is described at a later point within the DB to thereby position the edge which passed through the
description. The controller can then control a stepper motor beam 58 of electromagnetic radiation at the edge 66 of the
which drives the take up spool support so that it monitors the labelling peel beak 30.
number of steps the stepper motor is commanded to take in It will be appreciated that the displacement of the web
a given time . By multiplying the number of steps the stepper 15 along the web path calculated by the controller based on the
motor is commanded to take in a given time by the known sensor signal 56 and the pitch length Lp ( i.e. , the sum of the
angular movement of the stepper motor per step , the con- label length L? and the gap length LG) may be used to both
troller can calculate the angular movement of the stepper determine (i.e. in this particular context measure) and con
motor and hence the take up spool support in said given trol the displacement of a portion of the label stock along the
time . By multiplying the radius (half the diameter) of the 20 web path from any desired position and / or by any desired
spool supported by the take up spool support and the angular length.
movement of the take up spool support in said given time , It will be appreciated that in the described embodiment
the controller can calculate the linear displacement of the the sensor configured to produce a sensor signal 56 indica
label stock due to label stock being wound on to the take up tive of a periodic property of a portion of the label stock 18
spool support during said given time . Such displacement 25 is an electromagnetic radiation detector which produces a
information can be used to determine L?, LG and / or Lp. sensor signal indicative of the electromagnetic transmittance
The controller of the labelling machine is configured to of the label stock . In other embodiments any appropriate
calculate a displacement of the web along the web path sensor may be used in order to detect any appropriate
based upon the sensor signal 56 and a length of a component periodic property of a portion of the label stock .
of the label stock 18. In this case , the sensor signal is 30 In the embodiment described , the electromagnetic radia
provided by the electromagnetic detector and the length of tion source may include a light emitting diode which emits
a component of the label stock is the pitch length Lp ( i.e. , the electromagnetic radiation in the visible spectrum . The elec
sum of the label length Ly and the gap length LG) . In use the tromagnetic radiation detector is chosen such that it can
controller monitors the sensor signal 56 and counts the detect electromagnetic radiation which is produced by the
number of periods of the periodic sensor signal which are 35 electromagnetic radiation source (in this case in the visible
provided to it . As previously discussed , this corresponds to spectrum ). It will also be appreciated that in other embodi
the number of times the beam 58 of electromagnetic radia- ments, any appropriate electromagnetic radiation source
tion passes through a label 62 and an adjacent gap 64 . may be used , providing the electromagnetic radiation detec
Consequently, the controller calculates the displacement of tor is sensitive to the electromagnetic radiation produced by
the web along the web path by multiplying the number of 40 the electromagnetic radiation source.
periods of the sensor signal provided to it by the pitch length In other embodiments, the sensor may be configured to
Lp of the label stock 18 . produce a sensor signal which is a function of a periodic
In some embodiments, the controller may also be config- property of a portion of the label stock other than its
ured to monitor the period of the periodic sensor signal 56 . electromagnetic transmittance . Examples of such properties
The controller may then calculate a speed of the web along 45 include, but are not limited to , the electromagnetic reflec
the web path by dividing the pitch length Lp ( i.e. , the sum tivity of a portion of the label stock , the acoustic transmit
of the label length L , and the gap length Lo ) by the period tance or reflectivity of a portion of the label stock, the
of the sensor signal 56 . electrical conductivity of a portion of the label stock , the
In some embodiments the controller may use a monitored thickness of at least a portion of the label stock , the
period of the periodic sensor signal 56 in combination with 50 capacitance of a region which includes a portion of the label
a count of the number of periods of the sensor signal (which stock and the colour of at least a portion of the label stock .
need not be an integer number) which have been supplied to It will be appreciated that, depending on the periodic prop
the controller in order to determine the displacement of the erty of the portion of the label stock which is to be measured
web at times other than when an edge of a label 62 passes by the sensor, any appropriate sensor must be used . Any
through the beam 58 of electromagnetic radiation . For 55 known appropriate sensor may be used in this regard . For
example , if it is known that the time period since a label example, if it is desired to measure the acoustic transmit
leading edge passed through the beam of electromagnetic tance of a portion of the label stock , the sensor may comprise
radiation is half the monitored period, it can be deduced that an acoustic generator configured to direct acoustic energy
the displacement is equal to half the pitch length Lp. through a portion of the label stock , and an acoustic detector
The displacement of the web along the web path calcu- 60 upon which acoustic energy which passes through said
lated by the controller based on the sensor signal 56 may be portion of the label stock is incident. If it is desired to
used in several different contexts . For example, the displace- measure the capacitance of a region which includes a portion
ment calculated by the controller may be used to provide of the label stock , a capacitive sensor may be used . If it is
information as to the total amount of label stock which has desired to measure a thickness of a portion of the label stock ,
passed the sensor. 65 an example of a sensor which may be used in some appli
In another example , a desired displacement of the web cations is a microswitch . The microswitch may include a
may be effected to control the position of a given portion of lever portion which contacts the label stock . The lever acts
US 10,988,276 B2
39 40
as a distance magnifier. The lever is configured to contact the support and such that for every full rotation of the spool
label stock as the label stock passes the lever. An end of the support in a given direction , both of the two magnets pass
lever which contacts the label stock moves a relatively small the reed switch and activate the reed switch in succession .
distance between its position when the end of the lever is Consequently, the reed switch will be energised twice per
contacting a label of the label stock and its position when the 5 rotation of the spool support.
end of the lever contacts the web of the label stock between
labels . The relatively small distance between these positions As described above , a rotation monitor ( e.g. , tachometer
is magnified by the lever such that the other end of the lever or reed switch) is configured to output a rotation signal
to that which contacts the label stock moves a relatively indicative of a rotation of one of the spool supports. The
rotation signal is supplied to the controller and the controller
large distance which is significant enough to cause a change 10
in state between on and off states of the microswitch .
is configured to calculate the diameter of the spool supported
In the described embodiment, the portion of the label by the spool support based upon the calculated displacement
stock of which a periodic property is measured by the sensor of the web along the web path and the rotation signal. In
comprises the web and the attached labels . In other embodi particular, the controller may calculate the displacement of
ments, this need not be the case. For example, some embodi- 15 the web along the web path for a given time and for the same
given time monitor the rotation signal so as to determine the
ments may only measure a periodic property of the labels amount of rotation of the spool support (and hence spool )
attached to the web . This may occur when the label stock during said given time . The controller may calculate the
includes labels which are attached to a web and which are diameter of the spool Ds supported by the spool support as
adjacent to one another such that there is no gap between follows:
adjacent labels. In this case , the sensor may detect a periodic 20
property of the labels attached to the web which varies
periodically due to the fact that said property is different at (1 )
the border between two adjacent labels compared to at Ds LWP
another location on said label.
In another embodiment, the sensor may only measure a 25
periodic property of the web . For example, a sensor may be where Lwp is the displacement of the web along the web
configured to measure a property of the web after the labels path ( determined, for example, by monitoring of the periodic
have been detached from the web . For example, some label signal 56 output from the electromagnetic radiation sensor
stock may have a web which , even once the labels have been 52 ) and n is the number of rotations of the spool support.
removed , possesses some periodic feature. For example, if 30 In one embodiment including a rotation monitor compris
the labels are die - cut when the label stock is produced, then ing a reed switch and two magnets as described above , the
the web may include indentations resulting from said die- controller may calculate the diameter of the spool supported
cutting which are present on the web even once labels have by the spool support according to the above formula in the
been removed . These indentations may have a property following manner . When a magnet attached to the spool
which is different to portions of the web which have not been 35 support passes the reed switch the controller is triggered to
indented . For example, the thickness of the web at the start counting the number of steps that the motor driving the
location of an indentation may be less than the thickness of other spool support is commanded to undertake. The con
the web at a position which has not been indented . Conse- troller also monitors the signal supplied to the controller by
quently, a sensor which is capable of measuring this differ- the reed switch and counts the number of times a magnet has
ence in thickness of the web between indented portions and 40 passed the reed switch after the controller was triggered to
non - indented portions would be capable of producing a start counting the number of steps that the motor driving the
sensor signal indicative of a periodic property of a portion of other spool support is commanded to undertake.
the label stock such that the controller can calculate the When the controller counts that the number of times a
displacement of the web and perform the functions set out magnet has passed the reed switch is equal to a predeter
above . 45 mined number then the count of the number of steps that the
The displacement of the web along the web path calcu- motor driving the other spool support is commanded to
lated by the controller ( based upon the sensor signal and the undertake is stopped . The predetermined number may be
length of a portion of the label stock) may also be used to any number corresponding to any desired rotation amount of
calculate the diameter of at least one of the take up spool or the spool support. In this example the predetermined number
supply spool mounted on the take up spool support or supply 50 is two, which corresponds to a single rotation of the spool
spool support respectively. This may be done as follows. support. The counted number of steps that the motor driving
The labelling machine may further include a rotation the other spool support is commanded to undertake is used
monitor configured to monitor the rotation of one of the to determine the displacement of the web along the web path
spool supports and thereby monitor the rotation of the spool by multiplying the counted number of steps by the angular
attached to the spool support). An example of a suitable 55 rotation per step , and by the radius of the spool supported by
rotation monitor is a tachometer mounted to one of the spool the other spool support. The radius of the spool supported by
supports . A further example of an appropriate rotation moni- the other spool support may have previously been deter
tor is a trigger device which produces a signal every time the mined either by measuring the change in web path length
spool ( and hence the spool support supporting the spool ) between the spool supports for a given rotation of the other
rotates through a given portion of a complete rotation . 60 spool support, or by measuring the amount of rotation of the
For example, a trigger device may include a reed sensor other spool support for a given displacement of the web
and at least one magnet, or a Hall effect sensor and at least along the web path ( for example , for the displacement of the
one magnet. In one embodiment, a pair of magnets are web along the web path by the pitch length of the label
attached to a spool support such that they are angularly stock) . Both of these methods are discussed within this
spaced about the axis of rotation of the spool support by 180 65 description . Any other appropriate method may be used for
degrees . The reed sensor is located at a portion of the determining the radius of the spool supported by the other
labelling machine which does not rotate with the spool spool support.
US 10,988,276 B2
41 42
It will be appreciated that this method of calculating spool used to determine spool diameter in a labelling machine
diameter may be used to determine the diameter of either or where the spools carry label stock .
both of the spools. Furthermore, a lever which contacts the outside of the
It will also be appreciated that although various sensors spool and which is connected to a position sensor which has
have been described as part of a rotation monitor which is 5 an output that is dependent upon the rotational position of
configured to monitor rotation of the spool , any appropriate the lever may also be used to determine the diameter of the
method may be used in order to determine the amount of supply spool .
In an alternative embodiment, the signal indicative of the
rotation of the spool . For example , the rotation monitor may, amount
if utilized to measure the amount of rotation of a spool which of label stock on the supply spool may be a count of
is driven by a position -controlled motor ( such as a stepper 10 the number of labels which have passed a particular point in
motor ), include a monitoring device which monitors the the web path . If the initial number of labels on the supply
spool is known, then by counting the number of labels which
control signal provided to the position -controlled motor in have passed a particular point in the web path will enable the
order to monitor the amount of rotation the position -con remaining number of labels on the supply spool to be
trolled motor has been commanded to undertake and use this 15 calculated .
as a measure of the amount of rotation that the motor and
hence spool support has undertaken . For example, in the ingWhile various examples of ways of determining a remain
quantity of labels have been set out above , it will be
case of a stepper motor, the rotation monitor may include a appreciated that any appropriate method may be used for
counting device which counts the number of steps that the determining the amount of label stock remaining on the
stepper motor has been commanded to advance. Where a 20 supply spool at any given time.
rotation of the stepper motor comprises a predefined number One example of how to determine the rate at which label
of steps (as is usual ) it is a straightforward matter to stock is being paid out from the supply spool is to provide
determine a number of rotations ( or parts of rotations ) which a signal to the controller which is indicative of the linear
correspond to a particular number of steps through which the speed of a portion of the label stock along the web path . In
motor has moved . 25 one example the controller may calculate the time at which
Known labeling machines may provide an operator with the supply spool requires replacement by using a signal
information as to the number of labels remaining on the label indicative of the diameter of the supply spool in order to
stock before all of the labels have been used up . work out the length of label stock remaining on the supply
Providing the operator of the labeling machine with an spool and then dividing the length of label stock in the
indication as to the number of labels remaining on the label 30 supply spool by the linear speed of the label stock along the
stock before there are no remaining labels on the label stock web path . Again , it will be appreciated that any appropriate
has been found to be not particularly helpful. This is because method may be used for determining the rate at which label
the operator of the labeling machine has no useful indication stock is being paid out from the supply spool . In some
as to when the label stock will require replacement, but only embodiments the rate at which label stock is being paid out
how many labels will be dispensed from the label stock 35 is determined by monitoring the period of the periodic signal
before the label stock requires replacement. 56 output from the electromagnetic radiation detector 52 as
A labeling machine according to the present invention described above .
may include a controller which is configured to calculate a In any case , the controller will perform a calculation
time indicative of when the label stock ( or more specifically whereby the amount of label stock remaining on the supply
the supply spool of label stock ) will require replacement in 40 spool is divided by the rate at which label stock is paid out
order for the labeling machine to be able to carry out further by the supply spool in order to determine the time it will take
labeling operations. That is to say, the controller is config- for the supply spool to be used up .
ured to calculate a time indicative of when the supply spool Another example of how determination of a time at which
is empty (i.e. , the labeling machine has used all of the further label stock will be required may be carried out is by
available labels on the label stock) . 45 using a sensor to count the number of labels that have passed
In order to calculate a time indicative of when the supply a particular point in the web path and also use the sensor to
spool requires replacement, the controller is provided with a measure the rate at which the labels are passing a particular
signal which enables it to determine the amount of label point in the web path (which can be determined using a
stock on the supply spool and also with a signal which sensor of the type described above by monitoring the period
enables the controller to determine the rate at which label 50 of the periodic signal 56 output by the electromagnetic
stock is being paid out from the supply spool . radiation detector 52 ) . Then , given knowledge of the initial
One example of a signal which may be provided to the number of labels on the supply spool, the remaining labels
controller in order for it to determine how much label stock on the supply spool can be determined by the controller. The
there is in the supply spool is to provide the controller with remaining number of labels on the supply spool can then be
a signal indicative of the diameter of the supply spool . Any 55 divided by the rate at which labels are passing the particular
appropriate method may be used in order to provide the point in the web path ( and hence the rate at which labels are
signal indicative of the diameter of the supply spool . For being paid out by the supply spool ) in order to calculate a
example, the method of determining the diameter of a spool time indicative of when the supply spool will be used up
discussed previously within this description may be used . (and hence require replacement).
Alternatively, optical measuring apparatus may be used to 60 It will be appreciated that other methods of measuring the
measure the diameter of the spool . Such an optical measur- remaining label stock on the supply spool and the rate of
ing apparatus is described in the international patent appli- label stock being paid out from the supply spool may be
cation published under the Patent Cooperation Treaty (PCT ) used . For example, if the label pitch of the label stock is
with the publication number WO 02/22371 A2 . Although the either known or determined , the displacement of the label
measuring apparatus described therein is for measurement of 65 stock along the web path may be used ( given knowledge of
spools of inked ribbon used in a thermal transfer printer, the the initial number of labels on the label stock) to determine
inventors have realised that such an apparatus can also be the number of labels remaining on the supply spool . This
US 10,988,276 B2
43 44
may be done by calculating the number of labels that have FIG . 5 shows a perspective view of a portion of an
been used and subtracting this from the initial number of embodiment of a labelling machine of the type shown in
labels . In order to calculate the number of labels used , a FIG . 1 or FIG . 2. FIG . 5 shows the supply spool support 10 ,
measured linear displacement of the label stock along the the dancing arm 28 and a brake assembly 70. The supply
web path may be divided by the pitch length of the label 5 spool support 10 includes a support disc 72 and a supply
stock . Measuring the linear speed of a portion of the label spool 16 of label stock supported by the supply spool
stock along the web path may also be used in order to support 10 .
determine the rate at which labels are paid out from the As previously discussed in relation to FIGS . 1 and 2 , the
supply spool. This can be done by dividing the linear speed labelling machine of which the supply spool 16 forms part
of a portion of the label stock along the web path by the pitch 10 also includes a take up spool support adapted to take up a
length of the label stock . portion of the web of the label stock . A web path is defined
Another way to calculate the remaining number of labels between the supply spool and the take up spool . The dancing
is to measure the number of labels per unit cross - sectional arm 28 is a moveable element which , in use , defines a
area of label stock on the supply spool . In this case the portion of the web path . In fact, in use , the label stock passes
cross -sectional area is measured perpendicular to the axis 15 from the supply spool 16 and runs over the roller 32 which
about which the supply spool rotates . Then , at any point in is mounted on the dancing arm 28. In FIG . 5 , neither the take
time , given the diameter of the supply spool — which may be up spool , nor the web of the label stock running along the
measured using methods described previously — and also the web path , are shown so as to aid clarity of the figure.
diameter of the core holding the label stock on the supply As previously discussed , the dancing arm 28 and supply
( which may be measured or previously determined ), cross- 20 spool support 10 are both mounted for individual rotation
sectional area of label stock remaining on the supply spool about a common axis A. In other embodiments , the supply
may be calculated . This is done by subtracting the cross- spool support 10 and dancing arm 28 may rotate about their
sectional area of the core from the total cross - sectional area own respective axes .
of the supply spool (i.e. including the core) which is deter- FIGS . 6 to 11 show further different views of the brake
mined using the outer diameter of the supply spool measured 25 assembly 70 which is configured to apply a variable braking
in the manner discussed above . By multiplying the cross- force to the supply spool support 10 , the braking force
sectional area of the supply spool by the number of labels resisting rotation of the supply spool support 10. The brake
per unit cross - sectional area of label stock on the supply assembly 70 includes a brake disc 74 which is attached to the
spool , the number of labels remaining can be calculated . supply spool support 10 such that it co - rotates with the
The number of labels per unit area may be calculated as 30 supply spool support 10 (and consequently any supply spool
follows. A first measurement of the spool diameter is made which is supported by the supply spool support 10 ) .
using any of the methods discussed above . A corresponding The brake assembly also includes a brake belt 76 which
first cross - sectional area of the spool is calculated . Subse- extends around part of the outer circumference 88 of the
quently, after a known or measured number of labels have brake disc 74. The brake belt is fixed at a first end 76a to an
been dispensed , a second measurement of the spool diameter 35 attachment pin 78 which is part of a mounting block 80
is made, and a corresponding second cross - sectional area of which is fixed so that it does not rotate with the supply spool
the spool is calculated . The number of labels per unit area support 10. The brake belt 76 is attached at second end 76b
may be calculated by dividing the known or measured via a spring 82 to a pin 84 of a lever arm 86. The spring may
number of dispensed labels by the difference between the be any appropriate resilient biasing member. In one embodi
first and second cross - sectional areas of the spool . 40 ment the spring 82 is tension spring number 523 having a
As previously discussed , information about the number of rate of 4.48 N mm/ produced by Kato -Entex Ltd , UK .
labels remaining on the supply spool and information about In the embodiment shown , the brake belt 76 has a
the rate at which labels are being utilised (e.g. dispensed ) generally rectangular cross - section and it contacts a portion
may be used to calculate a measure of the time it will take of the outer circumference 88 of the brake disc 74 which has
for the supply spool to be used up ( i.e. a time remaining 45 a substantially flat surface parallel to the axis A. That is to
before the supply spool requires replacement). say, the substantially flat circumferential surface 88 of the
In some embodiments of the invention , once the control- brake disc 74 corresponds to the substantially flat surface of
ler has calculated a time remaining before the supply spool the belt 76 which engages the outer circumference 88 of the
requires replacement, the controller may be configured to brake disc 74. It will be appreciated that in other embodi
use this information in combination with the time of the day 50 ments of the labelling machine , the outer circumferential
in order to calculate the time of the day and / or date at which surface of the brake disc and the brake belt may have any
the supply spool will require replacement. For example, the appropriate corresponding profile . For example, the outer
controller may calculate that the supply spool will require circumferential surface of the brake disc may include a
replacement at 4.45 pm or at 9.15 am on 19th February . The V -shaped groove which cooperates with generally circular
controller may provide a signal indicative of the time of day 55 cross - section brake belt .
and / or date at which the supply spool will require replace- The brake belt 76 may be made from any appropriate
ment to a suitable display. Calculating the time of the day material for example the brake belt may be made out of a
and / or date at which the supply spool will require replace- combination of fabric and polymeric material or of poly
ment may be useful because it will enable an operator of the urethane. In one embodiment the brake belt is 10 mm wide ,
labelling machine to determine at what time of the day he or 60 280 mm long and formed from a material referred to as
she will need to be present in order to replace the label stock Habasit TG04 . In this embodiment the brake disc (which
supply spool . Alternatively, or in addition, if the labelling may be of any appropriate size in other embodiments) has a
machine is operated by operators which are employed in a diameter of 100 mm .
shift pattern , the information provided by the labelling The lever arm 86 is pivotally mounted to the mounting
machine may enable the operator of the labelling machine to 65 block 80 by a pivot pin 90. A first end of the lever arm 86
see on which operator shift the supply spool will require includes the pin 84. A second end of the lever arm 86
replacement. engages an armature 92 of a solenoid 94. An example of a
US 10,988,276 B2
45 46
suitable solenoid is an MCSMT-3257812STD solenoid sup- As seen best in FIGS . 7 , 8 and 10 , the solenoid 94 includes
plied by Premier Farnell UK Limited . a coil (not shown) housed within a solenoid housing 96 and
As can be seen best in FIG . 7 , the distance between the the armature 92 which is a linearly moveable relative to the
pivot pin 90 and the point 96a on the pivot arm 86 at which coil . One end of the armature 92 engages the lever arm 86 .
the armature 92 of the solenoid 94 engages the pivot arm 86 5 Attached to the other end of the armature 92 is a reflective
is greater that the distance between the pivot pin 90 and the element 99 which forms part of an armature position sensor.
In one embodiment the reflective element 99 is a generally
pin 84 to which the brake belt 76 is attached . In this way , the annular
lever arm 86 provides a mechanical advantage such that any machined part made from white acetal material.
force applied by the armature 92 of the solenoid 94 to the The armature position sensor further includes a transmit
lever arm 86 is magnified when it is applied to the brake belt 10 ter 100 configured
a receiver 102 whichto transmit electromagnetic
is configured radiation and
such that electromagnetic
76 via the pin 84 . radiation transmitted by the transmitter 100 and reflected by
In use a resilient biasing member 98 ( which in this the reflective element 99 is incident on the receiver 102. The
embodiment is a spring different to the spring 82 , but may
be any other appropriate resilient biasing member) biases the 15 transmitter 100 and receiver 102 can be seen most clearly in
FIG . 8. In this embodiment the transmitter 100 is a light
lever arm 86 in a direction such that the spring 98 causes the emitting diode and the receiver 102 is a photodiode. Both the
brake belt 76 to contact the outer circumference 88 of the transmitter 100 and the receiver 102 are supported by a
brake disc 74 so as to apply a braking force to the brake disc sensor support 104 which is in a fixed positional relationship
74 and therefore resist rotation of the brake disc 74 and with regard to the body 96 of the solenoid 94 ( and hence the
attached supply spool support 10. In one embodiment the 20 coil of the solenoid contained within the body 96 ) . In one
spring 98 is compression spring number 940 having a rate of embodiment the transmitter 100 and receiver 102 are a
0.94 N /mm produced by Kato -Entex Ltd , UK . The direction single part, HDSL - 9100-021 proximity sensor, produced by
of the force applied by the spring 98 to the second end 76b Avago Technologies, U.S. Inc.
of the brake belt 76 is denoted S in FIG . 7. This ensures that, In use , the transmitter 100 in this case an LED ) transmits
when no power is supplied to the solenoid 94 ( for example 25 electromagnetic radiation in a direction such that it is
when the labelling machine is powered down ), the spring 98 incident on the reflective element 99. The reflective element
causes a braking force to be applied to the brake disc 74 and 99 reflects at least a portion of the electromagnetic radiation
hence the supply spool support 10 . which is incident on it . Some of the electromagnetic radia
Extension of the armature 92 of the solenoid 94 in the tion which is reflected by the reflective element 99 is
direction towards the lever arm 86 and as indicated by arrow 30 incident on the receiver 102. As previously discussed , in this
F will cause the pin 84 to move in a direction of arrow F ' case , the receiver 102 is a photodiode. Consequently the
which is substantially opposite to that of the arrow F. voltage and /or current of a signal output by the photodiode
Consequently, if the solenoid 94 is energised such that the is indicative of the amount of electromagnetic radiation
armature 92 moves towards the lever arm 86 in the direction which is reflected by the reflective element 99 and incident
F, this will cause the lever arm 86 to overcome the biasing 35 on the receiver 102 .
force exerted on it by the spring 98 such that the pin 84 When the armature 92 of the solenoid 94 is moved the
moves in the direction F ' . This will cause the amount of position of the reflective element 99 relative to the trans
braking force exerted by the brake belt 76 on the brake disc mitter 100 and receiver 102 will change. The further the
74 to decrease . It follows that by controlling the position of reflective element 99 is away from the transmitter 100 and
the solenoid armature 92 ( and hence controlling the position 40 receiver 102 (i.e. the further the armature 92 of the solenoid
of the pin 84 via the lever arm 86 ) that the amount of braking 94 is moved in the direction F ) the less electromagnetic
force applied to the supply spool support 10 via the brake radiation produced by the transmitter 100 and reflected by
disc 74 can be varied . the reflective element 99 will be incident on the receiver
The surface of the brake belt 76 which contacts the outer 102. Consequently, in this case where the receiver is a
circumferential surface 88 of the brake disc 74 may be 45 photodiode , the less the magnitude of the voltage and / or
referred to as a first braking surface . The outer circumfer- current signal produced by the receiver 102. It follows that
ential surface 88 of the brake disc 74 which is contacted by the receiver 102 of the armature position sensor outputs a
the first braking surface may be referred as a second braking signal (which may be referred to as an armature position
surface . In a braking mode the controller controls the current signal) which is indicative of the position of the armature 92
supplied to the coil of the solenoid so as to urge the first 50 relative to the coil of the solenoid 94. It will be appreciated
braking surface against the second braking surface . As that the armature position signal is also indicative of the
previously discussed , this is done by moving the armature 92 position of a lever arm 86 and hence of the braking force
of the solenoid in a direction which is substantially opposite which is being applied by the brake belt 76 (which is
to the direction F ( shown by arrow F ' ) , thereby allowing the attached to pin 84 of the lever arm 86 ) to the brake disc 74
spring 98 to bias the end of the lever arm 86 which includes 55 and hence to the supply spool support 10 .
the pin 84 in a direction which is substantially parallel to the In a standard solenoid of the type used in FIG . 7 , the
direction F (i.e. substantially in direction S ) . Due to the fact extent of relative movement between the armature and the
that the second end 76b of the brake belt 76 is connected to coil is dependent on the current supplied to the coil . The
the pin 84 and due to the fact that the first end 76a of the armature of the solenoid is biased relative to the coil by a
brake belt 76 is attached to a fixed pin 78 , movement of the 60 resilient biasing member ( not shown ) towards a first end
pin 84 in a direction which is substantially parallel to the position . Hence, when no current is supplied to the coil , the
direction F causes the first braking surface to be urged solenoid is biased towards the first end position . When
against the second braking surface, thereby applying a current of a particular magnitude is applied to the coil of the
braking force to the brake disc 74. The second braking solenoid the armature overcomes the biasing force which
surface 88 is part of the brake disc 74 which is attached to 65 urges it into the first end position such that the armature
the supply spool support 10. Consequently the supply spool moves towards a second end position . Removing the current
support 10 is associated with the second braking surface 88 . provided to the coil will result in the armature being urged
US 10,988,276 B2
47 48
by the resilient biasing member back to the first end position . armature position sensor (which is capable of producing an
Consequently, solenoids tend to be bi - stable , i.e. depending armature position signal which indicative of the position of
on the operating state of the solenoid , the armature tends to the armature relative to the coil ) may be used .
be located relative to the coil at the first end position or the A conventional PID controller is configured such that an
second end position . The armature cannot be reliably located 5 increase in the signal output by the adder which combines
relative to the coil at a position between the first end position the proportional, integral and derivative components ( e.g.
and the second end position . 112 in FIG . 14 ) causes an increase in the feedback signal .
A labelling machine described herein includes a solenoid However in the case of the embodiment previously
control system which includes a solenoid controller and is described with reference to FIG . 14 the opposite occurs . An
configured to control the current supplied to the coil of the 10 increase in the signal output by the adder 112 results in an
solenoid based upon the armature position signal output by increase in the current in the coil provided by the coil driver
the armature position sensor so as to urge the armature 114 , which causes a decrease in the feedback signal FB ( t)
towards a desired rest position relative to the coil which is produced by the armature position sensor 116. This may be
intermediate the first and second end positions of the sole- compensated for in a number of ways. For instance, the
noid discussed above. The solenoid controller implements a 15 range of the feedback signal may be inverted such that a
conventional PID (proportional, integral and derivative) small signal is generated when the reflector is close to the
algorithm as part of a closed loop system in order to control transmitter, and a larger signal generated when the reflector
the current supplied to the coil of the solenoid . is further away from the transmitter. Alternatively, the
FIG . 14 shows a diagrammatic representation of the PID connections of the signals to the subtractor 110 may be
control algorithm implemented by the solenoid controller. At 20 swapped.
any given time a set point value SP ( t) is provided to the A suitable frequency for the pulse width modulated volt
control algorithm . The set point value SP (t) is indicative of age is approximately 10 kHz . That is to say , during each
the desired position of the armature of the solenoid relative 1 / 10,000 of a second the voltage applied is taken high , and then
to the coil . The set point signal SP (t) is provided to one input low again . Within each 1 /10,000 of a second the duration for
of a subtractor 110. A feedback signal FB (t) which is 25 which the signal is high and the duration for which the signal
indicative of the actual position of the armature relative to is low are varied , however in each case the sum of the
the coil of the solenoid is supplied to a second input of the duration for which the signal is high and the duration for
subtractor 110. The subtractor 110 subtracts the feedback which the signal is low is always equal to 10,000 of a second .
signal FB (t) from the set point signal SP (t) and outputs an Of course , any appropriate frequency of pulse width modu
error signal E ( t ). 30 lated voltage may be used .
The error signal E ( t) is supplied to three portions of the The armature position sensor is calibrated as follows. The
PID algorithm . These are the proportional component P , the solenoid is caused to enter a de-energised state by the
integral component I , and the derivative component D. As controller. In this state , substantially no current is provided
can be seen from the figure, the proportional component P to the coil of the solenoid . The armature is urged to the limit
outputs a signal which is given by a constant Kp multiplied 35 of its movement in the direction F ' by the biasing force of the
by the error signal E (t) . The integral component I outputs a spring 98 (an also by any resilient biasing member within the
signal which is given by a constant K , multiplied by the solenoid ). At this point the controller records the value of the
integral of the error signal E?t ). The derivative component D signal output by the armature position sensor. This value
of the algorithm outputs a signal which is given by a may be referred to as the maximum braking value because
constant Ky multiplied by a derivative of the error signal 40 it corresponds to the configuration of the brake assembly (in
E ( t) with respect to time . this case the position of the armature ) in which the maxi
An adder 112 combines the signals output by the propor- mum braking force is applied to the spool support by the
tional P , integral I and derivative D components of the brake assembly.
algorithm . The output from the adder 112 is provided to a The solenoid is then caused to enter a fully energised state
coil driver 114. The coil driver 114 is connected across the 45 by the controller. In this state , enough current is provided to
coil of the solenoid so that it can apply a voltage across the the coil of the solenoid such that the armature is urged
coil . The coil driver 114 supplies a pulse width modulated against the biasing force of the spring 98 to the limit of its
voltage signal across the coil of the solenoid . The coil driver movement in the direction F. At this point the controller
114 controls the duty cycle of the pulse width modulated records the value of the signal output by the armature
voltage signal applied across the coil as a function of the 50 position sensor. This value may be referred to as the mini
signal output to it by the adder 112 of the PID control mum braking value because it corresponds to the configu
algorithm . ration of the brake assembly (in this case the position of the
By varying the duty cycle of the pulse width modulated armature ) in which the minimum braking force is applied to
voltage applied across the coil of the solenoid, the current the spool support by the brake assembly.
supplied to the coil , and hence the position of the armature 55 In this embodiment the exact relationship between arma
of the solenoid relative to the coil , can be changed. An ture position and braking force applied by the brake assem
armature position sensor 116 outputs an armature position bly to the spool support is unknown. What is known is that
signal which is indicative of the position of the armature when the armature position sensor outputs a signal to the
relative to the coil of the solenoid . The armature position controller which has a value equal to the maximum braking
signal may also be referred to as the feedback signal FB (t ). 60 value , then the braking force applied by the brake assembly
In the previously described embodiment shown in FIGS . 5 to the spool support is a maximum . Likewise, when the
to 13 , the armature position sensor 116 includes the trans- armature position sensor outputs a signal to the controller
mitter 100 , the reflective element 99 and the receiver 102. As which has a value equal to the minimum braking value , then
previously discussed, it is the receiver 102 which outputs the the braking force applied by the brake assembly to the spool
armature position signal. Details of the operation of the 65 support is a minimum . When the armature position sensor
armature position sensor can be found in the description outputs a signal to the controller which has a value between
above . However, it will be appreciated that any appropriate the minimum braking value and the maximum braking
US 10,988,276 B2
49 50
value , then the braking force applied by the brake assembly error signal E (t) is calculated in the manner already
to the spool support is between the minimum and maximum described by the subtractor 110 .
braking force . The closer the value of the signal output by Other embodiments incorporating a dead band may func
the armature position sensor to the maximum braking value , tion in a slightly different manner . These embodiments
the closer the braking force applied by the brake assembly 5 operate in the same manner as the dead band previously
to the spool support is to the maximum braking force. described except that if the feedback signal FB (t) falls
outside of the dead band then the error signal E (t) is
Likewise , the closer the value of the signal output by the calculated
armature position sensor to the minimum braking value , the back signalbyFBcalculating
(t ) and the
the difference between the feed
edge of the dead band which is
closer the braking force applied by the brake assembly to the
spool support is to the minimum braking force. In other 10 closest to the feedback signal FB (t). For example, if the dead
embodiments the armature position sensor may be calibrated band is + 1 % of the set point signal SP ( t ), and the feedback
signal FB ( t) has a value of the set point signal SP ( t) plus 1 %
such that the relationship between armature position and of the set point signal SP (t) plus u, then the value of the error
braking force applied by the brake assembly to the spool signal is -u . Likewise , if the dead band is + 1 % of the set
support is known. 15 point signal SP (t) , and the feedback signal FB (t) has a value
In order to avoid the armature colliding with a portion of of the set point signal SP (t) minus 1 % of the set point signal
the coil or an end - stop ( if present) during operation, a SP ( t) and minus u , then the value of the error signal is u . In
limited range of the full movement of the armature may be an alternative example, if the dead band is 11 % of the
used . That is to say, the solenoid controller and / or PID maximum possible set point signal ( i.e. the set point signal
algorithm may be configured such that the coil driver 20 which is equivalent to a desired fully energised state of the
provides a maximum current to the coil which is less than coil of the solenoid , or a desired de - energised state of the
the current required for the solenoid to enter its fully solenoid ), and the feedback signal FB (t) has a value of the
energised state; and such that the coil driver provides a set point signal SP ( t) plus 1 % of the maximum possible set
minimum current to the coil which is greater than the current point signal, plus u , then the value of the error signal is -u .
required for the solenoid to enter its de -energised state . 25 Likewise , if the dead band is + 1 % of the maximum possible
Extension of the armature 92 of the solenoid 94 in the set point signal, and the feedback signal FB (t) has a value of
direction towards the lever arm 86 and as indicated by arrow the set point signal SP (t) minus 1 % of the maximum possible
F will cause the pin 84 to move in a direction of arrow F ' set point signal SP (t ) and minus u , then the value of the error
which is substantially opposite to that of the arrow F. signal is u.
Consequently, if the solenoid 94 is energised such that the 30 Where a non- zero value is used for Kp, some form of low
armature 92 moves towards the lever arm 86 in the direction pass filtering ( a concept which is well known in the art) may
F, this will cause the lever arm 86 to overcome the biasing be used to reduce the noise present in the feedback signal .
force exerted on it by the spring 98 such that the pin 84 That is to say low pass filtering may be used either to reduce
moves in the direction F ' . This will cause the amount of the amount of relatively high frequency noise from the
braking force exerted by the brake belt 76 on the brake disc 35 derivative component D of the PID algorithm ( compared to
74 to decrease . It will be appreciated that in other embodi- the relatively low frequency desired portion of the derivative
ments the brake assembly may be configured such that component D of the PID algorithm ) or to reduce the amount
energising the solenoid increases the braking force applied of relatively high frequency noise from the feedback signal
to the spool support and de -energising the solenoid ( compared to the relatively low frequency desired portion of
decreases the braking force applied to the spool support. In 40 the feedback signal ). It will be appreciated that if a low pass
other embodiments any suitable braking arrangement may filter is used as a form of low pass filtering, then the cut-off
be used , for example brake disc and brake pad , brake drum frequency of the low pass filter would be chosen (in a
and brake shoe or appropriate motor as discussed in more manner well known in the art) such that relatively high
detail below . frequency noise from the derivative component D of the PID
Any appropriate gain constants Kp, K , and Ky may be 45 algorithm or feedback signal is attenuated but the relatively
used . In some embodiments , at least one of these constants low frequency desired portion of the derivative component
may be equal to zero . However, in a preferred embodiment, D of the PID algorithm or feedback signal is allowed to pass .
all of these constants are non - zero . The reason a form of low pass filtering may be used to
In some embodiments, an offset may be applied to ensure remove noise if a non - zero value of K ) is used is because the
that with zero error between the set point signal and the 50 derivative term acts to amplify the rate of change of the
feedback signal , a control signal is generated which is in the feedback signal and is thus particularly sensitive to high
centre of the range of valid control signals. frequency content as this has a greater rate of change than
In some embodiments, the PID control algorithm may low frequency content ( assuming equal amplitude ). The
incorporate a dead band . In such embodiments, the error noise may be caused by various factors . For example, the
signal E (t) is set to zero if the feedback signal FB (t) is within 55 noise may be intrinsic to the emitter / detector arrangement, it
a given range of the set point signal SP ( t). For example, the may be electronic circuit noise, it may be electromagneti
dead band may operate such that if the difference between cally - induced interference or it may be any other noise
the set point signal SP (t) and the feedback signal FB (t) is source . In the case where the armature position sensor
less than 11 % of the set point signal SP ( t) then the error comprises a radiation detector, noise may be caused by the
signal E (t) is set to zero . Alternatively, if the difference 60 presence of unintended radiation . One example of a form of
between the set point signal SP (t) and the feedback signal low pass filtering includes a simple averaging algorithm .
FB ( t) is less than + 1 % of a maximum possible set point The averaging algorithm may take a number of samples of
signal ( i.e. the set point signal which is equivalent to a the feedback signal FB ( t) or the derivative component D of
desired fully energised state of the coil of the solenoid, or a the PID algorithm and then output the mean value of those
desired de -energised state of the solenoid ) then the error 65 samples. However, any appropriate form of low pass filter
signal E (t) is set to zero . If, in either of these cases , the ing or any appropriate known method of reducing noise may
feedback signal FB (t) falls outside of this range then the be used .
US 10,988,276 B2
51 52
It is possible that a braking assembly included in a that in other embodiments the components of the braking
labelling machine ( as described above or otherwise ) may assembly which may be subject to wear may be any appro
include at least one component that is subject to wear over priate components .
time . Once said at least one component of the braking In the embodiment discussed above the output of the
assembly has worn to the extent that performance of the 5 armature position sensor (or feedback signal FB ( t )) is moni
labelling machine is unacceptably adversely affected then tored by the controller and the controller maintains the value
said at least one component of the braking assembly may in the memory as a function of the output of armature
require replacement. In order to replace said at least one position sensor ( or feedback signal FB ( t)) over time . If, over
component it may require that the labelling machine is shut time , the controller detects that the magnitude of the value
down at an inconvenient time which results in down time of 10 exceeds a predetermined value which has been chosen to
a production line of which the labelling machine forms part. indicate a potentially unacceptable level of wear of a com
One embodiment which obviates or mitigates this prob- ponent of the braking assembly, then the controller outputs
lem is discussed below . The controller may include a a signal indicating that the braking assembly requires main
memory. The controller may be configured so as to monitor tenance . Any appropriate method of monitoring a parameter
a parameter which is indicative of the state of the braking 15 which is indicative of the state of the braking assembly so as
assembly and to maintain ( store and update ) a value in the to detect a potential wear condition of the braking assembly
memory which is indicative of the accumulated use of the may be used.
braking assembly. For example, the controller may be con In another example, incorporating the braking assembly
figured to monitor the set point signal and / or feedback signal described above , the output of the armature position sensor
of a control algorithm which controls the braking assembly. 20 (or feedback signal FB ( t)) is monitored by the controller and
In one example incorporating the braking assembly above , the controller records a value in the memory which is
the output of the armature position sensor (or feedback indicative of the output of the armature position sensor (or
signal FB (t) ) is monitored by the controller and the control- of the feedback signal FB ( t)) during the first use of the
ler maintains the value in the memory as a function of the labelling machine (or the first use of the labelling machine
output of the armature position sensor ( or feedback signal 25 after the braking assembly has been maintained . For
FB (t)) over time. example, the controller may determine and record a value in
For example , the armature position sensor may output a the memory which is indicative of the average output of the
signal (e.g. a voltage ) which increases in magnitude as the armature position sensor ( or the average of the feedback
braking force applied by the solenoid increases . The con- signal FB (t) ) whilst the labelling machine transfers the first
troller may monitor the output of the armature position 30 reel of label stock from the supply spool support to the take
sensor and periodically (i.e. after every time a fixed period up spool support ( or whilst the labelling machine transfers
of time passes ) add the output of the armature position the first reel of label stock after maintenance of the braking
sensor at that time to the value currently stored in the assembly from the supply spool support to the take up spool
memory . In this way , the greater the magnitude of the value support ). The controller is configured to subsequently moni
stored in the memory, the greater the amount of braking 35 tor the output of the armature position sensor ( or feedback
force ( over time) that has been applied by the braking signal FB (t) ) and, in a similar manner to that done in relation
assembly. The controller may monitor the magnitude of the to the first reel of label stock , calculate a value indicative of
value . It is thought that the total braking force applied over the average output of the armature position sensor (or the
time is proportional to the accumulated value stored in the average of the feedback signal FB ( t )) whilst the labelling
memory
assembly.
and to the wear of components of the braking 40 machine transfers each subsequent reel of label stock from
the supply spool support to the take up spool support. The
Consequently, if the controller detects that the magnitude controller may be configured to output a signal indicating
of the value exceeds a predetermined value which has been that the braking assembly requires maintenance if the value
chosen to indicate a potential level of wear of a component indicative of the average output of the armature position
of the braking assembly which may be unacceptable ( but 45 sensor (or the average of the feedback signal FB ( t)) whilst
some time before the component fails ), then the controller the labelling machine transfers a subsequent reel of label
may be configured to output a signal indicating that the stock from the supply spool support to the take up spool
braking assembly requires maintenance. The controller may support differs by more than a predetermined amount from
be configured to output a signal indicating that the braking the value stored in the memory indicative of the average
assembly requires maintenance if the value stored in the 50 output of the armature position sensor (or the average of the
memory falls within any appropriate predetermined range. feedback signal FB (t) ) whilst the labelling machine transfers
The signal which indicates the braking assembly requires the first reel of label stock from the supply spool support to
maintenance may be supplied to a suitable indicator (e.g. an the take up spool support. For example, the controller may
audible and /or visual indicator) which is configured to be configured to output a signal indicating that the braking
indicate that the braking assembly requires maintenance to 55 assembly requires maintenance if the value indicative of the
an operator of the labelling machine . The braking assembly average output of the armature position sensor ( or the
may then be maintained at the next convenient opportu- average of the feedback signal FB (t )) whilst the labelling
nity - for example when the production line of which the machine transfers a subsequent reel of label stock from the
labelling machine forms part is powered down or when the supply spool support to the take up spool support differs by
production line is experiencing downtime for another rea- 60 more than approximately 20% from the value stored in the
son . In this way inconvenient downtime of the production memory indicative of the average output of the armature
line caused by servicing /maintenance of the braking assem- position sensor ( or the average of the feedback signal FB (t) )
bly is avoided . whilst the labelling machine transfers the first reel of label
Within the braking assembly described above, examples stock from the supply spool support to the take up spool
of components which may be subject to wear and hence 65 support.
require maintenance / replacement include the brake belt 76 , In the embodiment discussed above each valve indicative
the brake disc 74 or the solenoid 94. It will be appreciated of the average output of the armature position sensor ( or the
US 10,988,276 B2
53 54
average of the feedback signal FB (t )) whilst the labelling appropriate resilient biasing member) is attached to the arm
machine transfers a reel of label stock from the supply spool 128 via a pin 132. In one embodiment the spring 130 is
support to the take up spool support may be determined by tension spring number 2137 having a rate of 1.05 N /mm
the controller as follows. As the labelling machine transfers produced by Kato - Entex Ltd , UK . As can be seen best in
a reel of label stock from the supply spool support to the take 5 FIG . 7 , a second end 130b of the resilient biasing member
up spool support, the controller may periodically take a 130 is fixed via a pin to the mounting block 80. In FIG . 7 ,
number of readings of the output of the armature position the pin used to secure the second end 130b of the resilient
sensor (or the average of the feedback signal FB ( t) ). In order biasing member 130 to the mounting block 80 has been
to determine the average, the controller then sums the omitted for clarity. The resilient biasing member 130 biases
readings and divides the summed readings by the number of 10 the dancing arm 28 in the clockwise direction as shown in
readings. FIG . 7. This direction is indicated by arrow G.
It will be appreciated that although the braking arrange- The labelling machine includes a sensor configured to
ment described is configured so as to enable a braking force produce a sensor signal indicative of the position of the
to be applied to the supply spool support, in other embodi- moveable element in this case dancing arm 28 ) . The sensor
ments, the same brake assembly may be used in conjunction 15 is configured to produce a sensor signal indicative of the
with the take up spool support, so as to apply a braking force position of the moveable element. In this case the sensor
to the take up spool support. produces a sensor signal indicative of the rotational position
It will also be appreciated that, although a particular brake of the moveable element. As best seen in FIG . 11 the sensor
assembly is described above which utilises a brake belt , includes a multipole strip magnet 140 which is attached to
brake disc and actuating solenoid , in other embodiments, 20 a circumferential surface 142 of the annular portion 120 of
any appropriate brake assembly may be used providing the the dancing arm 28 .
brake assembly is capable of selectively applying a braking FIG . 15 shows a schematic plan view of a portion of the
force to the relevant spool support. multipole strip magnet 140 which has been removed from
For example , the brake assembly may include a motor that the annular portion 120 of the dancing arm 28 and has been
is mechanically linked to the relevant spool support ( e.g. the 25 laid flat in the plane of the paper. The multipole strip magnet
supply spool support) such that the motor rotates with the 140 is such that along its length LS there are alternating
spool support. In one example the motor may be a DC motor. regularly spaced north N and south S magnetic pole regions
As is well known, by controlling the amount of current 143. The length of each pole region 143 is Lpole . In some
provided to the DC motor, the amount of torque exerted by embodiments the pole length Lpole may be 1 mm or 2 mm .
the DC motor can be controlled . Consequently, by driving 30 The multipole strip magnet 140 may be attached to the
the DC motor in a direction such that it opposes the direction circumferential surface 142 of the annular portion 120 using
of rotation of the spool support, and by controlling the any appropriate method , for example, using adhesive.
amount of current provided to the DC motor, it is possible The sensor configured to produce a sensor signal indica
to control the amount of torque the DC motor applies to the tive of the position of the moveable element also includes a
relevant spool support in order to oppose (or resist) the 35 magnetic sensor (not shown) which is mounted to sensor
rotation of the relevant spool support. The torque applied by support 144. The magnetic sensor is mounted with sufficient
the motor to oppose the rotation of the relevant spool support proximity to the multipole strip magnet 140 such that the
may be referred to as a braking torque . magnetic sensor can readily sense the magnetic field pro
In another example the motor may be a stepper motor. An duced by the multipole magnetic strip 140. The magnetic
un -powered stepper motor has a holdback torque, which is 40 sensor may be of any appropriate type. For example it has
a torque of the stepper motor which opposes rotation of the been found that a magnetic sensor which comprises a
stepper motor. The amount of holdback torque can be plurality of Hall Effect sensors (also referred to as Hall
changed by changing an electrical resistance that is con- elements) is capable of providing approximately 1000 sen
nected across each of the windings of the stepper motor. For sor pulses for a full sweep of the dancing arm 28 when using
example , such a technique is described in U.S. Pat. No. 45 a multipole magnet strip which has a pole length Lpole of 2
5,366,303 . The greater the electrical resistance connected mm . In this example, the magnetic sensor which comprises
across each winding the greater the holdback torque of the a plurality of Hall elements is an AS5304 integrated Hall IC
stepper motor. Consequently, by controlling the electrical and the magnetic strip is an AS5000 - MS20-50 multipole
resistance connected across each winding of the stepper magnetic strip , both produced by ams AG , Austria. A full
motor, it is possible to control the braking torque of the 50 sweep of the dancing arm 28 is an angular displacement of
stepper motor. the dancing arm between the extents of the dancing arm's
As previously discussed in relation to FIGS . 2 and 5 , the angular movement.
labelling machine includes a moveable element in the form It will be appreciated that, given the knowledge of the
of a dancing arm 28 having a roller 32 . pole length Lpole of the multipole strip magnet 140 and also
Considering FIGS . 11 , 12 and 13 together, the dancing 55 knowing the diameter of the circumferential surface 142 to
arm 28 also includes a generally annular portion 120 which which the multipole magnetic strip 140 is attached , it is
is mounted for rotation about the axis A and about shaft 122 possible to count signal pulses provided by the magnetic
by bearings 124. The shaft 122 connects the supply spool sensor as the dancing arm 28 rotates in order to determine
support 10 to the brake disc 74 such that the supply spool angular displacement of the dancing arm 28. Furthermore, if
support 10 and the brake disc 74 co - rotate . The supply spool 60 it is known that for a full sweep of the dancing arm 28 a
support 10 , brake disc 74 and connecting shaft 122 are particular number of pulses are generated by the magnetic
mounted for rotation relative to the mounting block 80 about sensor and further known that a full sweep of the dancing
axis A by a second set of bearings 126 . arm 28 represents motion of the dancing arm through an arc
As seen best in FIG . 11 , an arm 128 projects from the of a particular angle (which can be measured based upon
annular portion 120 of the dancing arm 28. A first end 130a 65 physical restrictions on dancing arm movement) it is a
of a resilient biasing member 130 ( which in this case is a straightforward matter to determine the angular displace
tension spring, but may , in other embodiments, be any ment from a ' home' position ( described below ) based upon
US 10,988,276 B2
55 56
a number of pulses generated by the magnetic sensor since Theorem from the known positions of each of the rollers
the dancing arm 28 was in that home position . according to the following equations:
FIG . 16 shows a schematic representation of a portion of
a labelling machine as shown in the previous figures . It is P1 =V (X-3-X ,1)++Cr3 + y,1) (5 )
explained with reference to FIG . 16 how an angular dis- 5
placement of the dancing arm 28 can be used to calculate a
change in the length of the web path 20 between the supply pz-V673-4->) +6 3+y.)? ( 6)
spool support 10 and take up spool support 12 .
A portion of the web path 20 is formed by the loop The line between the centres of rollers 22 and 32 has an
extending between the rollers 22 and 24 via the roller 32. 10 angle c from the y - axis , which can be calculated according
The length L of the portion of the web path 20 extending to following equation :
between the rollers 22 and 24 via the roller 32 can be
calculated as a function of the position of the dancing arm
28 (and hence roller 32 ) . E = tan
Xr3 – Xr1 7
(
)
With reference to FIG . 16 , the dancing arm 28 has a length 15 Yr3 + Yri
r and defines an arc through which roller 32 travels. The
length r is the linear distance between the axis of rotation A
of the dancing arm 28 and the centre of the roller 32. The The line between the centres of rollers 24 and 32 has an
dancing arm 28 has a home position, which may be defined angle y from the y - axis , which can be calculated according
as the position in which the line r is coincident with a line 20 to the following equation:
rn . During operation it can be determined whether the
dancing arm 28 is in the home position by the triggering of
a home position sensor (not shown ), such as a micro - switch y = tan Xy3 – Xr2 (8)
or any other appropriate position sensor . Yr3 + Yr2
Once the home position sensor has been triggered, an 25
angular displacement of the dancer arm 28 from the home
position can be measured by the sensor (in this case the The web path 20 will follow a substantially straight line
magnetic sensor ), which outputs a sensor signal indicative of between each of the rollers 22 , 24 , 32 it contacts . At the point
the position of the moveable element. This position signal of contact between the web path 20 and each of the rollers
takes the form of a series of pulses indicating an angular 30 22 , 24 , 32 ( and in particular an outer circumferential surface
displacement of the dancer arm 28 from the home position of each of the rollers 22 , 24 , 32 ) the web path 20 is tangential
as described above . to the respective roller. The angle between the web path 20
For ease of reference , an angle o representing the angular (between rollers 22 and 32 ) and the line p , between the
displacement of the dancer arm 28 is measured from a centres of the rollers 22 and 32 is a which can be calculated
horizontal (x) axis, shown in FIG. 16. It can be seen from 35 according to the equation:
FIG . 16 that the angle 8 can be calculated from an angle On
indicating angular displacement of the dancer arm from the
home position , and an angle On , of the home position from drl +
dr3 (9 )
a vertical ( y ) axis by the equation : a = sin 2 2
40 Pi
9 =* On - On'
where d, l is the diameter of roller 22 , and d.,z is the diameter
of roller 32 .
The axis A of rotation of the dancer arm 28 is used as a 45
The angle between the web path 20 ( between rollers 24
reference point for relative measurements, with horizontal and 32 ) and the line p2 between the centres of the rollers 24
( x -axis) and vertical ( y - axis ) displacements referring to the and 32 is B , which can be calculated according to the
horizontal and vertical distance from that point. equation:
It will be appreciated that the relative positions of roller 50
22 and roller 24 to the axis of rotation A of the dancer arm
28 are fixed and as such are known. The position of the roller dy2 d, ( 10 )
22 is defined by coordinates ( x - 1, Yr? ). Similarly, the position B = sin 2 P2 2
of the roller 24 is described by coordinates (X,2 , Y , 2 ).
The position of the roller 32 is defined by coordinates ( X - 3,
Yr3 ), although it will be appreciated that as the roller 32 55
moves (as the dancing arm 28 moves ) the values of these where d , 2 is the diameter of roller 24 .
coordinates will not be fixed , and as such , both Xy3 and Yr3 The length of the web path 20 between each of the rollers
are functions of the angle o and length r and can be 22 , 24 and 32 can now be calculated . The length 11 of the
calculated as follows: web path 20 between the rollers 22 and 32 can be calculated
60
Yr3 = r sin e (3 )
according to the following equation :
X -V7 -y. (4) d, 2 ( 11 )

The distance p , between the centre of roller 22 and the 65 li = p? -CAMIdrl +
2
centre of roller 32 , and the distance pz between the centre of

roller 24 and the centre of roller 32 , is given by Pythagoras'
US 10,988,276 B2
57 58
The length 12 of web path 20 between the rollers 24 and (having regard to the orientation of the figure ) and dotted
32 can be calculated according to the following equation: line ‘ c ' is y - ß . Consequently, the angle between dotted line
' b ' ( i.e. the vertical) and dotted line ' c'is
dr2 dr3 ( 12) 5
I12 = P3 - ( 2
T
B
2 + y - B.
In order to calculate the total length L of the web path 20

between the location at which the web path 20 contacts roller 10
22 and the location at which the web path 20 contacts roller arcz = y + . dr22 ( 15 )
24 , the lengths of the arcs which are made by the web path
20 at the circumference of each of the rollers 22 , 24 and 32
where the web path 20 contacts the rollers must be calcu where arcz is the length of the arc between point at which the
15
lated .
As discussed above, at the point of contact with each ( withmakes
web contact with roller 24 on the right-hand side
roller, the web path 20 is tangential to the respective roller. circumferencetoofFIG
respect . 16 ) and the lowermost point on the
Therefore , because the x - axis and y - axis are orthogonal, an arcz is illustrated in FIG24. 16(again
roller with respect to FIG . 16 ) .
angle between a normal to each respective roller at the point ference of the roller 24 between the portion
by the of the circum
dotted line ' d ' and the
of contact of the web path to the respective roller and the 20 dotted line e ' . The angle between the horizontal ( having
X - axis is the same as the angle between the web path 20 and regard to the orientation of the figure ) and dotted line ‘ d ' is
the y - axis .
The angle between the y - axis and the web path 20 vertical) and dotted, thelineangle
Y - B . Consequently
' d '
between dotted line ‘ e ' (i.e. the
is
between rollers 22 and 32 is given by e - a . The angle
between the y - axis and the web path 20 between rollers 24 25
and 32 is given by y - ß .
The length of each arc can be calculated as the product of
the radius of the respective roller and the angle subtended by
2 -y +B.
the arc , with each of the arcs calculated as follows: 30
arc? =
TT
+ a - E dr3 ( 13 )
anc - 6( +26
+ ) Taip ( 16 )
35 where arc4 is the length of the arc between the point at which
where arc , is a length of an arc between a point at which the
web makes contact with roller 32 on the left-hand side (with the web makes contact with roller 22 on the right-hand side
respect to FIG . 16 ) and the uppermost point on the circum (with respect to FIG . 16 ) and the lowermost point on the
ference of roller 32 (again with respect to FIG . 16 ) . arc , is circumference of roller 22. arc4 is illustrated in FIG . 16 by
illustrated in FIG . 16 by the portion of the circumference of the portion of the circumference of the roller 22 between the
the roller 32 between the dotted line ' a ' and the dotted line 40 dotted line ' f' and the dotted line “ g ” . The angle subtended
' b' . by the arc in equation ( 16 ) is derived as follows. Angles at
The angle subtended by the arc in equation ( 13 ) is derived the rotational axis of roller 22 are considered . The angle
as follows. Angles at the rotational axis of roller 32 are subtended between the y - axis and the line p , between the
considered . The angle subtended between the y - axis and the centres of rollers 22 and 32 is ? . The line p1 , web path 20 and
lineP1 between the centres of rollers 22 and 32 is ? . The line 45 dotted line ‘ f ' form a right angled triangle. Within this right
Pi , web path 20 and dotted line ‘ a ’ form a right angled angled web path
triangle , the angle subtended between line p , and the
20 is a . Consequently, the angle subtended by the
triangle. Within this right angled triangle, the angle sub
tended between line Pi and the web path 20 is a . Conse subtended by dotted
line P? and line ‘ fº is w / 2 - a . Because the angle
the arc in equation ( 16 ) is the angle subtended
quently, the angle subtended by the line Pi and dotted line ' a '
is a/2 - a . Because the angle subtended by the arc in equation 50 between
of ? and
the y -axis and dotted line ‘ f ’, it is given by the sum
/2 - a , subtracted from it . This is equal to n / 2 + a - e .
( 13 ) is the angle subtended between the y - axis and dotted The total length L of web path 20 between where the web
line ‘ a ’ , it is given by the sum of ? and / 2 - a, subtracted path 20 contacts
from n . This is equal to /2 + c- as included in equation contacts roller 24 isroller 22 and where the web path 20
calculated as follows :
( 13 ) . 55
L = li + la + arci+ arcz + arcz+ arc4 ( 17)
( 14) It will be appreciated that while the length L has been
arc2 = = 6 + y - B). dr3
TT
calculated between the lowermost point on the circumfer
ence of roller 22 (being the point at which the normal to the
60 web path 20 is parallel with the y -axis ) and the lowermost
where arc , is the length of the arc between the uppermost point on the circumference of roller 24 ( again being the point
point on the circumference of roller 32 (with respect to FIG . at which the normal to the web path 20 is parallel with the
16 ) and the point at which the web makes contact with roller y - axis ) , the portion of the web path 20 considered could in
32 on the right-hand side of roller 32 ( again with respect to fact be any portion which includes the portion of the web
FIG . 16 ) . arcz is illustrated in FIG . 16 by the portion of the 65 path 20 which has a length that varies as a function of the
circumference of the roller 32 between the dotted line ' b ' position of the movable element in this case dancing arm
and the dotted line “ c ' . The angle between the horizontal 28 ) and in such a case it would be apparent to the skilled
US 10,988,276 B2
59 60
person , from the foregoing description, how the length of the web along the web path during said time by adding the
portion of the web path 20 of interest should be calculated . displacement of the web along the web path due to the take
Furthermore , in use , the absolute length L may be used as up spool taking up the label stock and the displacement of
an intermediate value to allow the measurement of a differ- the web along the web path due to a change in the length of
ential length AL which represents the difference in web path 5 the web path between the take up spool support and the
length between the dancer arm 28 being in a first position , supply spool support. For any given period of time the sum
having web path length Lposi ( determined using equation of the displacement of the web along the web path due to the
( 17 ) above) and the dancer arm 28 being in a second take up spool taking up the label stock and the displacement
position , having web path length Lposa ( also determined of the web along the web path due to a change in the length
using equation ( 17 ) above . The differential length AL can be 10 of the web path between the take up spool support and the
calculated according to the equation : supply spool support is equivalent to the length of label
L = Lpos 1-L pos2
AL ( 18)
stock removed from supply spool in said given period of
time .
It will be appreciated that the differential tape path length As previously discussed, if the displacement of the web
AL can be calculated for a plurality of further dancer arm 15 along the web path on to a take up spool or off a supply spool
positions , and that one of the positions may be the home is known in combination with the amount of rotation of the
position . take up spool or supply spool whilst said known displace
It will be appreciated from the foregoing description that ment of the web has occurred, then it is possible to calculate
given knowledge of various fixed dimensions ( e.g. roller the diameter of said take up spool or supply spool in
diameters , angular location of the home position relative to 20 accordance with equation ( 1 ) above .
the y axis , distances between roller centres etc. ) the length The controller may be configured to calculate the diam
of the web path between the roller and roller 24 can the eter of one of the spools in this manner based upon calcu
calculated in the manner described . lated displacement of the web along the web path (which is
It will be appreciated that although one particular method in turn based upon the sensor signal which is indicative of
of calculating a change in web path length has been 25 the position of the moveable element) and a rotation signal
described , any appropriate method of calculating a change in produced by a rotation monitor. The operation of a specific
web path length may be utilised . For example, in one rotation monitor and its alternatives have been previously
embodiment, the web path may extend from a first, fixed discussed and are therefore not referred to again so as to
roller to a second, movable roller and then to a third , fixed avoid repetition. Suffice to say, the rotation monitor may
roller adjacent to the first roller. The second, movable roller 30 include a sensor which produces pulses indicative of a given
moves in a linear manner relative to the first and third rollers . degree of rotation which can be counted, or, alternatively,
In this embodiment, movement of the second roller by a the rotation monitor may count step pulses which are
distance d along its linear path results in a change in web provided to a position controlled motor, such as a stepper
path length of 2d . Furthermore, although in the described motor.
embodiment the sensor which produces a signal indicative 35 A labelling machine of the type described herein may
of the position of the moveable element ( in this case dancing include a brake assembly ( for example , but not limited to ,
arm 28 ) is an angular position sensor , any appropriate sensor that previously described ). In this embodiment the controller
may be used . For example, at least one ultrasonic or laser is configured to calculate the diameter of the spool mounted
distance measurer may be used to measure the position of to one of the spool supports based upon the sensor signal
the moving element. 40 indicative of the position of the moveable element and the
The controller may be configured to calculate a displace- rotation signal indicative of the rotation of the spool the
ment of the web of the label stock along the web path based diameter of which is to be measured . In addition, in this
upon the sensor signal produced by the sensor which is embodiment, the brake assembly is configured to apply a
indicative of the position of the moveable element. braking force to the other one of said spool supports ( i.e. the
For example , if the supply spool is paying out label stock 45 spool support other than that supporting the spool whose
at a known linear speed along the web path ( determined, for diameter it is desired to calculate ) .
example, using one of the techniques described above ) for a In this embodiment, the controller is configured to calcu
known time , and during this time the sensor produces a late the diameter of said spool supported by said one of said
signal which is indicative of a change in position of the spool supports based upon the sensor signal which indicates
moveable element, then the controller may calculate the 50 movement of the dancing arm 28 when the brake assembly
change in the length of the web path between the take up applies a braking force to the other of said spool supports
spool support and supply spool support which has occurred which is sufficient to substantially prevent rotation of the
during said time . Consequently, the controller may calculate other of said spool supports. This is now described in more
the displacement of the web along the web path during said detail.
time by adding the displacement of the web along the web 55 Referring back to FIG . 2 for ease of reference, in this
path due to the supply spool paying out the label stock and embodiment, the brake assembly ( not shown in FIG . 2 )
the displacement of the web along the web path due to a applies a braking force to the supply spool support 10 which
change in the length of the web path between the take up is sufficient to substantially prevent rotation of the supply
spool support and the supply spool support. spool support 10 and supported supply spool 16. Whilst the
Similarly, if the take up spool is taking up label stock at 60 brake assembly substantially prevents rotation of the supply
a known linear speed along the web path for a known time , spool support 10 and supported spool 16 , the controller
and during this time the sensor produces a signal which is controls the motor 14 , which in this case is a stepper motor,
indicative of a change in position of the moveable element, so as to rotate the motor 14 a predetermined number of steps .
then the controller may calculate the change in the length of Rotating the motor 14 a predetermined number of steps is
the web path between the take up spool support and supply 65 equivalent to rotating the take up spool support 12 and
spool support which has occurred during said time . Conse- supported spool 34 by a predetermined angle. This is due to
quently, the controller may calculate the displacement of the the fact that, as noted above , the motor 14 rotates a known
US 10,988,276 B2
61 62
number of steps for a single complete rotation and also due It will be appreciated that the sensor configured to pro
to the fact that the nature of any gearing between the motor duce a sensor signal indicative of the position of the move
14 and the take up spool support 12 is known. able element of the labelling machine previously described
In this case , the take up spool support 12 is rotated in a is a sensor which measures relative displacement (in this
direction such as to wrap web of the label stock 18 on to the 5 case angular displacement) and uses this in combination
take up spool support 12 such that the web of the label stock with a known position in this case the home position ) in
travels along the web path in the direction C. It will be order to determine an absolute position (in this case angular
appreciated that, in other embodiments, the motor 14 and position) . In some embodiments the sensor configured to
hence take up spool support 12 may be rotated in the produce a sensor signal indicative of the position of the
opposite direction. 10 moveable element may be any appropriate sensor which
Rotation of the take up spool support 12 such that the web measures relative displacement and uses this in combination
of the label stock 18 travels along the web path 20 in the with a known position in order to determine absolute posi
direction C whilst a supply spool support 10 ( and hence tion . In other embodiments the sensor configured to produce
supported supply spool 16 ) are substantially prevented from a sensor signal indicative of the position of the moveable
rotating will cause tension in the web to increase . The 15 element may only measure relative displacement. In further
increase in tension in the web will cause the dancing arm to embodiments the sensor configured to produce a sensor
move against the biasing force provided by the spring 130 signal indicative of the position of the moveable element
( not shown in FIG . 2 , but shown in FIG . 7 , which biases the may measure absolute position directly.
dancing arm in an anti -clockwise direction ) in a clockwise Some known labelling machines include a dancing arm
direction so as to reduce the length of the web path 20 20 which is mechanically linked to a brake assembly. In one
between the supply spool support 10 and take up spool example of these known labelling machines, if the tension
support 12 . within the label stock is too great then the tension in the label
The clockwise movement of the dancing arm 28 whilst stock will cause the dancing arm to move so that a brake
the motor 14 is driven a predetermined number of steps will which forms part of the brake assembly and which is
be sensed by the sensor configured to produce a sensor 25 mechanically linked to the dancing arm is released to
signal indicative of the position of the moveable element (in thereby reduce braking force acting on the supply spool
this case the magnetic sensor). In accordance with the support and thereby reduce the tension in the label stock .
equations set out above , the controller calculates the change Conversely, if the tension in the label stock is too little , the
in the length ( equation ( 18 ) ) of the web path 20 between the tension in the label stock will cause the dancing arm to move
supply spool support 10 and take up spool support 12 during 30 such that the brake applies an increased braking force to the
the time the motor 14 is driven based upon the change of supply spool support to thereby increase tension in the label
position of the dancing arm 28 . stock .
Due the fact that the supply spool support ( and hence These known labelling machines suffer from several
supported supply spool 16 ) is prevented from rotating during problems. First , the system can oscillate such that the
this procedure, any change in the length of the web path 20 35 dancing arm oscillates between two positions whilst trying
between the supply spool support 10 and take up spool to maintain tension in the label stock . This can be problem
support 12 will have been caused by that amount of web atic due to the fact that the oscillating nature of the system
being wound on to the take up spool 34 supported by the take may cause the label stock to become misaligned on the
up spool support 12 . rollers which define the web path and hence become mis
The controller can calculate the number of rotations of the 40 aligned when it reaches the labelling peel beak . This may
take up spool support 12 ( and hence supported take up spool lead to incorrect positioning of labels on to a product or may
34 ) which have occurred due to the controller rotating the lead to the labelling machine becoming jammed Secondly,
motor 14 a predetermined number of steps. The controller the oscillating nature of the dancing arm means that the
can also calculate the change in the length of the web path movement of the dancing arm is not entirely predictable . As
20 between the supply spool support 10 and take up spool 45 such , there is the possibility that the dancing arm will collide
support 12 based upon the change in position of the dancing with other parts of the labelling machine or may present a
arm 28. Finally, the controller can calculate the diameter of hazard to a user operating the labelling machine. The
the take up spool 34 supported by the take up spool support labelling machine according to some of the embodiments
12 in accordance with equation ( 1 ) above. described herein provides a way of obviating or mitigating
The apparatus and method used to calculate the diameter 50 at least one of these problems.
of one of the spools above may be utilised when the machine The dancing arm position is indicative of the tension
is started up (to thereby provide an initial measurement of within the label stock due to the fact that the dancing arm is
spool diameter ) and / or may be used periodically as the mounted for rotation about axis A and is biased in the
labelling machine is operating so as to periodically measure direction G by the spring 130. It will be appreciated that
and update the diameter of the relevant spool . For example, 55 direction G in FIG . 2 is opposite to direction G in FIG . 7
the brake may be applied whilst the take up spool support is because FIGS . 2 and 7 show opposite sides of the labelling
being rotated during labelling , the rotation of the take up machine , and in particular of the supply spool support and
spool causing movement of the dancing arm and thereby attached brake disc . Due to the fact that the spring 130 is a
allowing determination of the take up spool diameter during variable force spring ( i.e. a spring which generally obeys
labelling. 60 Hooke's Law ), the force exerted by the spring will vary with
In one embodiment of the method described above , before the position of the dancing arm 28 ( and hence the amount of
carrying out the processing set out above, the controller is extension of the spring ). In particular, the greater the exten
arranged to release the brake completely such that the sion of the spring i.e. the further the dancing arm 28 is
dancing arm 28 assumes its home position ( given action of rotated about axis A in the direction opposite to that indi
the spring 130 ) . This provides a known starting point for 65 cated by G the greater the force exerted by the spring in
measurement of the angular displacement of the dancing order to urge the dancing arm 28 in the direction G) will be .
arm 28 using the methods described above . A component of the force applied by a spring 130 to the
US 10,988,276 B2
63 64
dancing arm will , in use , be applied to the label stock 20 , view of the dancing arm position control system which
thereby providing a tension within the label stock 20 . includes the dancing arm position control algorithm imple
Consequently, some embodiments described herein allow mented by the controller is shown schematically in FIG . 17 .
the dancing arm 28 to be maintained in a substantially The controller is provided with a dancing arm position set
constant position to thereby maintain tension in the label 5 point signal SP2 (t) which is indicative of the desired posi
stock 18 substantially constant. For example, in some tion of the dancing arm ( and hence the desired tension within
embodiments, the dancing arm may be maintained in a the label stock) at any given time . For example, in some
position such that if the labelling machine is orientated as embodiments the dancing arm position set point signal
shown in FIG . 2 the dancing arm 28 is substantially hori- SP2 (t) may correspond to a position of the dancing arm such
zontal. 10 that if the labelling machine is the same as that in FIG . 2 , the
In order to control the position of the dancing arm 28 , an dancing arm may be substantially horizontal. Of course , in
embodiment of the present invention is provided with a other embodiments the dancing arm position set point signal
sensor configured to produce a sensor signal indicative of SP2( 1) may correspond to any desired dancing arm position .
the position of the dancing arm 28. In this case the sensor is The dancing arm position set point signal SP2 ( t ) is provided
the magnetic sensor previously discussed which measures 15 to one input of a subtractor 200. Another input of the
the change in magnetic field caused by the movement of the subtractor 200 is supplied with a feedback signal FB2 (t)
multipole strip magnet which is affixed to a portion of the (described below ) and the subtractor 200 outputs an error
dancing arm 28 . signal E2 (1) which is the difference between the dancing arm
It will be appreciated that, although the moving element position set point signal SP2 (t) and the feedback signal
of this embodiment is a dancing arm , it is within the scope 20 FB2 (t).
of the invention for the moveable element to be any appro- The error signal E2 (t) is supplied to three portions of the
priate moveable element which can define a portion of the PID algorithm . These are the proportional component P, the
web path . Furthermore , it will also be appreciated that integral component I , and the derivative component D. As
although the sensor of this embodiment is the magnetic can be seen from the figure, the proportional component P
sensor as described , any appropriate sensor which is con- 25 outputs a signal which is given by a constant Kp2 multiplied
figured to produce a sensor signal indicative of the position by the error signal E2 (t) . The integral component I outputs
of the moveable element may be used . a signal which is a constant K12 multiplied by the integral of
The present embodiment of the invention also includes a the error signal E2 ( t ). The derivative component D of the
brake assembly configured to apply a variable braking force algorithm outputs a signal which is given by a constant Kp2
to one of said spool supports in this case the supply spool 30 multiplied by a derivative of the error signal E2 (t) with
support, however, in other embodiments, it may be the take respect to time.
up spool ) . The brake assembly may apply the variable An adder 202 combines the signals output by the propor
braking force based upon the sensor signal indicative of the tional P, integral I and derivative D components of the
position of the moveable element. It will be apparent that the algorithm . The output of the adder 202 is a signal which is
braking force applied to the supply spool support will resist 35 indicative of the desired position of the solenoid armature
rotation of the supply spool support ( and hence of the supply relative to the coil in order to produce a desired braking
spool supported by the supply spool support ). force which acts on the supply spool support. Consequently,
This arrangement has the advantage that, unlike the the output of the adder 202 may be referred to as the set point
known labelling machines in which the dancing arm is signal SP ( t) which forms part of the solenoid armature
mechanically linked to a brake of a brake assembly, the 40 position control scheme described earlier. Consequently, the
position of the dancing arm 28 is mechanically decoupled signal SP (t) output by the adder 202 is provided to a solenoid
from the braking force which is applied to the supply spool armature position control scheme 204 which was described
by the brake assembly. By mechanically decoupling the above with reference to FIG . 14 .
brake assembly from the dancing arm it is possible for By controlling the braking force which is applied by the
processing to be performed on the sensor signal indicating 45 brake assembly to the supply spool support, as previously
dancing arm position so as to calculate what braking force discussed, this will affect the tension within the label stock
should be applied to the supply spool support by the brake and consequently affect the position of the dancing arm 28 .
assembly The position of the dancing arm 28 is measured by the
In one embodiment, the brake assembly previously dis- magnetic sensor 206 which has previously been described .
cussed which utilises a controlled solenoid to provide a 50 The magnetic sensor 206 outputs a sensor signal indicative
variable braking force via a brake belt acting on a brake disc of the position of the dancing arm . This signal constitutes the
may be used . In this situation , the braking force applied to feedback signal FB2 ( t) which is provided to the first sub
the supply spool support 10 via the brake belt 76 and brake tractor 200. It is preferred that the value of the signal FB2 (t)
disc 74 depends upon the position of the armature 92 of the should increase as output of the adder 202 (i.e. the control
solenoid 94 . 55 signal to the brake assembly via the solenoid armature
The control scheme used in order to control the current position control scheme) is increased . If this is not the case
supplied to the coil of the solenoid in order to position the then the same functionality may be achieved by swapping
armature of the solenoid at a desired location relative to the over the inputs to the subtractor 200 .
coil has already been discussed and so will not be repeated Any appropriate gain constants Kp2, K 12 and Kp2 may be
here . However, that control scheme requires that the control 60 used . In some embodiments, at least one of these constants
algorithm as shown schematically in FIG . 14 is provided may be equal to zero . However, in a preferred embodiment,
with a set point signal SP (t ). The set point signal SP (t) is all of these constants are non -zero .
determined by a second control algorithm which will be As is common in the art, the gain constants Kp2, K 12 and
referred to as the dancing arm position control algorithm . Kp2 of the dancing arm position control algorithm and the
The dancing arm position control algorithm is imple- 65 gain constants Kp, K , and Ky of the solenoid armature
mented by a controller ( which may or may not be the same position control algorithm may be determined empirically or
controller as previously discussed controllers ). A schematic by using commercially available PID tuning software . In
US 10,988,276 B2
65 66
either case , it is desirable that the value of the gain constants
the measured dancing arm position differs from the desired
Kp , K and Kpe of the dancing arm position control dancing arm position set point in a direction opposite to that
algorithm are chosen such that the signal SP ( t) output by the in which the brake must be applied in order to bring the
dancing arm position control algorithm to the solenoid dancing arm position towards the set point. When the
armature position control algorithm has values which are 5 measured dancing arm position differs from the desired
substantially between the minimum braking value and the dancing arm position set point in a direction opposite to that
maximum braking value . in which the brake must be applied in order to bring the
In some embodiments, the PID control algorithm may dancing arm position towards the set point a PID algorithm
incorporate a dead band . In such embodiments, the error as discussed above may be implemented in the usual way
signal E2 ( t) is set to zero if the feedback signal FB2 ( t) is 10 in other words , a non -symmetric PID algorithm may be
within a given range of the set point signal SP2 (t) . For used .
example, the dead band may operate such that if the differ- In some embodiments , the integral term of the PID
ence between the set point signal SP2 (t) and the feedback algorithm may have a relatively small constant K12 or the set
signal FB2 (t) is less than 15 % of the set point signal SP2 (t) point for the integral term may be different to the set point
( or of the maximum possible value of the set point signal , 15 for the proportional and differential terms. This may be
which corresponds to a desired maximum braking value or useful in control systems which include an integral term
a desired minimum braking value of the set point signal ) because the integral portion of the PID algorithm ‘remem
then the error signal E2 ( t) is set to zero . If the feedback bers ' previous positions of the dancing arm and hence
signal FB2 ( t) falls outside of this range then the error signal attempts to apply an incorrect correction to that which is
E2 (t) is calculated in the manner already described by the 20 required. For example, the correction determined by the
subtractor 200 . integral term may be greater than required , less than required
As previously discussed , other embodiments incorporat- or in the wrong direction . This problem may occur when a
ing a dead band may function in a slightly different manner. labelling machine is in a first steady state ( for example,
These embodiments operate in the same manner as the dead continual dispensing of labels at a first rate ) and then
band previously described except that if the feedback signal 25 changes to a second steady state ( for example, continual
FB2 ( t) falls outside of dead band then the error signal E2 (t) dispensing of labels at a second rate ). It may take time for
is calculated by calculating the difference between the the integral term to change its output from the ideal value for
feedback signal FB2 ( t) and the edge of the dead band which the first state , to the ideal value for the second state . In such
is closest to the feedback signal FB2( t). For example, if the a situation the integral term may be incorrect for a period of
dead band is 15 % of the set point signal SP2 (t) , and the 30 time after the operation of the labelling machine changes to
feedback signal FB2 ( t) has a value of the set point signal the second state .
SP2 (1) plus 5 % of the set point signal SP2 (t) plus u , then the In order to mitigate the problem described above , in some
value of the error signal is –u . Likewise, if the dead band is embodiments, the set point for the integral component of the
25 % of the set point signal SP2 (t) , and the feedback signal PID algorithm may be equivalent to a dancing arm position
FB2 ( t) has a value of the set point signal SP2 ( t) minus 5 % 35 which, if the labelling machine is orientated as shown in
of the set point signal SP2 (t) and minus then the value of the FIG . 2 , is about 5 degrees clockwise from the set point
error signal is u . In another embodiment, if the dead band is position for the proportional and differential terms. Further
+ 5 % of the maximum possible set point (which corresponds more , in some embodiments, a limit to the degree of effect
to a desired maximum braking value or a desired minimum which the integral term may contribute to the overall amount
braking value of the set point signal ) , and the feedback 40 of correction may be applied . For example, the contribution
signal FB2 (1) has a value of the set point signal SP2 (t) plus of the integral term to the applied braking may be limited .
5 % of the set point signal SP2 ( t) plus u , then the value of the In one example , if the braking force is provided by a braking
error signal is –u . Likewise , if the dead band is 25 % of the assembly including a stepper motor as shown in FIGS . 18 to
maximum possible set point signal SP2 ( t ) , and the feedback 20 , the contribution of the integral term of the PID sum may
signal FB2 ( t) has a value of the set point signal SP2 (t) minus 45 be limited to an equivalent of 50 microsteps of the stepper
5 % of the set point signal SP2 (t) and minus then the value motor.
of the error signal is u . In the above described embodiment the controller imple
In some embodiments , the derivative term D within the ments the dancing arm position control algorithm such that
PID algorithm may be calculated not as a function of the the controller evaluates and applies the PID algorithm 1000
derivative of the error signal E2 ( t ), but rather by multiplying 50 times per second . In other embodiments the controller may
a speed of the dancing arm by a constant K 2. The speed of evaluate and control the dancing arm position at any appro
the dancing arm may be calculated based upon the rate of priate rate .
change of the magnetic field detected by the magnetic sensor It will be appreciated that although within the presently
as the multipole magnetic strip attached to a portion of the described embodiment the dancing arm position control
dancing arm moves past the magnetic sensor. Alternatively, 55 scheme includes a PID algorithm , other embodiments of the
the speed of the dancing arm may be calculated based upon invention may use any appropriate control scheme so as to
the rate of change of the signal output by the magnetic control the position of the dancing arm ( or other suitable
sensor . moving element).
In some embodiments, the dancing arm position control Some embodiments the labelling machine may include a
algorithm may be implemented such that if the measured 60 motive means which is configured to propel the web along
dancing arm position differs from the desired dancing arm the web path from the supply spool towards the take up
position set point in a direction such that the brake must be spool . For example , the motive means may include a single
applied in order to bring the dancing arm position towards motor which drives the take up spool support, motors which
the set point, the algorithm may provide an output to the drive each of the take up spool support and supply spool
braking assembly which causes the braking assembly to 65 support, or a motor driving a platen roller in combination
apply the maximum braking force, the braking assembly with a motor driving at least one of the take up spool support
only applying less than the maximum braking force when and supply spool support. The controller may be configured
US 10,988,276 B2
67 68
to control both the motive means and the brake assembly spring is substantially constant regardless of the position of
based upon the sensor signal ( in this case the signal output the movable element, the tension of the label stock will be
by the magnetic sensor) so as to urge the dancing arm substantially constant regardless of the position of the mov
towards a desired position . Urging the dancing arm towards able element. It follows that, in such embodiments, moving
a desired position is equivalent to attempting to obtain a 5 the movable element will not change the tension in the label
desired tension in the label stock , for the reasons previously stock and hence urging the movable element towards a
discussed . Consequently, the controller enables control of desired position cannot be used to set tension in the label
the motive means and the brake assembly based upon the stock .
sensor signal so as to obtain a desired tension in the label Regardless of what type of biasing means biases the
stock and maintain said tension in the label stock between 10 movable element, because the movable element defines a
predetermined limits . portion of the web path , movement of the movable element
The brake assembly 70 within the described embodiments will cause the path length of the web path between the
is said to be capable of applying a variable braking force. supply and take -up spools to change. Changing the path
This is because , the position of the armature of the solenoid length of the web path between the supply spool and take - up
determines the extension of the spring 82 and therefore the 15 spool may allow differences between the speed at which the
braking force applied to the spool support. The armature is take up spool is taking up label stock and the speed at which
controlled so that it can take any position between the the supply spool is paying out label stock to be accommo
extents of movement of the armature . dated . For example, if the take up spool support is driven to
In other embodiments, the brake assembly need not be advance label stock along the web path and the take up spool
capable of applying a variable braking force . For example, 20 support is accelerated, the take up spool may accelerate
in some embodiments the brake assembly may only have more quickly than the supply spool . This may be because the
two states : a braked state and an un - braked state . In the supply spool has a relatively large moment of inertia . This
braked state the brake assembly applies a greater braking difference in acceleration between the take up spool and
force to the spool support than in the un - braked state . In one supply spool may be compensated for by the dancing arm
embodiment, the brake assembly may be controlled by the 25 moving so as to reduce the path length of the web path
controller as a function of the sensor signal indicative of the between the supply spool and take -up spool . Conversely, if
position of the movable member ( e.g. dancing arm ) such that the take up spool support is driven to advance label stock
when the controller determines that the sensor signal indica- along the web path and the take up spool support is decel
tive of the position of the movable member indicates that erated, the take up spool may decelerate more quickly than
more braking force applied to the spool support is required , 30 the supply spool . Again , this may be because the supply
then the controller commands the brake assembly to enter its spool has a relatively large moment of inertia . This differ
braked state . Conversely , the brake assembly may be con- ence in deceleration between the take up spool and supply
trolled by the controller as a function of the sensor signal spool may be compensated for by the dancing arm moving
indicative of the position of the movable member (e.g. so as to increase the path length of the web path between the
dancing arm ) such that when the controller determines that 35 supply spool and take -up spool .
the sensor signal indicative of the position of the movable If the movable element has a limited extent of movement,
member indicates that less braking force applied to the spool between a first extent at which the path length of the web
support is required, then the controller commands the brake path between the supply and take up spools is a maximum ,
assembly to enter its un -braked state . and a second extent at which the path length of the web path
In another embodiment in which the brake assembly has 40 between the supply and take up spools is a minimum , it may
only braked and un - braked states , the brake assembly (in be desirable to urge the movable element towards a position
particular, in this case , the coil of the solenoid of the brake which minimises the likelihood that the movable element
assembly ) may be provided with a pulse width modulated will reach the limits of its extent of movement in trying to
signal ( in this case a voltage signal across the coil of the compensate for differences between the speed at which the
solenoid ). A coil driver which is controlled by the controller 45 take up spool is taking up label stock and the speed at which
may control the duty cycle of the pulse width modulated the supply spool is paying out label stock during operation
voltage signal applied across the coil as a function of the of the labelling machine . If the movable element reaches a
sensor signal provided to the controller which is indicative limit of its extent of movement then it will be unable to
of the position of the movable member. compensate for any further difference between the speed at
By varying the duty cycle of the pulse width modulated 50 which the take up spool is taking up label stock and the
voltage applied across the coil of the solenoid, the current speed at which the supply spool is paying out label stock .
supplied to the coil can be changed. This results in a change The inability to compensate for any further difference
in the position of the armature of the solenoid relative to the between the speed at which the take up spool is taking up
coil and hence a change in the braking force applied by the label stock and the speed at which the supply spool is paying
brake assembly to the spool . 55 out label stock may result in excess tension in the label stock
Although the above described embodiment discusses urg- (which may result in breakage of the label stock) or may
ing the moveable element (e.g. dancing arm ) towards a result in too little tension in the label stock (which may result
desired position ( for example, by setting a desired dancing in the label stock becoming slack ).
arm position set point within the dancing arm position In some embodiments the position which minimises the
control algorithm ) in order to control the tension of the label 60 likelihood that the movable element will reach the limits of
stock . In other embodiments the movable element may be its extent of movement may be a position which is substan
urged towards a desired position for any other appropriate tially equidistant between the limits of its extent of move
purpose . ment. In other embodiments, the characteristics of the label
For example, in some embodiments the movable element ling machine may be such that the position which minimises
may be biased by a constant force spring (i.e. such that the 65 the likelihood that the movable element will reach the limits
spring does not obey Hooke's Law ) . In such embodiments , of its extent of movement may be a position which is closer
because the force applied to the movable element by the to one of the limits of its extent of movement than the other .
US 10,988,276 B2
69 70
For example, in a labelling machine in which the take up The brake belt 76 may be made from any appropriate
spool support is driven to advance label stock along the web material. For example, the brake belt may be made of a
path and in which the supply spool can be braked , the combination of fabric and polymeric material, a combina
position which minimises the likelihood that the movable tion of metal and polymeric material or of a polymeric
element will reach the limits of its extent of movement may 5 material on its own . In one embodiment the brake belt is
be closer to the limit of the extent of the movement of the made out of steel reinforced polyurethane. In one embodi
movable element which corresponds to the maximum path ment the brake belt may be 10 mm wide, 280 mm long and
length of the web path between the supply and take - up formed from material referred to as Habasit TG04 . In
spools . The reason for this is that a brake on the supply spool another embodiment the brake belt is a T2.5 synchroflex
support makes it a lot less likely that there will be a 10 timing belt which has a width of 10 mm and a length of 280
difference between the speed at which the take up spool is mm . In this case the belt is formed from steel reinforced
taking up label stock and the speed at which the supply spool polyurethane and has teeth having a standard T profile
is paying out label stock when the take-up and supply spools according to DIN7721 . Such belts are available from Belt
are decelerating. As such , the movable element is less likely ingonline , Fareham , UK . Because this belt has teeth it is
to have to move in a direction towards the limit of the extent 15 mounted such that the flat surface of the belt (i.e. the
of movement of the movable element which corresponds to opposite surface to that which has the teeth ) is the surface
the maximum path length of the web path between the which contacts the brake disc . In other embodiments the belt
take - up and supply spools . It follows that the position which may be mounted such that the toothed side of the belt
minimises the likelihood that the movable element will contacts the brake disc . In the above described embodiments
reach the limits of its extent of movement may be closer to 20 the brake disc (which may be of any appropriate size in other
the extent of the movement of the movable element which embodiments ) has a diameter of 100 mm .
corresponds to the maximum path length of the web path A generally disc - shaped cam 82c ( also referred to as cam
between the supply and take -up spools . piece ) is mounted on the end of a shaft 82d which is
FIGS . 18 and 19 show a perspective view of a portion of supported for rotation relative to the mounting block 80a
a further embodiment of labelling machine of the type 25 about an axis F via a bearing which supported by the
shown in FIG . 1 or FIG . 2. FIG . 18 shows the dancing arm mounting block 80a . The cam piece is 82c is mounted to the
28 and an alternative brake assembly 70a . The brake assem- shaft 82d such that the cam piece 82c is eccentric with
bly 70a may be substituted for the brake assembly 70 shown respect to axis F of rotation of the shaft 82d . The cam piece
in FIGS . 5 to 11 . 82c is mounted to the shaft 82d such that the cam piece 82c
As before, the dancing arm 28 and supply spool support 30 rotates with the shaft 82d when the shaft 82d rotates about
( not shown within FIG . 18 ) are both mounted for individual axis F. Furthermore, the cam piece 82 is received by the
rotation about a common axis A. In other embodiments, the socket 82b of the end piece 82a such that the end piece 82a
supply spool support and dancing arm 28 may rotate about may freely rotate relative to the cam piece 82c . For example,
their own respective axes . a bearing may be located between cam piece 82c and end
The brake assembly 70a is configured to apply a variable 35 piece 82a to enable relative rotation therebetween .
braking force to the supply spool support, the braking force The shaft 82d and attached cam piece 82c may be driven
resisting rotation of the supply spool support. Although the for rotation about axis F by any appropriate drive means . In
brake assembly 70a is configured to apply braking force to some embodiments the drive means includes a position
the supply spool support, in other embodiments the brake controlled motor which drives the shaft 82d . The position
assembly 70a may be used to apply a braking force to the 40 controlled motor may be any appropriate position controlled
take - up spool support. motor, for example a servo controlled motor or a stepper
The brake assembly 70a includes a brake disc 74 which motor. In the present embodiment the shaft 82d is the shaft
is attached to the supply spool support such that it co - rotates of the position controlled motor, the position controlled
with the supply spool support ( and consequently any supply motor ( indicated schematically by broken lines in FIG . 19 )
spool which is supported by the supply spool support). 45 being mounted to the mounting block 80a . In other embodi
The brake assembly also includes a brake belt 76 which ments the shaft 82d may be mechanically linked to the
extends around part of the outer circumference 88 of the position controlled motor by an appropriate linking arrange
brake disc 74. The brake belt 76 is fixed at a first end 76a to ment. For example, the position controlled motor and shaft
an attachment pin 78 which is mounted to a mounting block may be mechanically linked by a belt , chain or the like . In
80a which is fixed so that it does not rotate with the supply 50 other embodiments the cam (cam piece) may be driven for
spool support. The brake belt 76 is attached at a second end rotation by a position controlled motor in any appropriate
76b to an end piece 82a . The end piece 82a includes a socket manner. For example, in some embodiments the cam may be
82b. driven for rotation by the position controlled motor without
In the embodiment shown , the brake belt 76 has a driving an intermediate shaft to which the cam is mounted
generally rectangular cross - section and it contacts a portion 55 for example a belt driven by the position controlled motor
of the outer circumference 88 of the brake disc 74 which has may directly drive the cam .
a substantially flat surface parallel to the axis A. That is to In the described embodiment the position controlled
say, the substantially flat circumferential surface 88 of the motor is a stepper motor. In particular it is a 42 mm frame
brake disc 74 corresponds to the substantially flat surface of size Sanyo Denki motor ( part number 103H5205-5210 )
the belt 76 which engages the outer circumference 88 of the 60 marketed by Sanko Denki Europe SA , 95958 Roissy Charles
brake disc 74. It will be appreciated that in other embodi- de Gaulle, France .
ments of the labelling machine, the outer circumferential Referring now to FIG . 19 , the position controlled motor
surface of the brake disc and the brake belt may have any and attached cam piece 82 are shown in an initialisation
appropriate corresponding profile. For example the outer position . It will be appreciated that if the position controlled
circumferential surface of the brake disc may include a 65 motor is energised so as to rotate the shaft 82d and attached
V - shaped groove which cooperates with generally circular cam piece 82c in a clockwise direction (as shown in FIG .
cross - section brake belt . 19 ) , then the end piece 82a may be urged in a direction (e.g.
US 10,988,276 B2
71 72
towards the brake disc 74 ) such that the brake belt 76 is or anti -clockwise from the initialisation position ) i.e. fur
loosened around the brake disc 74. In other words , the ther clockwise movement will result in increased braking
tension in the brake belt 76 is reduced . Put another way , force and anti -clockwise movement will result in decreased
when the shaft 82d and attached cam piece 82c are rotated braking force.
in a clockwise direction , the cam will urge ( in this case via 5 Although within the previously described embodiment
the end piece 82a ) at least a portion of the second braking the first braking surface is the outside diameter of the brake
surface ( the surface of the brake belt 76b which may contact disc 74 and the second braking surface is the surface of the
the brake disc 74 in order to produce the braking force) brake belt 76 , which can contact the brake disc , in other
towards the first portion of the belt 76a or in other words embodiments the first and second braking surfaces may be
away from the cam or the second portion of the belt 76b 10 any appropriate first and second braking surfaces provided
( along the path of the brake belt between first and second that when the first and second braking surfaces are urged
ends 76a , 76b ) , thereby urging the second braking surface into contact (or together, or towards one another) via the
( i.e. the relevant surface of the belt 76 ) in a direction out of position controlled motor, friction between the first and
contact with the first braking surface ( i.e. the braking surface second braking surfaces thereby producing the braking
of the brake disc 74 ) . Consequently, energising the position 15 force. For example, the second braking surface may , in some
controlled motor such that it causes the shaft 82d and embodiments, not be a brake belt - for example, it may be
attached cam piece 82c to rotate in a clockwise direction a brake pad, brake shoe etc. Likewise , the first braking
from the initialisation position shown in FIG . 19 will cause surface may not form part of a brake disc . Any appropriate
the braking force exerted by the belt 76 on the braking disc cooperating first and second braking surfaces and corre
74 (and hence attached spool support) to be reduced . 20 sponding braking method may be used .
Conversely, if the position controlled motor is energised A resilient biasing member (which in this embodiment is
so as to rotate the shaft 82d and attached cam piece 82c in a spiral spring 82e , but may be any other appropriate
an anticlockwise direction from the initialisation position resilient biasing member) biases the shaft 82d and attached
shown in FIG . 19 , then this will cause at least a portion of cam piece 82c in a direction such that, within FIG . 19 , the
the brake belt 76 to be moved away from the first end 76a 25 shaft 82d and cam piece 82c are urged in an anti - clockwise
of the brake belt 76 ( along the belt path between the first and direction .
second ends 76a , 76b of the belt 76 ) . In other words, when In the illustrated embodiment the spiral spring has a 25.4
the position controlled motor is energised such that the shaft mm outer diameter and an 11 mm inner diameter. The spring
82d and attached cam piece 82c are rotated in an anti- consists of 4.5 turns of 0.31 mm thick spring steel having a
clockwise direction from the position shown in FIG . 19 , the 30 width of 3.20 mm and produces 33.6 Nmm of force at 1.5
tension in the brake belt 76 is increased, thereby increasing turns of deflection from its natural state . Of course , any
the braking force exerted on the brake disc 74. Put another appropriate type of spiral spring may be used in other
way, then the cam ( cam piece ) is rotated in an anti -clockwise embodiments .
direction by the position controlled motor, the cam ( cam The spiral spring 82e is fixed at a first, outer end to the
piece) urges at least a portion of the second braking surface 35 mounting block 80a by fixing bolt 82f and at a second inner
( surface of the belt 76 which contacts the brake disc 74 so end ( not shown) to the cam piece 82c . The resilient biasing
as to apply the braking force ) in a direction such that the member biases the cam piece 82c in a direction to cause the
second braking surface is urged towards the first braking brake belt 76 to contact the outer circumference 88 of the
surface (i.e. the outer circumference of the brake disc 74 ) . In brake disc 74 so as to apply a braking force to the brake disc
particular, the cam (cam piece 82c) urges a portion of the 40 74 and therefore resist rotation of the brake disc 74 and
second braking surface towards the cam or second portion of attached spool support. The biasing of the cam by the
the belt 76b , or in other words away from the first portion of resilient biasing member ( and hence the biasing of the brake
the belt 76a and retaining pin 78 (along the path of the brake belt towards the brake disc ) ensures that when no power is
belt between first and second ends 76a , 766) . supplied to the position controlled motor ( for example when
In the way described above , the braking force applied to 45 the labelling machine is powered down ), the resilient biasing
the spool support by the frictional interaction between the member causes a braking force to be applied to the brake
brake disc 74 and brake belt 76 can be controlled by disc 74 and hence the spool support. This may help to
controlling the position of the cam (e.g. cam piece 820 ) prevent the spool support from undesirably rotating when
using the position controlled motor. The brake assembly 70a the labelling machine is powered down .
is capable of applying a variable braking force to the supply 50 During use of the labelling machine , if it is desired to
spool support via the attached brake disc 74. Within this reduce the amount of braking force applied by the brake belt
context, variable braking force may be taken to mean a range 76 to the brake disc 74 ( and hence to the spool support) the
of braking forces, not merely a first braking force when the position controlled motor is energised such that the biasing
brake assembly is in a brake engaged position and a second force produced by the resilient biasing means is overcome in
lesser braking force when the brake assembly is in a brake 55 asorder
disengaged position . For example, controlling the position
to enable rotation of the cam in a clockwise direction
shown in FIG . 19 .
controlled motor such that, in the context of FIG . 19 , it As previously discussed, by controlling the position con
causes the cam piece 82c to be rotated anti - clockwise will trolled motor such that the rotary position of the shaft 82d
increase the braking force on the spool support, whereas and attached cam piece 82c is controlled , the amount of
controlling the position controlled motor such that the cam 60 braking force applied to the spool support via the brake disc
piece 82c is rotated clockwise will result in a reduced 74 can be varied . A position controlled motor controller may
braking force applied to the spool support. It will be appre- be used to control the position of the position controlled
ciated that within the embodiment shown in FIG . 19 , if the motor and hence the position of the cam piece 82c to thereby
cam piece 82c were rotated by more than about 90 ° clock- control the braking force . The position controlled motor
wise or anticlockwise from the initialisation position shown 65 controller may be configured such that it is programmed
in FIG . 19 , then the situation will be reversed (whilst the with a position which corresponds to a maximum braking
cam piece 82c is rotated by more than about 90 ° clockwise force to be applied and a position which corresponds to a
US 10,988,276 B2
73 74
minimum braking force to be applied . In such embodiments , the bias force defined maximum braking position by the
in order to control the braking force applied by the braking resilient biasing member. When the labelling machine (and
assembly, the position controlled motor is controlled such hence stepper motor) is energised from the powered off state
that, as required, its position is the position which corre- the cam piece and stepper motor will enter the initialisation
sponds to the maximum braking force; its position is the 5 position as shown in FIG . 19. The initialisation position may
position which corresponds to the minimum braking force; be slightly different to the bias force defined maximum
or its position is between these two positions . braking position . The reason for this is that, when energised,
In some embodiments, the cam piece 82c may be urged in the stepper motor rotor will move from the bias force defined
a direction by a resilient biasing member which urges the maximum braking position to the closest stable position of
brake assembly to apply a braking force to one of the spool 10 the stepper motor rotor relative to the stepper motor stator.
supports as previously discussed . The resilient biasing mem- This may result in a movement between the bias force
ber acting on the cam may define a bias force defined defined maximum braking position and initialisation posi
maximum braking position of the cam and attached motor. tion of up to 2 steps ( equivalent to 16 microsteps in this case )
The bias force defined maximum braking position corre- either clockwise or anticlockwise. In order to compensate
sponds to the position of the cam piece and attached motor 15 for the fact that in the initialisation position the cam may
when the resilient biasing means applies a given biasing cause the brake belt to apply a braking force which is less
force to the cam piece when the motor of the braking than the bias force defined maximum braking force, upon
assembly is de -energised. initialisation the controller commands the stepper motor to
The position controlled motor controller may be pro- rotate 2 steps ( 16 microsteps ) anticlockwise ( as shown in
grammed with the angular distance between a maximum 20 FIG . 19 ) from the initialisation position . This position may
braking position ( for example the bias force defined maxi- be referred to as the compensated maximum braking posi
mum braking position , although any appropriately defined tion . The controller stores this position as the position of the
maximum braking position may be used) and a minimum stepper motor which corresponds to maximum applied brak
braking position of the position controlled motor. The angu- ing force . The controller also sets the position of the stepper
lar distance may, for example, be a number of encoder pulses 25 motor which corresponds to minimum applied braking force
produced by a servo motor or a number of steps of a stepper to be 355 microsteps clockwise rotation from the position of
motor. However, any appropriate parameter may be pro- the stepper motor which corresponds to maximum applied
grammed into the controller which corresponds to the angu- braking force.
lar distance between the maximum braking position and the It will be appreciated that the compensated maximum
minimum braking position of the position controlled motor. 30 braking position (and hence compensated maximum braking
In such an embodiment, when the machine is started up , the force) will be the same as the bias force defined maximum
position controlled motor controller will know that the braking position in the case where the initialisation position
current position of the position controlled motor is a maxi- is 2 steps clockwise of the bias force defined maximum
mum braking position which is equivalent to the bias force braking position . Otherwise, if the initialisation position is 1
defined maximum braking position ( because in the powered- 35 step clockwise of the bias force defined maximum braking
down state of the labelling machine the resilient biasing position , the same as the bias force defined maximum
means has biased the cam piece into the bias force defined braking position , or 1 or 2 steps anti -clockwise of the bias
maximum braking position) and that the minimum braking force defined maximum braking position , then the compen
position of the position controlled motor is substantially a sated maximum braking position will be anti - clockwise of
clockwise rotation of the cam piece by said known angular 40 the bias force defined maximum braking position , and hence
distance between the maximum braking position and the the braking force at the compensated maximum braking
minimum braking position. position may be greater than the braking force at the bias
For example, if the position controlled motor is a stepper force defined maximum braking position . In the case that the
motor, then the position controlled motor controller may be position controlled motor is a stepper motor, the position
programmed with information about the angular distance 45 controlled motor controller may include a stepper motor
between the maximum braking position of the stepper motor driver. Where the position controlled motor is another type
and the minimum braking position of the stepper motor in of motor, the person skilled in the art will appreciate that the
the manner of a known number of motor steps. Of course , position controlled motor controller will include appropriate
the exact number of steps will depend on many variables drive means for the relevant type of motor.
such as the particular type of stepper motor used , the type of 50 The position controlled motor controller may replace the
mechanical linkage between the stepper motor and the cam solenoid armature position control scheme 204 within the
piece , and the geometry of the braking arrangement. dancing arm position control algorithm shown schematically
In one embodiment of the present invention , the position in FIG . 17. The constants Kp2, K12, and Kp2 within the
controlled motor is a stepper motor. In this embodiment the dancing arm position control algorithm may be suitably
stepper motor has 200 full steps per complete rotation . The 55 adjusted to ensure that the set point value SP (t) provided to
stepper motor is driven by a stepper motor driver such that the position controlled motor controller fall within a suitable
it is microstepped , as is well known in the art . In this range for the position controlled motor controller. The
embodiment each full step is split into 8 microsteps. There- position controlled motor controller may then be configured
fore, in this embodiment, there are 1600 microsteps per to convert the set point signal SP (t) into a desired position
complete rotation . Other embodiments may utilise a stepper 60 of the position controlled motor which is between the
motor which has any appropriate number of steps/mi- maximum braking position and minimum braking position .
crosteps per full rotation . For example, in one embodiment Kp2 = 0.6 , K12 = 0.005, and
The cam piece 82c may be urged towards a bias force K12 = 0.6.
defined maximum braking position by a resilient biasing In general terms, the dancing arm position control algo
member as previously discussed . When the labelling 65 rithm will co - operate with the position controlled motor
machine ( and hence stepper motor) is in a powered off state controller such that if the dancing arm position is different
the cam piece and attached stepper motor will be biased into to the desired dancing arm position , the position controlled
US 10,988,276 B2
75 76
motor controller will actuate the braking assembly in order the position controlled motor such that the cam piece 82c is
to try to move the dancing arm towards to desired dancing mounted to the portion of the shaft 82d which extends out of
arm position . In general, the greater the difference between a first end of the position controlled motor ( and which in this
the dancing arm position and the desired dancing arm case is on a first side of the mounting block 80a ) , and such
position , the greater the magnitude of the change in dancing 5 that the brake release catch 28c is mounted to a portion of
arm position that the position controlled motor controller the shaft 82d which extends out of a second end (opposite to
will effect in order to attempt to correct the dancing arm the first end) of the position controlled motor (and which in
position . For example, if the position controlled motor is a this case is on a second side ( opposite the first side) of the
stepper motor, the greater the difference between the danc mounting block 80a ) .
ing arm position and the desired dancing arm position , the 10 It will be appreciated that, whilst in this embodiment the
greater the number of steps the position controlled motor brake release catch is mechanically linked to the second
controller will effect in a given time in order to attempt to braking surface via the shaft 82d, cam piece 82c and end
correct the dancing arm position . It will be appreciated that
the exact behaviour of the position controlled motor con piece 82a , in other embodiments the brake release catch may
troller will be determined by the dancing arm position 15 beappropriate
mechanically linked to the second braking surface in any
manner. For example, in some embodiments the
control algorithm .
In embodiments of the invention in which the braking second braking surface may not be mechanically linked to a
assembly includes a position controlled motor in the form of position controlled motor and the brake release catch may be
a stepper motor, the controller may be configured such that mechanically linked to the second braking surface by
it implements a control scheme for controlling the stepper 20 another method. The brake release arm 286 and brake
motor which reduces the likelihood of the stepper motor release catch 28c are configured such that when the dancing
stalling and thereby preventing operation of the braking arm 28a is rotated clockwise as shown in FIG . 20 beyond a
assembly. Such a control scheme may include any number certain position , the brake release arm 28b engages the brake
of the following aspects . First , a ' start delay’ may be used release catch 28c . Once the brake release arm 28b and brake
which prevents the stepper motor from executing a step until 25 release catch 28c are engaged, further clockwise rotation of
a predetermined amount of time has passed from the motor the dancing arm 28a causes the brake release catch 28c to
coils of the stepper motor being energised. This helps to rotate the shaft 82d in anti -clockwise direction as shown in
ensure that the motor is in a steady state before it starts FIG . 20. This causes the brake release catch 28c to rotate the
operating. In some embodiments the predetermined amount shaft 82d in an anti - clockwise direction as shown in FIG . 20 .
of time is 2 ms , but any appropriate time may be used in 30 Referring now to FIG . 19 , rotation of the shaft 82d within
other embodiments. Secondly, a turn - around delay may be FIG . 20 in an anti -clockwise direction as shown in FIG . 20
implemented. This prevents the stepper motor from execut- will result in the cam piece 82c within FIG . 19 rotating in a
ing a step in the opposite direction to that in which the motor clockwise direction as shown in FIG . thereby reducing
is currently travelling within a predetermined amount of tension in the brake belt 76 and hence releasing the brake,
time of the previous step . In some embodiments the prede- 35 reducing the braking force applied by the brake assembly to
termined amount of time is 5 ms , but any appropriate time the spool support. It follows that, using the brake release
may be used in other embodiments . arrangement shown in FIG . 20 , if an operator wants to
As previously discussed , the brake assembly 70a is con- release the braking force applied by the braking assembly ,
figured such that in a powered down state of the labelling this can be achieved by the operator rotating and holding the
machine the brake assembly applies a braking force to the 40 dancing arm in a clockwise direction as shown in FIG . 20
spool support such that the spool support and supported such that the brake release arm 28b and brake release catch
spool is substantially prevented from rotating. In some 28c engage so as to cause the braking force applied by the
situations it may be desirable to provide a manual override brake assembly to be released as previously discussed . In
for the brake assembly which enables a user to manually some embodiments the dancing arm may be rotated and held
reduce the braking force applied by the brake assembly 45 in a clockwise direction as shown in FIG . 20 by the action
whilst the machine is in a powered -down state . For example, of a user passing label web from a new supply spool
if the spool support which is braked by the braking assembly mounted to the supply spool support around the dancing arm
is the supply spool support, and if it is desired to mount a and the user pulling the label web along the web path to the
new roll of label stock to the supply spool support whist the take up spool support. In this way, when a user is feeding
machine is powered off, it may be beneficial for the supply 50 label web along the web path to the take up spool support
spool support and attached supply spool to be able to rotate from a newly mounted supply spool , the brake assembly is
so that the label stock can be mounted on the supply spool , automatically released thereby enabling the supply spool
pulled from the supply spool , fed along the label path and support to pay out label web from the supply spool .
then attached to the take up spool support. Although the above described braking assembly utilises a
FIG . 20 shows an arrangement which enables the braking 55 position controlled motor, in other embodiments any appro
force applied by the braking assembly to be manually priate type of motor may be used , providing the control
reduced whilst the labelling machine is in a powered down scheme for its operation is suitably modified . For example,
state . In this embodiment the dancing arm 28a includes a in some embodiments a torque controlled motor such as a
brake release arm 28b which is attached to the dancing arm DC motor may be used . In such an embodiment, as is well
28a such that the brake release arm 28b co -rotates with the 60 known in the art, the amount of braking force applied by the
dancing arm 28a . motor is proportional to the current supplied to the motor.
A brake release catch 28c is mounted on the shaft 82d Consequently, the control scheme for such an embodiment
which supports the cam piece 82c ( the cam piece is not may be configured such that the current supplied to the
shown in FIG . 20 , but located on the other side of the motor is a function of the braking force required. For
mounting block 80a to the brake release catch 28c) . In the 65 example , the output of the dancing arm position control
present embodiment the shaft 82d is the shaft of the position algorithm may be a current determined by the dancing arm
controlled motor. The shaft 82d extends out of both ends of position control algorithm which is provided to the motor.
US 10,988,276 B2
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Furthermore, in the above described braking assembly The torque application member is configured such that the
movement of the motor is transmitted to the brake belt via torque applied to the spool support causes the spool support
a cam . In other embodiments any appropriate means may be to be accelerated such that it rotates , also referred to as
used for transmitting movement of the motor to the brake angular acceleration . The rotation ( change in angular posi
belt (or any suitable second braking surface ). For example, 5 tion) of the spool support due to this angular acceleration is
the motor may be linked to a crank which is moved by the measured by the rotation monitor. For an applied torque T
motor so a portion of the brake belt is wound on to the crank the angular acceleration A is related to the moment of inertia
or unwound from the crank by the motor in order to urge the MI by the following equation :
second braking surface towards the first braking surface (or T =MI A ( 19)
otherwise ) and thereby control the braking force applied to 10 The rotation monitor provides a signal to a controller
the spool support. which is indicative of the rotation of the spool support and
The desired tension within the label stock (and hence the supported spool . The controller is configured to determine
desired position of the dancing arm ) may be dependent on the angular acceleration of the spool support based on the
various factors. For example the desired tension may be 15 signal indicative of the rotation of the spool support. Based
greater than the minimum tension required to keep the label on the angular acceleration of the spool support determined
stock taut enough as it passes a print head so that the printer by the controller and the known torque applied to the spool
can successfully print on the labels of the label stock . In support by the torque application member, the controller can
addition, the desired tension may be dependent on the width determine the total moment of inertia of the spool support
and / or thickness of the web of the label stock (i.e. perpen- 20 and supported spool .
dicular to the web path ). The desired tension may be chosen The controller is also provided with information concern
such that the stress within the web of the label stock (which ing the moment of inertia of the spool support. The control
is given by the tension in the web divided by the cross ler can subtract the contribution to the total moment of
sectional area of the web ; where the cross sectional area of inertia of the spool support from the total moment of inertia
the web is the product of the width of the web and the 25 spool so as . to determine the moment of inertia of the supported
thickness of the web ) is less than the breaking stress of the
web . This ensures the tension in the web does not lead to the The controller is further provided with information con
web of the label stock snapping. For example, in some cerning the outer diameter of the spool supported by the
embodiments , the desired tension in the web may be spool support and the outer diameter of the spool support. If
between 1N and 50N . 30 the supported spool is modelled as a thick -walled cylinder
In some labelling machines the desired tension of the then the moment of inertia I of the cylinder is given by
label stock is determined (e.g. calculated ) by a controller
based upon the width of the label stock and is subsequently ( 20 )
set. In some labelling machines the width of the label stock =
1=
=m (r*+ r })
is input into the controller of the labelling machine by a user . 35
In some applications, reliance on a user inputting the width
of the label stock may lead to problems. For example, if the where ri is the outer radius of the spool support, r2 is the
width of the label stock is inputted incorrectly , then the outer radius of the supported spool and m is the mass of the
labelling machine may incorrectly determine and set tension supported spool . Based on this the controller can determine
within the label stock . Incorrect label stock tension may lead 40 the mass of the supported spool of label stock . Again ,
to the label stock breaking or to the label stock being fed modelling the spool as a thick -walled cylinder, the mass of
incorrectly by the labelling machine. the spool of label stock is given by
A labelling machine in accordance with an embodiment of m = pawir ,2-1,3 ) (21 )
the invention is capable of determining a measure indicative
of the width of the label stock as described below. 45 where p is the average density of the spool of label stock and
The labelling machine includes a spool support config- w is the width of the label stock . Consequently, the control
ured to support a spool of label stock , a rotation monitor ler is provided with the average density of the spool of label
configured to monitor rotation of the spool support and a stock and based on this and the equation above the controller
torque application member. can determine the width of the spool of label stock supported
The torque application member is configured to ( either 50 by the spool support.
directly or indirectly ) apply a known torque to the spool The average density of the spool of label stock will differ
support and any supported spool ). For example, the torque for different types of label stock . In some embodiments the
application member may be a movable member, such as a average density of the spool of label stock is known and
dancing arm , which is configured to apply a known force to inputted to the controller by a user or is determined by any
the label stock. The force applied to the label stock by the 55 appropriate known density determining method . In other
movable member results in a tension in the label stock which embodiments a fixed value for the average density of the
applies a torque to the spool support via the spool of label spool of label stock is used regardless of what type of label
stock supported by the spool support. It can be said that the stock is mounted to the spool support. This is possible
movable member applies a torque to the spool support because the majority of types of label stock have a similar
indirectly — in this case torque is applied to the spool support 60 average density of the spool of label stock . In these embodi
by the movable member via the label stock . In another ments, because the average density of the spool of label
example, the torque application member may be a motor, stock used by the controller to determine the width of the
such as a DC motor. The motor mechanically linked to the label stock is an approximation , the width of the spool of
spool support may be energised to apply a known torque to label stock determined by the controller will also be an
the spool support. It can be said that motor applies torque to 65 approximation. However, this approximate width of the
the spool support directly because it is mechanically linked spool of label stock , or indication of the width of the spool
to the spool support. of label stock is , in some embodiments, sufficient for the
US 10,988,276 B2
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controller to determine a correct tension to be applied to the rotation and / or rate of rotation of the supply spool . Based on
label stock as indicated above . this information, as discussed above, the controller can
In some embodiments, the labelling machine includes a determine an indication of the width of the label stock which
supply spool support, take up spool support, motive means is supported by the supply spool support.
configured to move label stock from the supply spool 5 The embodiment discussed above requires a rotation
support to the take up spool support, a brake assembly monitor configured to monitor rotation of the spool support.
configured to apply a braking force to the supply spool, and The rotation monitor may monitor rotation of the supply
a movable member ( e.g. a dancing arm ) which defines a spool support ( and hence the supported supply spool )
portion of the web path between the supply spool support directly or in directly , For example, the rotation monitor may
and take uphome
towards spoolposition
supportby. Thebiasing
movable
meansmember
( e.g. aisspring
biased) . 10 monitor rotation directly by using a tachometer mounted to
The biasing means may include a biasing member. Move monitor the supply spool support. A further example of a rotation
ment of the movable member away from the home position , which monitors rotation of the supply spool directly
is a trigger device which produces a signal every time the
ofagainst the action of the biasing member, causes the length
the web path between the supply spool support and take 15 rotation
spool support rotates through a given portion of a complete
. An example of a suitable trigger device has already
up spool support to decrease.
In this embodiment, the take up spool support, supply been discussed earlier in this application .
spool support, motive means , brake assembly, biasing mem An example of a rotation monitor which monitors the
ber and movable member are as previously described, rotation of the supply spool indirectly is a movable member
although it will be appreciated that in other embodiments 20 ( for example a dancing arm ) which monitors a change in the
any appropriate take up spool support, supply spool support, web path length between the supply spool support and
motive means , brake assembly , biasing member and / or take -up spool support. The change in web path length may
movable member may be used . be equivalent to the length of label stock which has been
In this embodiment, the width of the label stock is removed from the supply spool support. If the controller has
determined as follows. The brake assembly is provided with 25 information as to the diameter of the supply spool (which
a signal by a controller such that it enters a braking mode in may be determined in any of the ways discussed within ),
which the brake assembly applies a braking force to the then based on the change in web path length (and hence the
supply spool which substantially prevents the supply spool length of label stock which is removed from the supply
support and supported supply spool from rotating. The spool ) the controller may calculate the amount and /or rate of
motor which rotates the take up spool support and supported 30 rotation of the supply spool ( and hence supply spool sup
take up spool is energised by the controller in a direction port ). In some embodiments the movable member may be
such that it increases the tension within the label stock the dancing arm 28 , whereas in other embodiments the
between the supply spool support and the take up spool movable member may be any appropriate movable member,
support. The increase in tension in the label stock causes the for example a dancing arm which is not dancing arm 28. In
dancing arm 28 to move away from its home position against 35 some embodiments, the rotation monitor may monitor the
the action of the spring 130. The controller energises the rotation of the supply spool in a combination of both directly
motor until the position of the dancing arm measured by the and indirectly.
sensor configured to produce a sensor signal indicative of In the embodiment described above an indication of the
the position of the moveable element ( in this case dancing width of the label stock is measured with reference to the
arm 28 ) is a desired position . 40 supply spool support and supported supply spool. It will be
Based on the position of the movable element and at least appreciated that in other embodiments an indication of the
one known property of the biasing member which biases the width of the label stock may be measured in the same
movable member towards the home position the controller manner as described above, but instead with reference to the
determines the force being applied by the movable member take up spool support and supported take up spool .
to the label stock when the movable member is at the desired 45 In the embodiment discussed above, the torque is applied
position . In this case the at least one known property of the by the movable member i.e. the torque application member )
biasing member is the extension of the spring 130 and the to the spool support and supported spool via the label stock .
spring constant (or rate ) of the spring 130. Based on the In this case it may be said that the torque is applied to the
force being applied to the label stock by the moveable spool support and supported spool by the torque application
member and the radius of the supply spool (which may be 50 member in an indirect manner (i.e. via an intermediate — in
determined in any appropriate manner, including any of this case the label stock) . In other embodiments the torque
those discussed within the present application ) the controller may be applied to the spool support and supported spool in
can determine the torque applied to the supply spool support any appropriate manner . For example, the torque may be
and the supply spool by the movable member. Consequently, applied directly to the spool support. In one example the
in this embodiment, the movable member is the torque 55 spool support is linked to a DC motor which can rotate the
application member. spool support. The torque applied to the spool support ( and
The brake assembly is provided with a signal from the supported spool ) is proportional to the current supplied to
controller such that it enters an un - braked mode such that the the DC motor. Consequently, by calibrating the DC motor
brake assembly provides substantially no braking force to such that the relationship between torque and applied current
the supply spool . In the un - braked mode of the brake 60 is known, and by measuring the current supplied to the
assembly the supply spool support and supported supply motor, the controller can determine the torque provide to the
spool ) is free to rotate . The force applied to the label stock spool support and supported spool . It follows that this
by the movable member due to the action of the biasing embodiment the DC motor is the torque application member.
member causes the supply spool support and supported As previously discussed, and as seen best in FIG . 3 , an
supply spool to undergo angular acceleration as discussed 65 embodiment of the present invention includes a gap sensor
above . A rotation monitor, as discussed above , provides a including an electromagnetic radiation source 50 and an
signal to the controller which is indicative of the amount of electromagnetic radiation detector 52 .
US 10,988,276 B2
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Known labelling machines which incorporate a gap sen- removing the need for manual adjustment of the sensor
sor of this type may incorrectly sense the edge of certain position in the direction perpendicular to the direction C.
labels . This is explained further in conjunction with FIGS . FIG . 24 shows a portion of the label stock 18a shown in FIG .
21 to 23 . 22 passing through a portion of a labelling machine having
FIG . 21 shows a portion of label stock 18 which may pass 5 a gap sensor according to an embodiment of the present
between the electromagnetic radiation detector 52 and the invention .
electromagnetic radiation transmitter 50 of the gap sensor. In this embodiment the gap sensor includes a transmitter
The label stock has a width Wls. The position on the label portion and receiver portion which are similar to those
stock 18 at which the beam of electromagnetic radiation 58 shown in FIG . 3. The transmitter portion and receiver
passes through the label stock 18 as the label stock 18 10 portion are configured to receive a portion of the label stock
moves past the beam of electromagnetic radiation 58 ) is 18a between them .
indicated by a line h . It can be seen that the line h is located However, the gap sensor of this embodiment is configured
approximately halfway across the width Wls of the label to produce a sensor signal which is a function of a property
stock 18. As the label stock 18 travels along the web path in
the direction C the gap sensor will detect the leading edge of 15 ofThata portion of the label stock 18a at a plurality of positions.
is to say, at any given time , the gap sensor produces a
label 62 when the label stock 18 is aligned with the gap
sensor such that the beam 58 of electromagnetic radiation sensor signal which is a function of a property of the label
produced by the electromagnetic transmitter 50 of the gap stock at a plurality of positions at said given time .
sensor passes through point H. The gap sensor then provides In the case shown in FIG . 24 the transmitter portion
a signal to a controller to indicate the position on the label 20 includes two electromagnetic radiation sources ( for example
stock at which a leading edge of a label has been detected . light emitting diodes , although in other embodiments any
The controller then advances the label stock 18 in the appropriate electromagnetic radiation source may be used ).
direction C a fixed ‘ feed distance to dispense a label . If the The electromagnetic radiation sources each produce a beam
label pitch of the label stock is larger than the distance DB of electromagnetic radiation which passes through the label
( shown in FIG . 3 ) then the feed distance will be approxi- 25 stock 18a . The positions on the label stock 18a at which the
mately Dr. This distance DB is the distance between the edge beams of electromagnetic radiation produced by the elec
66 of the labelling peel beak 30 and the point at which the tromagnetic radiation sources pass through the label stock
beam 58 of radiation passes from the transmitter 50 to the 18 (as the label stock 18 moves past the gap sensor) are
detector 52 as was described above . If the label pitch of the indicated by lines k and 1 respectively. It can be seen that in
label stock is less than the distance DB, then feed distance 30 this embodiment the electromagnetic radiation sources of
will be smaller than DB. to ensure that only one label is the transmitter portion are located such that the lines k and
dispensed . In either case the exact distance fed to dispense 1 are spaced approximately one - fifth of the label stock width
one label is usually provided with manual adjustment since W LS from a respective edge of the label stock 18a . It will be
different applications may require the label to stop at dif- appreciated that in other embodiments, the lines k and 1 may
ferent places relative to the labelling peel beak 30 . 35 be positioned at any appropriate spacing from a respective
Another reason why manual adjustment of the feed dis- edge of the label stock 18a . Furthermore, in some embodi
tance is generally provided is that known gap sensors ments, the lines k and 1 may be spaced different distances
typically have a single emitter and single detector and so from their respective edges .
only sense a single position along a label edge as shown by The receiver portion of the sensor includes at least one
the line h in FIG . 21. This means that the position of the 40 electromagnetic radiation detector. The one or more elec
sensor will typically be manually moved, across the width of tromagnetic radiation detectors are configured such that the
the label i.e. in a direction perpendicular to direction C , to beams of electromagnetic radiation which are emitted by the
accommodate different shapes and sizes of label. If the transmitter portion and passed through the label stock 18a
labels in use do not have leading edges which are straight are incident on the one or more electromagnetic radiation
and perpendicular to the direction of movement C , then the 45 detectors. In some embodiments there may be only one
position of the gap sensor along a line perpendicular to the electromagnetic radiation detector upon which both of the
direction of movement C will affect the stopping position of beamsof electromagnetic radiation are incident. In other
the label . Such manual adjustment of the gap sensor can be embodiments, each of the beams of electromagnetic radia
a further source of variation in label positioning relative to tion may be incident upon its own electromagnetic radiation
the labelling peel beak 30 . 50 detector.
FIGS . 22 and 23 show portions of two different label The receiver portion outputs a signal based on the amount
stocks 18a , 18b which have differently shaped labels , 626 of electromagnetic radiation emitted by the transmitter por
and 62d respectively, compared to those shown in FIG . 21 . tion which is transmitted through the label stock 18a and is
More particularly, FIG . 22 shows parallelogram shaped incident on the receiver portion .
labels having two edges arranged parallel to the direction of 55 As can be seen from FIG . 24 , as the label stock 18a passes
travel of the label 18a , while FIG . 23 shows crescent shaped along the web path in the transportation direction C the label
labels . It can be seen that as the label stocks 18a , 18b are 62b will at least partially obscure the beam of radiation
advanced in the direction C the gap sensor of the labelling passing through point K when the label stock 18a ( and hence
machine will sense the leading edge of the labels 62b and label 62b) is positioned relative to the transmitter and
62d when the beam 58 of radiation passes through points I 60 receiver portions as shown in FIG . 24. Due to the label 62b
and J respectively . Thus it can be seen that variation in the at least partially obscuring the beam of electromagnetic
position of the gap sensor, in the direction perpendicular to radiation passing through point K the sensor signal produced
direction C , will cause variation in the position along the by the receiver portion of the sensor will differ from the
direction C at which a label edge is detected and hence in the sensor signal before the label 62b reaches point K (i.e. , when
label stopping position. 65 the beam of radiation at point K is only passing through the
An embodiment of the present invention described below web and not a label) such that the controller determines that,
obviates or mitigates the above described problem by when the label stock 18a is at a position relative to the
US 10,988,276 B2
83 84
transmitter and receiver portion as shown in FIG . 24 , a stock . In order for these types of labelling machine to
leading edge 62h of a label 62b has been detected . operate correctly, it may be important for the gap sensor to
The controller may be configured such that, based upon a correctly detect the position of the first portion of each label .
change in the sensor signal ( for example, the change in the The position at which the first portion of each label is
sensor signal between when the label stock is positioned 5 detected by the gap sensor may be referred to as the trigger
such that the beams of electromagnetic radiation pass position . It is desirable that the trigger position corresponds
through only the web , and when at least one of the beams of to the same portion of each label as the label stock passes the
electromagnetic radiation is at least partially occluded by thegap sensor , even if the label stock tracks ( i.e. moves in a
leading edge 62h of a label 62b ) the controller may control direction perpendicular to the direction of travel C ) .
the motive means which advances the label stock 18a along 10 FIG . 26 shows a portion of label stock 18b in solid line
the web path in the direction C so as to position a portion of which passes through a known gap sensor of the type
the label stock at a desired location along the web path . discussed in relation to FIGS . 21 to 23. The label stock 18b
Some of the previously described embodiments operate passes between a detector and a transmitter of the gap sensor
such that in attempting to position a desired portion of each in the manner previously discussed . The beam of electro
label ( for example the forward -most point, with respect to 15 magnetic radiation produced by the transmitter portion of
the direction of travel C , of the leading edge of each label ) the gap sensor is incident on the label stock 186. As the label
at a desired position along the web path ( for example at the stock 18b moves past the beam of electromagnetic radiation
edge 66 of the labelling peel beak 30 ) , the gap sensor the beam of electromagnetic radiation traces a path along the
attempts to detect the desired portion of each label and then , label stock indicated by line n . It can be seen that, in this
once the desired portion of each label has been detected , the 20 case , line n is located approximately halfway across the label
controller advances the label stock a known distance along stock 18b .
the web path between the gap sensor and the desired position In this example the gap sensor is located across the web
along the web path . In other embodiments this need not be path (i.e. at a position perpendicular to the direction of travel
the case. C of the label stock) so that the trigger point for each label
For example, some embodiments may operate as follows. 25 is a leading edge of each label . As the label stock 18b travels
The gap sensor is positioned so as to detect a first portion of along the web path in the direction C , the gap sensor will
each label. Once the first portion of the label has been detect the leading edge 62m of the label 62n when the label
detected, the controller advances the label stock a predeter- stock 18b is aligned with the gap sensor such that the beam
mined distance along the web path such that the desired of electromagnetic radiation produced by the electromag
portion of the label (which is different to the first portion of 30 netic transmitter of the gap sensor passes through point
the label) is positioned at the desired position along the web indicated by P. The gap sensor then provides a signal to the
path . For example, if the gap sensor is configured to detect controller to indicate trigger position . In this case the trigger
a first portion of each label which is located 2 cm behind (in position correctly corresponds to the position of the label
a direction parallel to the direction of travel C ) the forward- stock 18b at which the leading edge 62m of a label 62n has
most point (with respect to the direction of travel C ) of the 35 been detected by the gap sensor. The controller may then use
leading edge of the label. If it is desired to locate the this information to advance the label stock a desired distance
forward -most point of the label at the edge of the labelling so as to position a desired portion of the label 62n at a
peel beak then this may be achieved as follows. Once the gap desired position along the web path . For example, the
sensor has detected the first portion of a label , the controller controller may control the take up motor to advance the
controls the take up motor to advance the label stock along 40 leading edge 62m of the label 62n so that it is located at the
the web path by the distance along the web path between the edge of the labelling peel beak .
edge of the labelling peel beak and the gap sensor, minus a In some labelling machines , as the label stock moves
distance of 2 cm ( i.e. the displacement in the direction of along the web path between the supply spool support and the
travel C between the portion of the label detected by the gap take up spool support, the label stock may move in a
sensor and the desired portion of the label ) . 45 direction perpendicular to the direction of travel C of the
In some embodiments the distance along the web path label stock 186. Such movement of the label stock 18b in a
between the desired position along the web path and the gap direction perpendicular to the direction of travel C may in
sensor, and the displacement in the direction of travel C some cases be undesirable and may be referred to as
between the portion of the label detected by the gap sensor ' tracking' of the label web .
and the desired portion of the label may be measured using 50 FIG . 27 also shows in dashed - line a portion of label stock
any appropriate distance measuring apparatus. In other 18C which is equivalent to the label stock 186 but has
embodiments the distance along the web path between the undergone tracking ( i.e., movement perpendicular to the
desired position along the web path and the gap sensor, and direction of travel of the label stock C ) relative to the label
the displacement in the direction of travel C between the stock 186 by moving upwards (with respect to the orienta
portion of the label detected by the gap sensor and the 55 tion of the Figure ) by a distance d?R . Due to the fact that the
desired portion of the label may be manually set by the user label stock 18c (and hence the attached labels 629 ) has
of the labelling machine. For example, the user may manu- moved upwards the leading edge 62p of the label 62q will
ally adjust the distance ( also known as the feed distance ) no longer be detected by the gap sensor as the label stock
which the controller controls the take up motor to advance moves along the web path in direction C. Instead , a second
the label stock along the web path after the first portion of 60 edge 62r of the label 62q will be detected . That is to say, the
a label has been sensed, so that the desired portion of each gap sensor will detect the second edge 62r of the label 629
label is located at the desired position along the web path when the label stock 18c is aligned with the gap sensor such
after the label stock is advanced by the feed distance that the beam of electromagnetic radiation produced by the
subsequent to the first portion of each label being detected electromagnetic transmitter of the gap sensor passes through
by the gap sensor. 65 point indicated by Q. The gap sensor then provides a signal
The feed distance is generally kept constant for a given to the controller to indicate trigger position . Due to the fact
combination of gap sensor configuration and type of label that the label web 18c has undergone tracking relative to the
US 10,988,276 B2
85 86
label web 18b , the trigger position no longer correctly beams of electromagnetic radiation are incident. In other
corresponds to the position of the label stock 18c at which embodiments , each of the beams of electromagnetic radia
the leading edge 62p of a label 62q has been detected by the tion may be incident upon its own electromagnetic radiation
gap sensor. Instead, the trigger position incorrectly corre- detector.
sponds to the position of the label stock 18c at which the 5 The receiver portion outputs a signal based on the amount
second edge 62r of a label 62q has been detected by the gap of electromagnetic radiation emitted by the transmitter por
sensor. Consequently, tracking of the label stock has resulted tion which is transmitted through the label stock 18d and is
in the trigger position becoming incorrect. incident on the receiver portion .
Incorrect determination of the trigger position by the gap As the label stock 18d travels along the web path in the
sensor may be problematic as follows. The labelling 10 direction C , the electromagnetic radiation of the transmitter
machine may be configured such that the feed distance ( i.e. of the gap sensor which is incident on line s will be occluded
the distance the controller advances the label stock after the by the leading edge 62s of the label 62r when the label stock
gap sensor has detected the trigger position ) is appropriate 18d is aligned with the gap sensor such that the first beam
for when the trigger position is when a particular portion of of electromagnetic radiation produced by the electromag
the label is detected by the gap sensor. If, instead, the trigger 15 netic transmitter of the gap sensor passes through the point
position becomes when another portion of the label is indicated by V. Likewise , as the label stock 18d travels along
detected by the gap sensor then the feed distance will no the web path in the direction C , the electromagnetic radia
longer be the correct distance to advance the label stock after tion of the transmitter of the gap sensor which is incident on
the gap sensor has detected the trigger position in order that line t will be occluded by the leading edge 62s of the label
the desired portion of the label is located at the desired 20 62r when the label stock 18d is aligned with the gap sensor
position along the web path . This is illustrated below . such that the second beam of electromagnetic radiation
It can be seen that positions P and the position Q are both produced by the electromagnetic transmitter of the gap
on the line n . However, the points P and Q are spaced by a sensor passes through the point indicated by U.
distance dTE : Thus, it will be clear that tracking of the label The controller is configured to process the signal pro
stock by a distance dtr has caused trigger position measured 25 duced by the receiver of the gap sensor and determines that
by the gap sensor to be displaced by a distance dTE. In the reduction in electromagnetic radiation received by the
particular, the trigger position is now incorrectly detected a receiver, which occurs due to the label 62r occluding the
distance de behind where it is correctly located . The feed electromagnetic radiation at points V and U when the label
distance has been set such that it is a distance FD based on stock 18d is positioned as shown in FIG . 27 , is indicative of
the trigger point being point P. If the trigger point is 30 the trigger position . In this case it is desired that the trigger
incorrectly measured by the gap sensor to be point Q and the position occurs when the leading edge 62s of the label 62r
label stock is advanced by distance FD when the gap sensor is at the gap sensor. As such , the controller correctly iden
triggers at point Q then the label stock will be advanced tifies the trigger position .
a position where the desired portion of the label stock is a FIG . 27 also shows, in dashed - line , a label stock 18e
distance de further along the web path in the direction C 35 having a label 62t which is equivalent to the label stock 18d ,
than it should be . This may lead to incorrect dispensing of but has moved ( or tracked ) in a direction perpendicular to
the labels such that they do not affix to a desired product the direction of travel C of the label web by a distance dtr :
adjacent the labelling machine in a desired position, or may As previously discussed , the distance dtr may be referred to
lead to jamming of the labelling machine. as a tracking distance which has been moved by the label
An embodiment of the present invention seeks to obviate 40 stock 18e.
or mitigate the above discussed problem . As the label stock 18e travels along the web path in the
FIG . 27 shows a portion of label stock 18d and an attached direction C , the electromagnetic radiation of the transmitter
label 62r passing a gap sensor according to an embodiment of the gap sensor which is incident on line s will be occluded
of the present invention . In this case , as in the embodiment by the leading edge 62u of the label 62t when the label stock
shown in FIG . 24 , the gap sensor comprises a transmitter 45 18e is aligned with the gap sensor such that the first beam of
portion and receiver portion which are capable of producing electromagnetic radiation produced by the electromagnetic
a sensor signal which is a function of a property of a portion transmitter of the gap sensor passes through the point
of the label stock at two positions which are spaced from one indicated by V. Likewise, as the label stock 18e travels along
another in a direction non - parallel to the web path . In the web path in the direction C , the electromagnetic radia
particular, the gap sensor comprises a transmitter portion 50 tion of the transmitter of the gap sensor which is incident on
which includes two electromagnetic radiation sources . The line t will be occluded by the second edge 62w of the label
electromagnetic radiation sources each produce a beam of 62t when the label stock 18e is aligned with the gap sensor
electromagnetic radiation which passes through the label such that the second beam of electromagnetic radiation
stock 18d . The positions on the label stock 18d at which the produced by the electromagnetic transmitter of the gap
beams of electromagnetic radiation produced by the elec- 55 sensor passes through the point indicated by W.
tromagnetic radiation sources pass through the label stock In the embodiment shown in FIG . 27 , even though , as is
( as the label stock moves past the gap sensor) are indicated the case for the known gap sensor shown in FIG . 26 , the
by lines s and t respectively . It can be seen that line t second beam of radiation produced by the gap sensor ( which
corresponds to line n in FIG . 26 . traces the line t) is not occluded by the leading edge 62u of
The receiver portion of the sensor includes at least one 60 the label 62t (but rather is occluded by the second edge 62w
electromagnetic radiation detector. The one or more elec- of the label), the controller still detects the trigger position
tromagnetic radiation detectors are configured such that the for label 62t is the same as for label 62r . That is to say. The
beams of electromagnetic radiation which are emitted by the trigger position for both label 62r and label 62t is the same
transmitter portion and passed through the label stock 18d and is when the leading edge 62s , 62u of the label 62r , 62t
are incident on the one or more electromagnetic radiation 65 is at a position along the web path such that it is at the gap
detectors. In some embodiments there may be only one sensor. Because of this, tracking of the label by a distance
electromagnetic radiation detector upon which both of the dtr has not changed the trigger point and consequently the
US 10,988,276 B2
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labelling machine will continue to feed labels to the desired capable of producing a sensor signal which is a function of
position despite the fact that tracking has occurred . a property of a portion of the label stock at two positions
As discussed, the controller detects the trigger position for which are spaced from one another in a direction non
label 62t is the same as for label 62r . This is because the parallel to the web path . In some embodiments the sensor
controller is configured to monitor the signal produced by 5 may comprise a transmitter portion and a receiver portion
the gap sensor and, in order to detect the trigger position , which are capable of producing a sensor signal which is a
require that the label 62t only occludes the electromagnetic function of a property of a portion of the label stock at more
radiation at one of the positions ( i.e. whilst the radiation at than two positions which are spaced from one another in a
the other position is not occluded) . This may be achieved in direction non -parallel to the web path . In some embodiments
various ways . One example is that the controller may 10 in which the sensor comprises a transmitter portion and a
monitor the electromagnetic radiation received at each posi- receiver portion which are capable of producing a sensor
tion individually. Once the controller detects that at one signal which is a function of a property of a portion of the
position the electromagnetic radiation has gone from being label stock at two or more positions which are spaced from
free to pass through the label web to being occluded by a one another in a direction non -parallel to the web path, the
label , then this may cause the controller to detect a trigger 15 transmitter portion and a receiver portion may be configured
position . In another example , the controller may monitor the such that there is a discrete receiver portion for each position
total amount of electromagnetic radiation received by the at which the property of the label stock is measured .
receiver at both positions . The controller may then detect a In this case , the sensor may be used to measure the length
trigger position when the total amount of electromagnetic of a label in the following way. The controller may measure
radiation received by the receiver falls within a predeter- 20 a property of a portion of the label stock using each receiver
mined range ( for example below a predetermined threshold ). portion. The controller will count the number of motor steps
Although the above described embodiment of the inven- during which each receiver portion produces a signal which
tion comprises a gap sensor which includes transmitter is indicative of the presence of a label (e.g. reduced elec
portion with two discrete sources of radiation and receiver tromagnetic radiation measured by the receiver ). This num
with two discrete electromagnetic detectors , other embodi- 25 ber of motor steps is the same as the number of motor steps
ments may include a gap sensor with any appropriate between when each receiver portion produces a signal which
configuration of transmitter and receiver. For example, the is indicative of the absence of a label either side of the label
receiver may include an elongate , planar photodiode which concerned . The controller will then compare the counted
extends lengthways in a direction that is non -parallel to the number of motor steps for each receiver portion and will
direction of travel of the label stock . In some embodiments 30 determine which receiver portion counted the greatest num
the planar photodiode may be substantially rectangular. An ber of steps. The greatest number of steps will then be used
example of a suitable photodiode is an SLCD - 61N4 pro- to determine the label length by multiplying the number of
duced by Silonex, Canada. steps by the linear label stock displacement per step . The
In some embodiments, the signal produced by the gap greatest number of steps is used to determine the label length
sensor may be monitored by the controller and the maximum 35 because this corresponds to the number of steps for the
and / or minimum value of the signal output by the gap sensor receiver portion which detected the presence of a label for
may be monitored to a measure of the amount by which the the greatest amount of time . The receiver portion which
label stock and attached labels have tracked (i.e. moved in detects the presence of a label for the greatest amount of
a direction perpendicular to the direction of travel of the time will detect a length of the label which is closest to the
label web ). In other embodiments the controller may moni- 40 actual length of the label .
tor the signal from each of a plurality of positions spaced FIG . 25 shows a portion of label stock 18a which is the
from one another in a direction non -parallel to the web path same as that shown in FIGS . 22 and 24 passing through a
and based upon the duration that each position is occluded labelling machine having an alternative gap sensor. In this
by a label as a label passes and / or based upon whether each embodiment the sensor of the labelling machine has a
position is occluded by a label at all , determine a measure of 45 transmitter portion which includes an emitter of electromag
the amount by which the label stock and attached labels have netic radiation which produces a beam of electromagnetic
tracked . radiation which is strip - like and which is incident on the
It will be appreciated that although the transmitter portion label stock 18a so as to form a line indicated by M. In some
and receiver portion of the sensor comprise an electromag- embodiments, the emitter of electromagnetic radiation may
netic radiation source and an electromagnetic radiation 50 be configured such that the intensity of the radiation pro
detector respectively such that they can collectively produce duced by the emitter, which , in use , is incident on the label
a sensor signal which is a function of the electromagnetic stock, is substantially uniform along the length of the beam .
transmittance of a portion of the label stock at a plurality of In some embodiments, the emitter of electromagnetic radia
positions spaced from one another in a direction non -parallel tion may be a linear array of LEDs . In this case , the line M
to the web path , any appropriate sensor which can produce 55 extends across approximately 90 % of the width Wls of the
a sensor signal which is a function of any appropriate label stock 18a . It will be appreciated that in other embodi
property of a portion of the label stock at a plurality of ments the line may have any appropriate length . For
positions spaced from one another in a direction non -parallel example, the line may extend beyond the width of the label
to the web path may be used . For example, a sensor which stock . In other embodiments the line M may extend across
is capable of producing a sensor signal which is a function 60 less than 90% of WLS : For example, in some embodiments
of the thickness of a portion of the label stock at a plurality the line M may extend across approximately 50 % of WLLS. :
of positions spaced from one another in a direction non- This may be particularly appropriate if the labels being used
parallel to the web path ( for example perpendicular to the are substantially symmetrical about a line which is substan
web path ) may be used . tially parallel to the path of the label stock . In this situation
As previously discussed , the sensor which is used in 65 the gap sensor may be configured such that the line M
combination with the label stock shown in FIG . 24 com- extends only across a portion of the label stock which is one
prises a transmitter portion and receiver portion which are side of the line of symmetry of the labels of the label stock .
US 10,988,276 B2
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The electromagnetic radiation produced by the transmitter substantially determining the exact position of the forward
portion in this embodiment ( which is henceforth referred to most (with respect to direction C ) point of the label 62b ,
as the strip of electromagnetic radiation ) may be produced such that the controller may correctly position the portion of
by a strip LED device . The strip of electromagnetic radiation the label stock at a desired location along the web path . For
is incident on the label stock 18a at the position M and 5 example , the very tip 62k of the label 62b may be positioned
passes through the label stock where it is incident on a at the edge 66 of the labelling peel beak 30 as shown in FIG .
receiver portion . The receiver portion may comprise a planar 3.
photodiode . The transmitter portion of the sensor may be In some labelling machines which include any of the gap
configured such that the strip of electromagnetic radiation sensors described above , the controller may, based on the
has a substantially uniform intensity of electromagnetic 10 sensor signal produced by the gap sensor, position a desired
radiation produced along its entire length . portion of the label stock at a desired location along the web
It will be appreciated that, in this embodiment, the strip of path which differs from locating the forward -most portion of
electromagnetic radiation is incident on the label stock at a a label at the edge of the labelling peel beak . For example,
plurality of positions which are spaced from one another in in some labelling machines it may be desirable to position
a direction non -parallel to the web path C (in fact, the 15 the forward -most portion of a label so that it is spaced from
positions are spaced from one another in a direction which the edge of the labelling peel beak . In some labelling
is substantially perpendicular to the web path , although this machines the forward -most portion of the label may be
need not be the case in other embodiments ). This is because positioned so that it is spaced a predetermined distance
the line M includes a plurality of positions along that line . before or after (with respect to the label stock transport
A portion of the strip of electromagnetic radiation M 20 direction) the edge of the labelling peel beak . This prede
which is incident on the label stock 18a passes through the termined distance may be set by a user of the labelling
label stock 18a and is incident on the receiver portion. In this machine based on the application of the labelling machine.
case the receiver portion includes a planar photodiode. An In some labelling machines the predetermined distance may
example of a suitable photodiode is an SLCD - 61N4 pro- be referred to as a feed distance .
duced by Silonex , Canada . The planar photodiode outputs a 25 In some embodiments the controller is further configured
sensor signal which is a function of the total amount of to control the motive means based upon particular charac
electromagnetic radiation which is incident upon it . Conse- teristics of the sensor signal . For example, the controller is
quently, due to the fact that the electromagnetic radiation configured to control the motive means based on the deriva
strip M must pass through the label stock 18a in order to tive ( also referred to as rate of change or gradient) of the
reach the planar photodiode of the receiver portion, the 30 sensor signal, based on the second order or greater derivative
sensor signal produced by the planar photodiode of the of the sensor signal and / or based a signature of the sensor
receiver portion is a function of the transmittance of elec- signal. An example of a signature of the sensor signal is
tromagnetic radiation of the portion of the label stock where a particular label passing the sensor causes the sensor
through which the strip of electromagnetic radiation M to produce a sensor signal with a given pattern. For example,
passes . Hence the sensor signal is a function of the trans- 35 the pattern may be a positive derivative , followed by a
mittance of electromagnetic radiation of a plurality of posi- substantially zero derivative, followed by a positive deriva
tions across the width of the label stock through which the tive , followed by a substantially zero derivative, followed by
strip of electromagnetic radiation M passes . The plurality of a negative derivative , followed by a substantially zero
positions through which the strip of electromagnetic radia- derivative, followed by a negative derivative . Each time the
tion passes are spaced from one another in a direction which 40 controller receives a signal from the sensor which has a
is non -parallel to the direction of transport C along the web signature having this pattern then the controller will know
path . that a single label has passed the sensor. Any appropriate
As can be seen in FIG . 25 , when the label stock 18a signature having any appropriate pattern of sensor signal
advances along the web path in the direction C and when the may be used . Furthermore, a feature of the signature may
label stock 18a is located relative to the transmitter portion 45 correspond to a feature of the label stock ( for example , the
and receiver portion of the sensor such that the strip of leading edge or trailing edge of a label ) and the controller
electromagnetic radiation M is located as shown in FIG . 25 , may detect this feature of the signature so as to detect said
as the label stock 18a advances further in the direction C , the feature of the label stock .
label 62b will begin to occlude at least a portion of the strip In some situations, monitoring a particular characteristic
M of electromagnetic radiation . Consequently, as the label 50 of the signal may enable a correct portion of an edge or other
stock advances in direction C beyond the position shown in feature of a label to be correctly determined by the controller
FIG . 25 , the amount of electromagnetic radiation transmitted such that the controller can control the motive means so as
through the label stock 18a such that it is incident on the to locate the determined edge portion or other portion of the
planar photodiode of the receiver portion will reduce . The label correctly at a desired location . For example, the
sensor signal is provided to the controller and the controller 55 controller may detect the presence of a leading edge of a
may identify the presence of an edge ( in this case the leading label (or other appropriate feature of the label stock ) by
edge 62h ) of the label 626 based on a change in the sensor comparing a characteristic (e.g. magnitude , derivative , sec
signal produced by the planar photodiode. For example, if ond order or greater derivative) of the sensor signal to a
the planar photodiode produces a signal which decreases threshold value . When the characteristic of the sensor signal
with decreasing total electromagnetic radiation incident 60 is greater than ( or less than depending on the application ) the
upon it , then the controller may determine the presence of an threshold then the controller will detect the presence of the
edge of a label due to a reduction in the magnitude of the leading edge of the label ( or other appropriate feature of the
sensor signal . label stock ). The threshold may be chosen based on the size
Because the strip M of electromagnetic radiation pro- and / or shape of the labels of a particular label stock .
duced in the described embodiment may be occluded by the 65 Consequently, the labelling machine may be configured such
very tip of a label , such that this occlusion is detected by the that the threshold is determined depending on the type of
sensor, then the sensor of this embodiment is capable of label stock being used . Hence the labelling machine may be
US 10,988,276 B2
91 92
configured to use different threshold values depending on direction along the track 310 which is substantially towards
the size and / or shape of labels of a particular label stock . the fixed rollers 304 , 306. By moving the movable member
The various gap sensors described within this description 308 in the direction N , the path length between the printer
are fixed in that their position parallel to the web path and 36 and labelling component 30 will increase . Conversely, by
perpendicular to the web path is fixed . In other embodi- 5 moving the movable member 308 in a direction opposite ( or
ments, the position of the gap sensor may be user adjust- anti -parallel) to the direction N , the path length between the
able — i.e . the position of the gap sensor along the web path printer 36 and the labelling component 30 will decrease .
and /or perpendicular to the web path may be adjusted by a Consequently, it may be said that the movable member 308
user. is configured such that movement of the movable member
FIG . 28 shows a schematic view of a portion of an 10 modifies a length of the web path between the printer and the
alternative labelling machine 300 in which various of the labelling component.
aforementioned features are applied . The labelling machine It will be appreciated that the motor which moves the
300 includes a supply spool support 10 which supports a movable roller 308 may be any appropriate motor, for
spool 16 of label stock . The label stock 18 travels in a example a position -controlled motor such as a stepper
direction C along a web path 20 between the supply spool 15 motor.
support 10 and a take up spool support 12. The take up spool The printer 36 is configured to perform a printing opera
support 12 wraps a portion of the label stock 18 around it to tion at a first linear speed . That is to say, the printer 36 is
form a take up spool 34. As the label stock 18 travels along configured to print on a portion of the label stock ( for
the web path 20 it passes a printer 36 which is suitable for example the labels ) whilst the label stock travels along the
printing on a portion of the label stock 18. The labelling 20 web path past the printer at a first linear speed . The labelling
machine 300 also includes a labelling peel beak 30 which component 30 (in this case a labelling peel beak) is config
functions so as to separate labels which pass the labelling ured to perform a labelling operation (in this case separation
peel beak 30 from the label stock 18. A motor 14 is linked of the labels from the label web ) at a second linear speed .
to the take up spool support 12 so as to drive the take up That is to say that the labelling component is configured to
spool support so as to propel the web of the label stock 18 25 perform a labelling operation with label stock travelling
along the web path 20 from the supply spool support 10 to along the web path and passing the labelling component at
the take up spool support 12. It will be appreciated that, the second linear speed.
although in the embodiment shown the motor 14 constitutes In some embodiments the first linear speed will be less
motive means configured to propel the web along the web than the second linear speed . This may be due to the fact that
path from the supply spool support towards the take up spool 30 in some cases the maximum linear speed at which certain
support, in other embodiments any appropriate motive printers may operate is less than the maximum speed at
means may be used as has been discussed previously in which the labelling component ( e.g. labelling peel beak)
relation to the embodiment shown in FIGS . 1 and 2 . may operate . For example, in some cases , the maximum
The operation of the labelling machine 300 as so far speed of the printer may be limited by the printing technol
described is substantially identical to the operation of the 35 ogy used by the printer, e.g. thermal transfer printers may
labelling machine shown in FIG . 2. Corresponding features operate at relatively slow speeds .
have been given the same numbering. In known labelling machines which do not include a path
The labelling machine 300 shown in FIG . 28 differs from length adjustor according to the present invention , if the
that shown in FIG . 2 in that it additionally includes a path printer is configured to perform the printing operation at a
length adjustor 302 . 40 first linear speed which is slower than a second linear speed
FIG . 29 shows a portion of the labelling machine shown at which a labelling component is configured to perform a
in FIG . 28. FIG . 29 shows the printer 36 for printing on the labelling operation , then the labelling machine must be
labels of the label stock 18. FIG . 29 also shows the labelling operated such that the label stock travels along the web path
peel beak 30 which is configured to separate labels passing at the lower of the two speeds : in this case the first linear
the labelling peel beak on the web of the label stock . The 45 speed . Consequently, the speed at which the labelling com
labelling peel beak 30 may be referred to as a labelling ponent can operate is limited by the linear speed at which the
component which is configured to perform a labelling opera- label stock must pass the printer.
tion ( in this case separating the labels from the label web ) . A labelling machine according to one embodiment which
It will be appreciated that in other embodiments the labelling includes a path length adjustor attempts to obviate or miti
peel beak 30 may be replaced by a labelling component 50 gate this problem . This is achieved as follows.
which is configured to perform any appropriate labelling A controller which forms part of the labelling machine is
operation. For example , the labelling component may configured to control movement of the movable member and
another type of dispenser, e.g. a vacuum pad . control the motive means so as to allow a first portion of the
The path length adjustor 302 includes a pair of fixed label stock to pass the printer at the first linear speed and a
rollers 304 , 306 and a movable member in this case a 55 second portion of the label stock to pass the labelling
movable roller 308 ) . The rollers 304 , 306 and movable component at the second linear speed . This is achieved as
member 308 are configured to contact a portion of the label follows.
stock 18 and define a portion of the web path 20 between the The following explanation relates to the situation (as
printer 36 and the labelling component 30 . shown in the figures) whereby the label stock travels along
In the present embodiment the movable member is a roller 60 the web path 20 such that the labelling component 30 is
around which the label stock 18 passes . The roller is downstream of the printer 36. If the first linear speed ( i.e.
movable along a substantially linear track 310 by a motor print speed ) is less than the second linear speed (i.e. labelling
312 which is linked to the movable roller 308. The movable speed) , then the path length adjustor 302 must shorten the
member 308 is movable by the motor 312 in a direction N length of the web path between the printer 36 and labelling
which is generally away from the fixed rollers 304 , 306 , or 65 component 30 during a printing operation in order to com
in a direction which is opposite ( or anti parallel) to the pensate for the difference between the first and second linear
direction N in which the movable member 308 moves in a speeds . If the first linear speed is greater than the second
US 10,988,276 B2
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linear speed , then the path length of the web path between region 330 which may be printed on by the printer. The label
the printer 36 and the labelling component 30 must be stock 320 moves along the web path in the direction C. The
increased during a printing operation in order to compensate length of each label is L?. The length of the first region 326
for the difference between the first and second linear speeds . of the label 324 is L1 . Likewise , the length of the second
In both cases , whilst a printing operation is not occurring, 5 region 328 of the label 324 is L2 . The length of the printable
the linear member is moved in the opposite direction to region 330 is Lz . Finally, the length of the gap between
achieve the opposite effect. adjacent labels is LG :
As previously discussed , the path length adjustor 302 The distance between any feature of one label 324 and the
modifies the length of the web path between the printer and same feature on the adjacent label is referred to as the pitch
the labelling component by moving the movable member 10 length Lp. The pitch length Lp is given by the sum of the
length Ly of the first region 326 , the length Ly of the second
308. In particular, the controller may control movement of region
the movable member such that, for a given time t the length 328 , the length L3 of the printable region 330 and the
magnitude of the change in the length of the web path LPL quently, theofpitch Lg the gap between adjacent labels 324. Conse
length Lp is also equal to the sum of the
is given by : 15 label length L? and the gap length LG as was noted above .
In each of these cases , the length has been measured in a
Si - S2 ( 22) direction parallel to the direction C of travel of the label
LPL t
stock 320 .
The length between adjacent printable areas is given by
20 the sum of length Ly of the second region 328 , LG of the gap
where S , is the first linear speed and S , is the second linear between adjacent labels 324 , and the length Ly of the first
speed . region 326 of the label 324. The length between the printable
For example, in the embodiment shown in FIG . 29 , for a regions 330 of adjacent labels 324 is indicated by Lyp. The
movement of the movable member 308 in a particular length Lnp may also be referred to as the non -printable
direction by a given amount, the length of the web path 25 length and may be defined as the pitch length Lp minus the
between the printer and the labelling component will be length L , of the printable region 330 .
changed by twice the given amount. It will be appreciated that the labels of the label stock
It will be appreciated that in the embodiment shown in shown in FIG . 30 are such that the printable region 330 is
FIG . 29 there is a limit to the amount of movement the sandwiched between two regions 324 and 328 which are not
movable member 308 can undertake along the track 310. 30 printed. In other embodiments there may be any appropriate
Consequently, there is a limit to the amount the movable number of printed regions and unprinted regions which form
member 308 can change the length of the web path between part of each label. For example, a label may include only a
the printer and the labelling component so as to compensate single non -printable region and a single printable region . In
for the difference between the first and second linear speeds . other embodiments the label may include a plurality of
This maybe acceptable in some embodiments provided that 35 printable regions and a plurality of non -printable regions .
the difference between the first and second linear speeds and The label stock 320 shown in FIG . 30 is utilised in
the total time for which the labelling machine is run with the conjunction with the path length adjustor 302 shown in FIG .
printer and labelling component operating at different first 29 as follows. It will be apparent that, as previously dis
and second linear speeds results in a required compensation cussed , when the region of each label 330 which is to be
in the length of the web path between the printer and the 40 printed upon by the printer 36 passes the printer 36 it does
labelling component which is sufficiently small such that it so at the first linear speed due to the fact that the printer is
can be compensated for by the movement of the movable configured to perform the printing operation at the first
member of the path length adjustor. linear speed . Conversely, when any region of the label stock
In some embodiments, the path length adjuster may be 320 which is not to be printed upon by the printer 36 (i.e. ,
located along the web path between two components (nei- 45 the portion of the label stock between the printable regions
ther of which need be a printer) of a labelling machine. One 330 of adjacent labels 324 indicated by Lnp ), then these
of the components may have a slow speed mode . For regions may travel past the printer 36 at any appropriate
example , the slow speed mode may be a safe mode which is speed because the printer 36 does not have to carry out a
utilised when trying to diagnose a fault with said component. printing operation on these regions and hence these regions
When the component enters the slow speed mode, the path 50 do not have to pass the printer 36 at the first linear speed at
length adjuster may be used to accommodate a difference which the printer is configured to carry out the printing
between the component speed ( linear speed of a portion of operation .
the label stock past the component) past the component in In the case where the first linear speed is less than the
the slow speed mode , and the component speed of the other second linear speed , and as a consequence of the fact that the
component. Likewise, the path length adjuster may accom- 55 printable region of each label must pass the printer at the first
modate any difference between the component speeds when linear speed, but any other region of the label stock can pass
the component operating at the slow speed is accelerated the printer 36 at any appropriate speed , the path length
back to a normal operating speed . adjustor 302 may be operated as follows.
In other embodiments the different first and second speeds Whilst a printable region 330 of each label 324 passes the
may be accommodated in a different way. FIG . 30 shows a 60 printer 36 , the controller of the labelling machine will
portion of label stock 320 which may be used in a labelling control movement of the movable member 308 and the
machine which includes a path length adjustor. The label motive means ( for example the motor which drives the take
stock 320 consists of a web 322 and a plurality of spaced up spool support) so that the printable region 330 of the label
labels 324 which are attached to the web 322. Each label 324 324 passes the printer 36 at the first linear speed . The
includes a first region 326 and a second region 328 which are 65 controller will control the movement of the movable mem
not printed on by the printer ( these may be referred to as ber and the motive means so as to allow the length Lz of the
non -printable regions ) . Each label also includes a printable printable portion 330 to pass the printer 36 at the first linear
US 10,988,276 B2
95 96
speed . During this time ( i.e. , the time at which the printable element 308 of the path length adjustor 302 causes the length
region 330 of the label 324 is passing the printer 36 ) the of the web path between the printer 36 and the labelling peel
controller also controls movement of the movable member beak 30 to increase .
and the motive means so as to allow a second portion of the Once the portion Lnp of the label stock 320 between the
label stock (i.e. , that adjacent the labelling peel beak 30 ) to 5 printable regions 330 of adjacent labels has been moved past
pass the labelling peel beak 30 at the second linear speed . the printer 36 such that the next printable region 330 is
In this example, due to the fact that the first linear speed located adjacent the printer, then the cycle described above
is less than the second linear speed , the controller achieves willIt will
repeat.
the movement of the first and second portions of the label 10 printable beregion appreciated that during any one cycle , whilst the
stock past the printer and the labelling peel beak respectively movable member330308ofofa label 324 passes the printer 36 the
by rotating the take up spool support at a sufficient speed so move in a direction which is oppositelength
the path adjustor 302 will
as to move the label stock downstream of the path length direction N. Conversely, during the part of a -cycle
( or anti parallel) to the
in which
adjustor 302 at the second linear speed . Simultaneously, the the region of the label stock ( indicated by Lyp) between the
controller will control the movement of the movable mem 15 printable area 330 of adjacent labels 324 passes the printer
ber 308 ( in this case by controlling the movement of the 36 the movable member 308 of the path length adjustor 302
motor 312 ) so as to decrease the path length between the will move in the direction N. Consequently, as the labelling
printer 36 and the labelling peel beak 30. In this case , machine undergoes a number of cycles , the position of the
decreasing the length of the web path between the printer 36 movable member 308 will oscillate .
and the labelling peel beak 30 will involve the controller 20 In a preferred embodiment, the controller is configured to
operating the motor 312 so as to move the movable member control the movement of the movable member and the
308 in a direction which is opposite ( or anti -parallel) to the motive means such that the distance travelled by the mov
direction N. able member 308 in the direction N (whilst the label stock
Once the printer 36 has carried out the printing operation 320 is advanced between printable regions 330 of adjacent
at the first linear speed on the printable region 330 of the 25 labels ) is substantially the same as the distance moved by the
label 324 , then the label stock adjacent the printer may be movable member 308 in a direction opposite ( or anti
advanced at any appropriate speed until the printable region parallel) to the direction N (i.e. , whilst a printable region 330
330 of the next label 324 reaches the printer 36. Conse- of a label 324 passes the printer 35 at the first linear speed ).
quently, during the time it takes for the label stock to In this way, provided that the track 310 is capable of
advance the length Lyp between the printable region 330 of 30 accommodating the movement of the movable member in
adjacent labels 324 the label stock 320 may be advanced at the direction N and in the direction opposite (or anti
any appropriate speed past the printer such as , for example, parallel) to the direction N for a single cycle , the track 310
a speed which exceeds the first linear speed and also exceeds will also be capable of accommodating the movement of the
the second linear speed . movable member in the direction N and in the direction
During this period of movement of the label stock 320 35 opposite ( or anti -parallel) to the direction N for any number
past the printer 36 , the controller controls movement of the of cycles and hence any length of label stock .
movable member 308 and the motive means ( for example a During operation , the movement of the movable member
motor which drives the take up spool support) so as to allow is controlled such that for the time t for one cycle :
a first portion of the label stock (i.e. , that adjacent to the Vit = Vpat + Vrbt ( 23 )
printer 36 ) to pass the printer at a speed which exceeds the 40
second linear speed, and also to allow a second portion of the where V , is the labelling speed ( i.e. linear speed of the label
label stock 320 (i.e. , that adjacent to the labelling peel beak stock past the labelling component ), Vp is the average linear
30 ) to pass the labelling peel beak 30 at the second linear speed of the label stock past the printer during a printing
speed . This is achieved as follows. operation , Ve is the average linear speed of the label stock
The controller controls the motive means so as to rotate 45 past the printer whilst the printer is not carrying out a
the take up spool support at a speed such that the linear speed printing operation, a is the proportion of time t that the
of the label stock 320 downstream of the path length adjustor printer is carrying out the printing operation and b is the
302 (and hence past the labelling peel beak 30 ) is the second proportion of time t that the printer is not carrying out the
linear speed . Simultaneously , the controller controls the printing operation. This expression is also applicable where
movement of the movable member 308 of the path length 50 the printer and labelling component are replaced by any
adjustor 302 so as to increase the length of the web path other appropriate components which operate at different
between the labelling peel beak 30 and the printer 36. In this
speeds.
case , the increase in the length of the web path between theIt will be appreciated that although the above described
labelling peel beak 30 and printer 36 is achieved by the embodiment is such that the first linear speed is less than the
controller controlling the motor 312 so as to move the 55 second linear speed, in other embodiments this need not be
movable member 308 in the direction N. the case . It will be appreciated that if the first linear speed
The combination of the motive means causing the label is greater than the second linear speed , then the path length
stock downstream of the path length adjustor to advance adjustor would have to operate in the opposite manner (i.e. ,
along the web path at the second linear speed, and the path so as to increase the length of the web path between the
length adjustor 302 increasing the length of the web path 60 labelling component 30 and printer 36 whilst the label stock
between the labelling peel beak 30 and printer 36 is that the travels past the printer at the first linear speed and simulta
label stock 320 upstream of the path length adjustor (i.e. , neously a second portion of the label stock travels past the
that which passes the printer 36 ) will move at a linear speed labelling component at the second linear speed ) .
which exceeds the second linear speed . In fact, the linear In the embodiment described above it is assumed that
speed at which the label stock 320 moves along the web path 65 label stock is constantly moved past the labelling compo
upstream of the path length adjustor 302 will be given by the nent. This need not be the case in all embodiments. For
second linear speed plus the rate at which the movable example , the take up spool support may be energised such
US 10,988,276 B2
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that the label stock moves past the labelling component in an Whilst the supply spool support 10 is free to rotate, the
intermittent manner . That is to say , at some points in time the force provided by spring 130 on the dancing arm 28 is
label stock may be stationary at the labelling component. At sufficient to rotate the dancing arm 28 about axis A in the
other points in time the label stock may move past the direction G. In order to enable the dancing arm 28 to rotate
labelling component at a relatively high speed (which 5 about axis A in the direction G the supply spool support 10
exceeds the speed at which the printer can operate ) . mayalso rotate about axis A in the direction G (as previously
The time during which the label stock is substantially discussed, the supply spool support 10 is free to move
stationary at the labelling component may be referred to as because the brake assembly is not applying a braking force
a dwell time . During the dwell time a path length adjuster to the supply spool support ). The dancing arm 28 rotates
( for example , like the one described above, although any 10 about axis A in the direction G until it reaches the home
appropriate path length adjuster may be used ) may be position which is detected by the home position sensor.
controlled by the controller such that the path length adjuster Processing passes from step S1 to step S2 .
increases the path length between the printer and the label- At steps S2 to S4 the controller determines the diameter
ling component at a desired rate to the cause the label stock of the take up spool supported by the take up spool support
to pass the printer at a desired rate ( for example the 15 12 .
operating speed of the printer ). Once a label is printed it is At S2 the controller places the supply spool support brake
then ' stored within a portion of the web path between the assembly under the control of the dancing arm position
labelling component and the printer. control algorithm , as described in relation to FIG . 17. For
Subsequently, after the dwell time , when the label stock is example , applying the dancing arm control algorithm , the
moved past the labelling component (for example by ener- 20 controller may supply a control signal to the position con
gising the take up motor ), the path length adjuster is controlled motor and attached cam piece 82c which will act to
trolled by the controller to reduce the path length between apply the brake fully, until such a time as the dancing arm
the printer and labelling component at a desired rate ( for moves from the home position beyond the set point. This
example , which is substantially equivalent to the speed at allows tension to be introduced into the label web . Alterna
which the label stock is moved past the labelling compo- 25 tively, in embodiments including a solenoid , the controller
nent) in order to allow the ' stored ' printed labels to be acted sends a control signal to the solenoid 94 ( and more particu
upon ( for example dispensed in the case of a labelling beak ) larly to the coil driver 114 ) such an amount of current (which
by the labelling component. Within this embodiment, it will may be no current) is provided to the coil of the solenoid 94
be appreciated that if the path length adjuster is the same as in order for the armature 92 of the solenoid 94 to move
that discussed further above , then the path length adjuster 30 sufficiently in the direction F ' such that the brake is applied
increases the path length between the printer and the label- fully, until such a time as the dancing arm moves from the
ling component by the controller controlling the motor 312 home position beyond the set point. Again , this allows
so as move the movable member 308 in the direction N. tension to be introduced into the label web .
Furthermore, the path length adjuster decreases the path The label stock is then tensioned as follows. At step S3 the
length between the printer and the labelling component by 35 controller energises the motor 14 so that it rotates the take
the controller controlling the motor 312 so as to move the up spool support 12 to wind web of the label stock on to the
movable member 308 in the direction opposite to N. take up spool support 12. As this happens, the tension in the
It will be apparent from the foregoing description that the web of the label stock increases . Increasing tension in the
various features described can be used alongside one another web of the label stock causes the web of the label stock to
in a single labelling machine . That is , unless the context 40 apply greater force to the roller 32 of the dancing arm 28 .
otherwise requires, or unless explicitly stated to the contrary The force applied by the label stock to the dancing arm
herein , it is envisaged that the features described can advan- opposes the spring biasing of the dancing arm 28 in the
tageously be used in a single labelling machine to realise the direction G by the spring 130. Consequently, increasing
various benefits described herein . That said , it will also be tension in the label stock due to rotation of the take up spool
appreciated that many of the features described herein can 45 support causes the dancing arm 28 to move in the opposite
be used separately of one another and as such a labelling direction to G. As previously discussed, the position of the
machine including one or more (but not necessarily all ) of dancing arm 28 is indicative of the tension in the label stock .
the features described herein is envisaged. When the controller is provided with a signal from the
Where a labelling machine including various features sensor which senses the position of the dancing arm which
described above is implemented, the following processing, 50 indicates that the dancing arm is at a desired position which
as illustrated in FIG . 31 , may be carried out at start- up of the is equivalent to a desired tension, processing then advances
labelling machine. to step S4 . In some embodiments the desired tension is a
At Si the controller determines the position of the danc- predetermined or calculated tension . In other embodiments
ing arm 28. In order to do this the controller sends a control the desired tension may be any appropriate tension other
signal to the position controlled motor so as to energise the 55 than no tension — that is to say, the desired tension may be
position controlled motor to rotate the shaft 82d and attached any appropriate tension which removes slack from the label
cam piece 82c in a clockwise direction (as shown in FIG . stock .
19 ) , to the extent that substantially no braking force is At step S4 the controller commands the motor 14 to rotate
applied by the brake belt 76 to the brake disc 74. Alterna- a given number of steps ( for example 50-150 steps) so as to
tively, the controller sends a control signal to the solenoid so 60 wind more label stock on to the take up spool support 12 .
as to energise the solenoid such that sufficient current is This causes the dancing arm 28 to move from its position at
provided to the coil of the solenoid 94 to move the armature the beginning of S4 . Based upon the number of commanded
92 of the solenoid 94 in the direction F to the extent that steps the motor 14 advances in step S4 and on the movement
substantially no braking force is applied by the brake belt 76 of the dancing arm 28 detected by the dancing arm move
to the brake disc 74 . 65 ment sensor (also referred to as the sensor configured to
Consequently, the supply spool support 10 ( and the sup- produce a sensor signal indicative of the position of the
ported supply spool ) is free to rotate . moveable element) during the rotation of the motor 14 the
US 10,988,276 B2
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controller calculates the diameter of the spool supported by where As is the angle by which the spool support rotates per
the take up spool support 12. This process has been dis- step of the motor and Ds is the spool diameter .
cussed in detail above . The predetermined length of the label stock is preferably
At S5 the controller determines the pitch length Lp of the in excess of twice the greatest pitch length of label stock that
label stock 18. This is achieved as follows. In this embodi- 5 will be utilised by the labelling machine . The predetermined
ment, this is done with the supply spool support brake length of label stock may be 300 mm .
assembly under control of the dancing arm position control In other embodiments the take up spool diameter may be
algorithm , although in other embodiments this need not be determined at step S4 and the label pitch length may be
the case . For example, in other embodiments the pitch length 10 determined at step S5 using the print roller encoder.
For example, the take up spool diameter may be deter
of the label stock may be determined with the brake assem mined
bly released ( i.e. not applying a braking force ). Again , in motor at14 step S4 as follows. The controller may energise the
to rotate so as to wind more label stock on to the
order to release the brake assembly, the controller sends a take up spool support 12. The controller may be energised so
control signal to the solenoid 94 ( and more particularly to as to wind a predetermined length of label stock on to the
the coil driver 114) such that sufficient current is provided to 15 take up spool support 12 as measured by the print roller
the coil of the solenoid 94 to move the armature 92 of the encoder. The controller monitors the number of steps of the
solenoid 94 in the direction F to the extent that substantially motor 14 which are required to wind the predetermined
no braking force is applied by the brake belt 76 to the brake length of label stock on to the take up spool support 12. The
disc 74. Consequently, the supply spool support 10 (and the controller then calculates the take up spool diameter based
supported supply spool ) is free to rotate . 20 upon a knowledge of the number of steps of the motor 14
The controller advances the motor which drives the take required for the motor to complete a single revolution , the
up spool support. The controller also monitors the signal 56 length of the predetermined distance , and the number of
provided by the detector 52 of the gap se sor . The controller steps the motor 14 executes in winding the predetermined
counts the number of steps the motor 14 is commanded to length of label stock on to the take up spool support 12 .
advance whilst a label is sensed and, as previously 25 In other embodiments the controller may be energised so
described , uses this information and the diameter of the as to rotate the motor 14 by a predetermined number of steps
spool supported by the take up spool support (determined in so as to wind label stock on to the take up spool support 12 .
step S4 ) to determine the length of a label L?. Likewise, the The controller monitors the length of label stock wound on
controller counts the number of steps the motor 14 is to the take up spool support 12 measured by the print roller
commanded to advance whilst a gap is sensed and, as 30 encoder whilst the motor 14 executes the predetermined
previously described, uses this information and the diameter number of steps . The controller then calculates the take up
of the spool supported by the take up spool support (as spool diameter based upon a knowledge of the number of
determined in step S4 ) to determine the length of a gap LG : steps of the moto 14 required for the motor to complete a
The controller then sums Lp and LG in order to calculate Lp. single revolution , the predetermined number of steps the
In some embodiments, the controller may count the 35 motor 14 executes , and the length of label stock wound on
number of steps the motor 14 is commanded to advance to the take up spool support 12 measured by the print roller
whilst a plurality of labels and gaps are sensed by the encoder whilst the motor 14 executes the predetermined
detector of the gap sensor. The controller may then work out number of steps.
the label length , gap length and /or pitch length by averaging The label pitch length may be determined at step S5 using
the measured label length , gap length and / or pitch length . 40 the print roller encoder as follows.
For example, the controller may count the number of steps The controller advances the motor which drives the take
the motor 14 is advanced whilst the controller monitors the up spool support. The controller also monitors the signal
signal 56 and senses that a total of three labels and three gaps output by the print roller encoder and the signal 56 provided
have passed the gap sensor. The controller may then divide by the detector 52 of the gap sensor. The controller uses the
the number of steps counted by the controller by three to 45 signal output by the print roller encoder to measure the
give the average pitch length Lp of the labels as a number of distance along the web path the label stock moves whilst a
steps . This average pitch length of the labels given in steps label is sensed and hence determines the length of a label L?:
can then be used in combination with the measured diameter Likewise , the controller uses the signal output by the print
of the take up spool in order to determine the label pitch in roller encoder to measure the distance along the web path the
a desired unit . 50 label stock moves whilst a gap is sensed and hence deter
In some embodiments in which the controller counts the mines the length of a gap LG . The controller then sums LL
number of steps the motor is commanded to advance whilst and LG in order to calculate Lp. In some embodiments the
a plurality of labels and gaps are sensed by the detector of controller may use the signal output by the print roller
the gap sensor, the controller may count the number of steps encoder to measure the distance along the web path the label
whilst the motor is commanded to advance a number of steps 55 stock moves between the gap sensor sensing a leading edge
which is at least a determined number of steps which is of a first label and a leading edge of the subsequent label
equivalent to a predetermined length of label stock . The this distance is then set by the controller as the pitch length
controllermay determine the determined number of steps Ns Lp of the label stock 18 .
using the diameter of the take up spool ( which may be In some embodiments, the controller may use the signal
obtained in any manner discussed within) and the predeter- 60 output by the print roller encoder to measure the distance
mined length of label stock LLP according to the equation : along the web path the label stock moves whilst a plurality
of labels and gaps are sensed by the detector of the gap
sensor. The controller may then work out the label length ,
Ns 2LLP ( 24) gap length and / or pitch length by averaging the measured
AsDs 65 label length , gap length and / or pitch length. For example, the
controller may measure the distance along the web path the
label stock moves whilst the controller monitors the signal
US 10,988,276 B2
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56 and senses that a total of three labels and three gaps have measured gap length for each measured gap . The controller
passed the gap sensor . The controller may then divide the may check that the measured gap length is above a minimum
measured distance by three to give the average pitch length predetermined gap length and / or below a maximum prede
Lp of the labels . termined gap length . In one embodiment the minimum
In some embodiments the take up spool diameter may be 5 predetermined gap length is 1 mm and the maximum pre
determined at step S4 and the label pitch length may be determined gap length is 10 mm , however, it will be
determined at step S5 at the same time — i.e. steps S4 and 55 appreciated that other embodiments may use any appropriate
may be carried out at the same time . For example , the minimum and / or maximum predetermined gap length . If a
controller may determine the pitch length of the label stock measured gap length is not greater than the minimum
as described above by advancing the motor which drives the 10 predetermined gap length and /or not less than the maximum
take up spool support and monitoring the signal output by predetermined gap length , then such a measured gap length
the print roller encoder and the signal 56 provided by the is not included by the controller when determining an
detector 52 of the gap sensor. The controller may advance average gap length of the label stock and / or an average pitch
the label stock along the label web path such that the signal length of the label stock .
56 indicates that one label and gap have passed the gap 15 In some embodiments erroneous data regarding measured
sensor. The controller may then use signal output by the print label length is rejected as follows. The controller monitors
roller encoder to determine how far the label stock has the measured label length for each measured label. The
advanced along the web path during said advancement and controller may check the measured label length and compare
hence determine the pitch length of the label stock . At the it to the measured label length for the preceding measured
same time , whilst the label stock has been advanced along 20 label . If the difference in length between the measured label
the web path , the controller counts the number of steps the length and the measured label length of the preceding
motor has executed to produce the advancement of the label measured label is greater than a predetermined amount then
stock . The controller then calculates the diameter of the take the measured label length is not included by the controller
up spool based upon the number of steps of the motor 14 when determining an average label length of the label stock
required for the motor to complete a single revolution, the 25 and / or an average pitch length of the label stock . In one
distance the label stock has advanced along the web path example the predetermined amount is 50% of measured
during said advancement as measured by the print roller label length for the preceding measured label . It will be
encoder, and the number of steps the motor 14 has executed appreciated that in other embodiments the predetermined
in producing said advancement of the label stock along the amount may be any appropriate amount.
label web path used to determine the pitch length of the label 30 In some embodiments erroneous data regarding measured
stock . In some embodiments , the controller may advance the label length is rejected as follows. The controller monitors
label stock along the label web path by a distance such that the measured label length for first measured label after the
a plurality of labels and gaps have passed the gap sensor labelling machine has been switched on . The controller may
the pitch length is then determined as an average as deter- then check the measured label length and compare it to the
mined above . The diameter of the take up spool may then be 35 measured label length for the subsequent measured label . If
determined using the advancement distance which is equiva- the difference in length between the measured label length of
lent to a plurality of labels and gaps . the first measured label and the measured label length of the
In some labelling machines the main source of inaccuracy subsequent measured label is greater than a predetermined
in measuring the pitch length of the label stock may be the amount then the measured label length of the first label is not
edge detection performance of the gap sensor . For instance 40 included by the controller when determining an average
the gap sensor may detect edges to within an error of +/- 0.25 label length of the label stock and / or an average pitch length
mm Therefore the distance between two edges may be of the label stock . In one example the predetermined amount
measured within an error of +/- 0.5 mm Shorter labels is 50 % of measured label length of the subsequent label . It
(hence label stock with a shorter label pitch) will have an will be appreciated that in other embodiments the predeter
error which is proportionally larger compared to that of 45 mined amount may be any appropriate amount.
longer labels (hence label stock with a longer label pitch) . At step S6 the controller positions the leading edge of a
For this reason , it may be advantageous in certain embodi- label at the edge of the labelling peel beak 30. This is
ments to measure the length of a plurality of labels and gaps achieved as follows. The controller monitors the signal 56
( as discussed above) and determine an average label length , provided by the detector 52 of the gap sensor so as to detect
average gap length and / or average pitch length . 50 the leading edge of a label . The controller then commands
In some embodiments erroneous data regarding measured the motor 14 to advance a calculated number of steps such
label length or measured gap length may be rejected whilst that the label stock advances by a linear displacement equal
determining an average label length , an average gap length to the distance DB ( as shown in FIG . 3 ) between the detector
and /or an average pitch length . 52 and the edge 66 of the labelling peel beak 30. The number
One potential cause of erroneous data may be missing 55 of steps is calculated by dividing the distance DB by the
labels . For example, if a label is missing then it will cause radius of the take up spool and by the rotation angle per step
the controller to measure a large gap between the labels in radians. In other embodiments, once the controller deter
either side of where the missing label would have been mines from the signal 56 provided by the detector 52 of the
located, the gap being larger than the standard gap between gap sensor that the leading edge of a label has been detected ,
adjacent labels . It will be appreciated that if the length of 60 the controller then commands the motor 14 to advance until
such a large gap resulting from a missing label were mea- the distance of advancement of the label stock along the
sured and then averaged in addition to the length of other, label web path measured by the print roller encoder is equal
standard , measured gaps, then this would result in an incor- to the distance DB between the detector 52 and the edge 66
rect average of greater length than the average length of of the labelling peel beak 30 .
standard gaps which would otherwise be determined . 65 At S7 the labelling machine is ready to operate .
In some embodiments erroneous data regarding measured During operation , periodically steps S8 and S9 are carried
gap length is rejected as follows. The controller monitors the out.
US 10,988,276 B2
103 104
At step S8 the controller calculates and updates the In other embodiments the controller may be energised so
diameter of the spool mounted to the supply spool support as to rotate the motor 14 by a predetermined number of steps
10 . so as to wind label stock on to the take up spool support 12 .
The process of calculating and updating the supply spool The controller monitors the length of label stock wound on
diameter is first discussed below in the case where the 5 to the take up spool support 12 measured by the print roller
movable element ( dancing arm ) does not move during the encoder whilst the motor 14 executes the predetermined
process. Subsequently, the case where the movable element number of steps. The controller also monitors the signal
moves during the process is discussed . produced by the supply spool rotation monitor to determine
In one embodiment, in order to achieve this, for a given the amount of rotation of the supply spool whilst the
amount of time the controller monitors the signal 56 pro- 10 predetermined number of steps is executed by the motor 14 .
vided by the detector 52 of the gap sensor. The controller The controller then calculates the supply spool diameter
counts the number of periods of the signal 56 during said based upon a knowledge of the length of label stock wound
given time and multiplies this by Lp in order to determine on to the take up spool support 12 measured by the print
the linear displacement of the label stock during said given roller encoder whilst the motor 14 executes the predeter
time . During said given time the controller also monitors a 15 mined number of steps , and amount of rotation of the supply
signal provided to it by a rotation monitoring sensor which spool whilst the predetermined number of steps is executed
monitors the rotation of the supply spool support 10 (and by the motor 14 .
supported supply spool ) . Hence the controller determines In an alternative embodiment at step S8 the controller
the amount of rotation of the supply spool support 10 (and calculates and updates the diameter of the spool mounted to
supported supply spool ) . As discussed above , the controller 20 the supply spool support 10 as follows. For a given amount
can then determine the diameter of the supply spool based of rotation of the supply spool support determined by
upon the linear displacement of the label stock and the monitoring the signal produced by the supply spool rotation
amount of rotation of the supply spool support 10 during monitor, the controller monitors the amount of label stock
said given time . The given amount of time may be defined wound on to the take up spool by monitoring the signal
as the time it takes for a predetermined number of periods of 25 output by the print roller encoder . The controller then
the signal 56 to be received by the controller, or may be calculates the supply spool diameter based upon knowledge
defined as the time it takes for the supply spool to rotate by of the length of label stock wound on to the take up spool
a predetermined number of rotations (as measured by the measured by the print roller encoder and the given amount
rotation monitoring sensor ). of rotation of the supply spool measured by the supply spool
In an alternative embodiment at step S8 the controller 30 rotation monitor. For example, in an embodiment in which
calculates and updates the diameter of the spool mounted to the supply spool rotation monitor includes a pair of magnets
the supply spool support 10 as follows. For a given amount attached to the spool support and a Hall Effect sensor such
of time the controller monitors the amount of rotation of the that the Hall Effect sensor outputs two pulses for every full
supply spool support by monitoring the signal produced by rotation of the spool support, as previously discussed , the
the supply spool rotation monitor. For example , the given 35 given amount of rotation of the supply spool discussed
amount of time may be the time it takes for the supply spool above may be a given number of pulses output by the Hall
support to undergo an integer number of complete rotations Effect sensor.
( as measured by the supply spool rotation monitor) . During During the given amount of time , given amount of rota
the given amount of time the controller counts the number tion of the supply spool , predetermined distance or prede
of steps that the take up motor is commanded to advance . 40 termined number of steps the controller also monitors the
Based upon this information and on the diameter of the take position of the dancing arm by monitoring the signal pro
up spool which has been determined by the controller in vided to the controller by the sensor configured to produce
either step S4 or step S9 , the controller can calculate the a sensor signal indicative of the position of the moveable
length of label stock which has been wound on to the take element (dancing arm ). By comparing the position of the
up spool in the given amount of time . In alternative embodi- 45 dancing arm at the beginning of the given amount of time ,
ments, the given amount of time may be defined as the time given amount of rotation of the supply spool , predetermined
it takes to advance the take up motor a predetermined distance or predetermined number of steps, and at the end of
number of steps , and rotation of the supply spool measured the given amount of time , given amount of rotation of the
by supply spool rotation monitor during this time may be supply spool , predetermined distance or predetermined
used to determine the diameter of the supply spool . 50 number of steps , as discussed above , the controller can
In a further embodiment, at step S8 the controller calcu- determine the change in path length between the supply
lates and updates the diameter of the spool mounted to the spool support and take up spool support which has occurred
supply spool support 10 as follows. The supply spool between the beginning of the given amount of time , given
diameter may be determined using the signal output by the amount of rotation of the supply spool , predetermined
print roller encoder and the signal produced by the supply 55 distance or predetermined number of steps, and the end of
spool rotation monitor. The controller may energise the the given amount of time , given amount of rotation of the
motor 14 to rotate so as to wind more label stock on to the supply spool , predetermined distance or predetermined
take up spool support 12. The controller may be energised so number of steps. The controller then adds the change in path
as to wind a predetermined length of label stock on to the length ( which is positive if the path length has increased and
take up spool support 12 as measured by the print roller 60 negative if the path length has decreased ) between the
encoder. The controller monitors the signal produced by the supply spool support and take up spool support during the
supply spool rotation monitor to determine the amount of given amount of time to the amount of label stock wound
rotation of the supply spool whilst the predetermined length onto the take up spool support during the given amount of
of label stock is wound on to the take up spool support 12 . time . This gives the amount of label stock which has been
The controller then calculates the supply spool diameter 65 unwound from the from the supply spool support during the
based upon knowledge of the amount of rotation of the given amount of time given amount of rotation of the supply
supply spool and the predetermined length . spool , predetermined distance or predetermined number of
US 10,988,276 B2
105 106
steps. Based uponthe amount of rotation of the supply spool tion sensor to determine when the distance of label stock
support during the given amount of time , given amount of unwound from the supply spool is equal to the determined
rotation of the supply spool , predetermined distance or circumference.
predetermined number of steps and on the amount of label In some embodiments determination of the supply spool
stock which has been unwound from the supply spool 5 diameter at step S8 may occur concurrently with at least one
support during the given amount of time the controller can of steps S3 , S4 , S5 and 56 .
determine the diameter of the supply spool . Whilst the controller calculates and updates the diameter
of the spool mounted to the take up spool support 12 the
At step S9 the controller calculates and updates the controller may carry out checks to detect erroneous data
diameter of the spool mounted to the take up spool support 10 regarding measured
12. In one embodiment, in order to achieve this, for a given any erroneous data islabel length or measured gap length . If
detected then the process of calculat
amount of time the controller monitors the signal 56 pro ing and updating the diameter of the spool mounted to the
vided by the detector 52 of the gap sensor. The controller take
counts the number of periods of the signal 56 during said updateupofspool support 12 may be aborted ( such that no
given time and multiplies this by Lp in order to determine 15 neous data ). Subsequentlyis, carried
the diameter
process
out based upon the erro
of calculating and updat
the linear displacement of the label stock during said given ing the diameter of the spool mounted to the take up spool
time . For example, the given time may be such that the support 12 is restarted ( such that an update can be carried out
number of periods of the signal 56 during said given time is without being affected by erroneous data ) . The controller
an integer number between 1 and 10. However, any appro- may detect the presence of erroneous data in any appropriate
priate given time may be used . During said given time the 20 manner. For example, the controller may detect the presence
controller also counts the number of steps that the motor 14 of erroneous data in any of the manners discussed above in
is commanded to take . Hence the controller determines the relation to step S5 .
amount of rotation of the take up spool support 12 (and In some embodiments, the start -up procedure may include
supported supply spool ) . As discussed above , the controller a check to see whether the dancing arm position changed
can then determine the diameter of the take up spool based 25 while the machine was powered off . In order to do this the
upon the linear displacement of the label stock and the controller uses the sensor configured to produce a sensor
amount of rotation of the take up spool support 10 during signal indicative of the position of the moveable element to
said given time . measure and record the position of the movable element
In some embodiments the given amount of time the before the machine is switched off. Subsequently, when the
controller monitors the signal 56 provided by the detector 52 30 machine is switched on , the controller uses the sensor
of the gap sensor may be the time it takes the label web to configured to produce a sensor signal indicative of the
advance a predetermined linear distance . The predetermined position of the moveable element to measure the position of
linear distance is preferably in excess of twice the greatest the movable element and compare it to the position of the
pitch length of label stock that will be utilised by the movable element recorded before the machine was switched
labelling machine . The predetermined length of label stock 35 off. If the position of the movable element is substantially
may be 300 mm . the same when the machine is switched on compared to
In other embodiments, at step S9 , the controller calculates when it was switched off then certain steps within the above
and updates the diameter of the spool mounted to the take up start - up routine may be omitted . For example, steps S2 to
spool support 12 using the print roller encoder in the same S4 , S3 to S5 , S3 to S6 or S3 to S4 may be omitted . In this
manner as discussed in relation to step S4 . 40 case the labelling machine may resume operation using the
In some embodiments , such as those which do not include last known value (i.e. before the machine was switched off)
an encoder measuring movement of the label stock using an of the take -up spool diameter. This is based upon the
encoder which measures rotation of a print roller, the con- assumption that the label stock cannot move (thereby chang
troller may determine the take up spool diameter and then ing the diameter of the spools ) without changing the position
wait until the take up spool has subsequently completed one 45 of the movable element ( e.g. dancing arm ). The purpose of
rotation before re -determining the take up spool diameter. omitting unnecessary steps is to reduce start - up time which
Likewise , in some embodiments the controller may deter- may be beneficial in some applications. In some embodi
mine the supply spool diameter and then wait until the ments data indicative of the position of the movable element,
supply spool has subsequently completed one rotation the diameter of the take up spool and /or any other appro
before re - determining the supply spool diameter. 50 priate parameter may be stored in a battery -powered
In order to determine whether the take up spool has memory or any other suitable non - volatile memory. In some
completed one rotation , the controller may wait for the take embodiments, data indicative of position of the movable
up motor to execute the number of steps equal to that for a member may be updated to the memory every time move
complete rotation . Alternatively, the controller may use the ment of the arm is detected by the controller. In other
determined diameter of the take up spool to determine the 55 embodiments data indicative of the position of the movable
circumference of the take up spool . The controller can then element, the diameter of the take up spool and / or any other
monitor the signal output by the printer roller encoder to appropriate parameter may be updated to the memory at a
determine when the distance moved by the label stock along suitable regular time interval.
the label web path is equal to the determined circumference . In some embodiments, the start -up sequence may be
In order to determine whether the supply spool has 60 modified compared to that discussed above. For example, in
completed one rotation, the controller may monitor the some embodiments the start -up sequence may be modified
supply spool rotation monitor to determine when the supply such that it proceeds in the order S1 , S2 , S3 , S4 , S6 , S7 , S5 ,
spool has completed a rotation . Alternatively, the controller S8 , S9 . Subsequently, as before , steps S7 , S8 and 39 then
may use the determined diameter of the supply spool to repeat during on - going operation of the machine . In some
determine the circumference of the supply spool . The con- 65 applications this start- up sequence may be advantageous
troller can then monitor the signal output by the printer roller because by not determining the label pitch until the labelling
encoder and the movable element (e.g. dancing arm ) posi- machine is operating so as to dispense labels on to an article
US 10,988,276 B2
107 108
to be labelled this can reduce the time the start -up procedure position such that the labelling peel beak and printer are
( e.g. up to the ready to operate state S7) takes to complete remote from the conveyor ( and hence articles on the con
and also prevent wastage of labels . This is because , in this veyor). Such labelling machines may then incorporate a
embodiment, the labels dispensed whilst determining the tamp (or any other appropriate label transfer device ) which
label pitch are used by the labelling machine ( i.e. applied to 5 is controllably moved so as to transfer each label from the
articles) as opposed to wasted (i.e. not applied to an article labelling peel beak of the labelling machine and subse
and dispensed only in order to determine label pitch) .
The previously described start-up sequence may equally quentlyHowever
apply it to the required position on each article.
, the use of a tamp (or any other appropriate label
be applied in conjunction with a braking assembly including transfer device ) in this manner may be disadvantageous. For
a solenoid as shown in FIGS . 5 to 11 or in conjunction with 10 example , the label transfer means will increase the com
a braking assembly including a position controlled motor as plexity and cost of the labelling machine . In addition , the
shown in FIGS . 18 to 20 .
As described above , some labelling machines may incor labelling machine whichis may
label transfer device an additional component of the
fail, thus causing the labelling
porate a printer and be referred to as print and apply
labelling machines. A known type of print and apply label- 15 machine to become inoperable. Furthermore, the time it
ling machine is a “ last label out ' labelling machine . ‘ Last takes for a printed label to be transferred by the label transfer
label out ’ labelling machines function so as to print a specific device from the labelling machine to the desired article on
label for a specific article and then apply that label to the the conveyor may increase the time it take for labels to be
specific article. For example, a ‘ Last label out ' labelling applied to an article, thereby reducing the throughput of the
machine may operate such that for each article that passes 20 labelling machine and / or conveyor.
the labelling machine a unique label is printed and then A labelling machine according to an embodiment of the
applied to the article . In some “ last label out' machines the present invention seeks to obviate or mitigate the above
printed label differs for each article, whereas in other last problem .
label out machines ' the printed label may differ during the FIG . 32 shows a schematic cross - sectional view of a
course of a production batch passing the labelling machine. 25 portion of a production line to which a labelling machine
Due to the fact that ‘ Last label out ' labelling machines may 400 according to an embodiment of the present invention is
print a unique label for each article before it is applied to the mounted .
article , it is common for the printer of the labelling machine The portion of the production line 402 shown in the figure
to be located in close proximity to the labelling peel beak . includes a base 403 having a sidewall 404. The base 403
The location of the printer adjacent the labelling peel beak 30 supports a conveyor belt 406. The conveyor belt 406 is
may make the portion of the labelling machine which driven such that it travels in a direction which is into the
includes the labelling peel beak bulky. page as shown in FIG . 32. The conveyor belt 406 is
Certain known label and /or barcode positioning standards configured to support articles to be labelled by the labelling
( e.g. the GS1 barcode positioning standard produced by GS1 machine 400. The figure shows one such article 408 to be
UK) require that labels incorporating a barcode are applied 35 labelled . In this case , the article 408 is a generally cuboid
by the labelling machine at a particular position on an article box , although may be any appropriate article .
( which may also be referred to as a traded unit or an outer The sidewall 404 of the base extends above the surface of
case) . For example, if the labelling machine is configured to the conveyor belt 406 which supports the articles to be
apply labels to articles which pass the labelling machine on labelled by the labelling machine 400. Thus, the sidewall
a conveyor, then known label positioning standards may 40 404 acts as a barrier to prevent any articles being supported
necessitate that the labelling machine is configured to apply by the conveyor belt 406 from falling off the side of the
labels to each article on the conveyor such that the bottom conveyor belt 406. In other embodiments the sidewall may
of a barcode symbol on each label is located at a height of be separate to the base . In some embodiments , the sidewall
approximately 32 mm from the base of the article (and hence may extend inboard of an edge of the conveyor belt .
approximately 32 mm from the conveyor ). Known label 45 The labelling machine 400 is mounted to the production
positioning standards may necessitate that the labelling line. In this case the labelling machine is mounted to the
machine is configured to apply labels to each article on the sidewall 404 of the base 403 of the production line 402. It
conveyor such that a barcode symbol on each label is located will be appreciated that in other embodiments the labelling
at a distance of greater than approximately 19 mm from an machine may be mounted in any appropriate manner to the
edge of the article. The edge of the article may be a front 50 production line . In some embodiments the labelling machine
edge of the article. The front edge of an article may be an may not be mounted directly to the production line . The
edge of an article which is forward -most with respect to the labelling machine may be mounted in any appropriate
direction of travel of the article on the conveyor. manner providing that the labelling machine has a fixed
In cases where known print and apply labelling machines positional relationship with a portion of the production line
of the ‘ last label out type are required to apply labels to 55 ( for example the conveyor (e.g. conveyor belt) ) .
articles at a relatively low height from a conveyor ( for The labelling machine 400 shown in FIG . 32 may have
example at a height such that the bottom of a barcode the same configuration as ( or a similar configuration to ) any
symbol on each label is located approximately 32 mm from of the previously discussed embodiments. The view of the
the conveyor ), due to the fact that the portion of the labelling labelling machine shown in FIG . 32 has been simplified so
machine which includes the labelling peel beak is bulky, it 60 as to aid clarity. Various components of the labelling
may not be possible to position such a known print and apply machine have been omitted . Furthermore , although label
labelling machine of the ‘ last label out ' type adjacent the stock and print ribbon are shown supported by the take up
conveyor such that labels can be printed and subsequently spool support and ribbon take up spool support respectively
applied to an article at a position adjacent the labelling peel (discussed in more detail below ) , neither the label stock or
beak and printer of the labelling machine. In order to solve 65 print ribbon are shown extending along their respective
this problem , some known print and apply labelling paths through the machine . Features of the labelling
machines of the “ last label out type may be located at a machine shown in FIG . 32 which correspond to features
US 10,988,276 B2
109 110
already discussed in relation to other embodiments have on the same side of the base plate may be advantageous in
been given the same numbering. certain applications. For example, due to the fact that there
The labelling machine 400 comprises a take up spool is little more than the pulleys and associated belts on the
support 12 for supporting label stock as it is wound onto the lower side of the of base plate ( i.e. the side of the base plate
take up spool support 12. The labelling machine 400 also 5 which includes the lower surface ), the distance between the
comprises a printer including a ribbon take up spool support
40 , for supporting printer ribbon as it is wound onto the bottom of the labelling machine and the labelling peel beak
(i.e. the point at which labels are dispensed from the
ribbon take up spool support 40. The take up spool support machine ) is reduced . A reduction in the distance between the
12 and ribbon take up spool support 40 are both driven for bottom of the labelling machine and the labelling peel beak
rotation by respective motors 14 and 414 . 10
means that if the labelling machine ( and mere specifically
All of the components of the labelling machine mentioned in has to be positioned above some feature to the side of the
the preceding paragraph are mounted to a base plate 410 and conveyor of the production line ( for example a side wall as
are housed in a casing 412. Each of the take up spool support shown in FIG . 32 ) , then the height h between the conveyor
12 , ribbon take up spool support 40 and motors 14 and 414 (e.g. the surface of the conveyor on which the conveyed
comprise a main body and a rotatable shaft which extends 15 articles are supported ) and the labelling peel beak is mini
from the main body. The main body of each of the take up
spool support 12 , ribbon take up spool support 40 and mised . By minimising the height h between the conveyor
motors 14 and 414 is mounted to an upper surface 410a of and the labelling peel beak, the minimum height on an
a base plate 410 such that their respective rotatable shafts article conveyed by the conveyor at which the labelling
pass through respective apertures in the base plate 410 and 20 machine can apply a label is also reduced . This may allow
extend beyond a lower surface 410b of the base plate 410 . the labelling machine to apply a label to an article at a height
Pulleys 416 , 420 , 418 , 422 are mounted to each of the which meets a desired standard (e.g. the GS1 standard )
respective shafts of the take up spool support 12 , ribbon take without the need for a label transfer device .
up spool support 40 and motors 14 and 414 such that each Within the embodiment described above , all the compo
pulley 416 , 420 , 418 , 422 is located on the other side of the 25 nents driven by motor are driven via a linkage (a pair of
base plate 410 compared to the respective main body. pulleys and a belt) . This need not be the case . For example,
The pulley 416 of the take up spool support 12 is in some embodiments at least one of the take up spool
connected to the pulley 418 of the motor 14 by a first belt support, supply spool support, ribbon take up spool support
( shown in dashed line and indicated by 424 ) , such that the and ribbon supply spool support may be driven directly. By
motor 14 can drive the take up spool support 12 for rotation 30 directly driven it is meant that the spool support may be
via the pulleys 416 , 418 and the belt 424. The pulley 420 of mounted co - axially with the shaft of the motor which drives
the ribbon take up spool support 40 is connected to the the spool support for rotation . The spool support may be
pulley 422 of the motor 414 by a second belt ( shown in mounted to a motor spindle of a motor. In some embodi
dashed line and indicated by 426 ) , such that the motor 414 ments, both the ribbon take up spool support and ribbon
can drive the ribbon take up spool support 40 for rotation via 35 supply spool support may be driven directly. In the case
the pulleys 420 , 422 and the belt 426 . where a spool support is driven directly by a motor, the
The supply spool support which supports the label stock motor may be mounted such that none of the motor pro
and the ribbon supply spool support which supports the trudes past the lower surface of the base plate or such that
printer ribbon are not shown so as to improve the clarity of the amount of the motor which protrudes past the lower
the figure. The supply spool support and ribbon supply spool 40 surface of the base plate is minimised .
support are also mounted to the upper surface 410a of the Although the base plate 410 in the described embodiment
base plate 410. If either of the supply spool support and is a single component, in other embodiments the base plate
ribbon supply spool support are driven for rotation by a may be constructed from a plurality of components.
respective motor, then they may be driven by a motor via a Although the embodiment discussed above includes an
belt and pulleys in a similar manner to that discussed above. 45 aperture in the base plate for each component shaft to pass
Any such motor may have a main body secured to the upper through the base plate, in other embodiments more than one
surface 410a of the base plate 410. Again , the shaft of any component shaft may pass through a single aperture. In
motor or driven supply spool support or driven ribbon some embodiments there may be a single aperture in the
supply spool support passes through a respective aperture in base plate through which all of the component shafts pass .
the base plate. 50 Although in the embodiment above the linkage between a
A labelling peel beak 30 is also mounted to the base plate spool support and motor comprises a belt and two pulleys ,
410. In use , the motor 14 drives the take up spool support 12 it will be appreciated that in other embodiments any appro
such that a portion of the web of the label stock is wound priate linkage may be used . For example , chains and gears
onto the take up spool support 12. A print head ( not shown) may be used instead, or alternatively meshing gear wheels
is controlled to transfer ink from the print ribbon onto labels 55 may be used . In some embodiments any linkage linking a
of the label stock to form a desired image on each label as motor to a spool support may be located on the upper side
it passes the print head . When required the motor 414 drives of the base plate such that there is no linkage on the lower
the ribbon take up spool support 40 to advance the print side of the base plate. That is to say , the spool support, motor
ribbon . The advancement of the conveyor 406 is co -ordi- and linkage linking the spool support and motor may all be
nated with the drive of the take up motor 14 such that as an 60 located on the same side of the base plate .
article 408 passes on the conveyor 406 , the take up motor 14 The construction and operation of various embodiments
is driven to advance the label stock such that a label which of a labelling machine have been described above . As has
has been printed for the article is advanced to the labelling been mentioned , such labelling machines may be used to
peel beak and then separated from the web by the labelling apply labels to articles /products passing on a conveyor of a
peel beak 30 and subsequently applied to the article 408 . 65 production line . Having carried out a start - up procedure, for
The arrangement of the labelling machine as discussed example, as described above , operation of the labelling
above , whereby the main body of each component is located machine to dispense labels can begin .
US 10,988,276 B2
111 112
The controller determines a linear speed V, at which the In particular, it may sometimes be appropriate to vary the
web is to be fed . In some applications it is necessary for this target speed V , as the label stock is moved . It will also be
linear speed to match the speed at which a product is appreciated that to achieve a particular target linear speed
conveyed past the labelling machine by a conveyor . The (i.e. speed of label stock moving along the web path ) the
speed at which the product is conveyed past the labelling 5 speed of the take up motor may change during the operation
machine can be provided as an input to the controller from up of the labelling machine as a function of changing take
a line encoder. Any appropriate encoder may be used to / supply spool diameters.
FIG . 34 is a flow chart showing operation of the labelling
determine the speed of the conveyor ( and hence the speed at machine
which the product is conveyed past the labelling machine). where a tocheck feed a single label . Processing begins at step S25
In one example , the line encoder may be attached to a wheel 10 product sensor hasis been
carried out to determine whether the
triggered by a passing product. If
of known diameter which runs against the conveyor such this is the case , processing passes to step S29 otherwise ,
that the linear movement of the wheel matches the linear
movement of the conveyor. The line encoder can thus triggered by a passing product. until the product sensor is
processing remains at step S25
provide details of a distance through which the wheel has At step S29 pulses provided by the line encoder discussed
turned. Given knowledge of the time taken to travel that 15 above are counted . At step S30 a check is carried out to
distance, the speed of the conveyor can easily be deter- determine whether the number of pulses received is equal to
mined . the distance which corresponds to a predetermined registra
In alternative applications the speed at which the label tion delay Rd . If this is not the case processing returns from
stock is to be moved may be input to the controller by an step S30 to step S29 and a loop is thereby established until
operator, as a manual input. 20 the conveyor has moved through the distance specified by
Operation of the labeller is normally initiated by a product the registration delay Rd. Processing then passes to step S26
sensor being triggered indicating that a product is approach- At step S26 a check is carried out to determine whether an
ing the labelling machine . It is preferred that the controller additional time registration delay is required. If an additional
is programmed with a so - called “ registration delay ". Such a time registration delay is required , processing passes from
registration delay can indicate a time which should elapse 25 then
step S26 to step S27 where a timer is initialised . Processing
passes to step S28 where a check is carried out to
(monitored by a simple timer ) after detection of the product determine whether the elapsed time is equal to the required
by the product sensor before the labelling process begins , or
alternatively indicate a distance through which the conveyor time registration delay Rtd. Processing remains at step S28
should move (as monitored by the encoder ) before the tion until the elapsed time is equal to the required time registra
labelling process begins. The registration delay may be input 30 delay Rich
to the controller by an operator of the labelling machine . It theWhen the distance ( and, if applicable, additional time) of
will be appreciated that by adjusting the registration delay, step registration
S28 or step
delay has passed , processing passes from
S26 to step S31 , where the controller
the position at which a label is affixed to a passing product calculates various parameters required to define the way in
may be adjusted.
Movementof the label stock during a label feed operation 35 which the label stock will be moved . Morethrough
particularly
which the
is illustrated by the speed /distance graph of FIG . 33. It can controller
stepper
computes the numbers of steps
motor is to be turned to cause the desired movement
the
be seen that the total distance through which the label stock of the label stock , the number of steps through which the
is moved in dispensing a single label is indicated No,
denoting that the stepper motor turns through N , steps to asstepper motor should be turned after detection of an edge so
to allow a label edge to be properly aligned with the
cause the movement of the label stock . Having detected a 40 labelling peel beak , and the step rate M, at which the stepper
label edge , the stepper motor turns through No steps before
the label stock comes to rest, where N. is determined as motor which drives the take up spool support should be
described below to ensure that a label edge is aligned with turned givenasthedescribed desired linear label stock speed which is
the edge of the labelling peel beak . In alternative embodi determined above .
In some embodiments, the total number of steps No
ments which include an encoder which outputs a signal 45 through
which can be used by the controller to determine an amount spool is which the stepper motor which drives the take up
to be turned is given by equation ( 25 )
of movement of the label stock along the label web path (e.g.
an encoder which monitors rotation of a print roller ), the
total distance through which the label stock is moved in
dispensing a single label is indicated Np, denoting the 50 Np = Lp Nrevolution
??,
( 25 )
distance measured by the encoder through which the label
stock is moved in dispensing a single label . Having detected
a label edge, the stepper motor advances the label stock by where Lp is the pitch length of the label stock , Nrevolution , is
a distance N, as measured by the encoder before the label the number of steps through which the stepper motor turns
stock comes to rest . 55 to rotate the take up spool support a single revolution and de
The label stock is accelerated from rest to the target speed is the diameter of the take -up spool .
V7 . The label stock then moves at the target speed V, before The distance E , through which the label stock should be
being decelerated to rest. Na indicates the number of steps fed following detection of an edge by the gap sensor in order
through which the stepper motor driving the take up spool to cause the leading edge of a label to be aligned with the
support turns to decelerate the label stock. It will be appre- 60 edge of the labelling peal beak can, if required, be converted
ciated that the numbers of steps N , N, and N are determined into a number of steps No using equation ( 26 ) :
with reference to the diameter of the take -up spool d, (which
maybe determined using any appropriate method , including
those described above ) as is now described . Although the No = Eo Nrevolution (26 )
graph of FIG . 33 shows a simple speed /distance profile for 65 ??,
the label stock, it will be appreciated that in some circum
stances different speed /distance profiles may be appropriate.
US 10,988,276 B2
113 114
The step rate M, at which the take up stepper motor should The linear distance s can be converted into a number of steps
step is determined with reference to the desired linear speed Nd, such that equation ( 29 ) becomes :
of the label stock V, which as described above can either by
input by an operator, or alternatively determined using an
encoder. The step rate M , is given by equation (27 ) : 5 V? N revolution (30)
Nd
2Dmax ?? ,
M, = V Nrevolution ( 27 )
??, Processing passes from step S34 of FIG . 34 to step S35 .
10 At step S35 a check is carried out to determine whether the
Referring again to FIG . 34 , having determined the necessary label position sensor (also referred to as the gap sensor) has
parameters at step S31 , processing passes to step S33 . detected a label edge . If this is the case , processing passes
At step S33 , the number of steps N , remaining in the from step S35 to step S36 where the number of steps
current feed is set to be equal to the total number of steps N , remaining in the current label feed N , is set to be equal to
in a single label feed. A parameter C, indicating the current 15 the number of steps No through which the label stock should
step rate is initialized to a value of zero . be moved to align a label edge with the labelling peel beak .
In alternative embodiments which include an encoder In alternative embodiments which include an encoder
which outputs a signal which can be used by the controller which outputs a signal which can be used by the controller
to determine an amount of movement of the label stock to determine an amount of movement of the label stock
along the label web path (e.g. an encoder which monitors 20 along the label web path (e.g. an encoder which monitors
rotation of a print roller ), at step S33 , if the total distance N ,
required to feed a single label is already known then the rotation of a print roller ), at step S35 , if label position sensor
distance N , to be measured by the encoder remaining in the (also referred to as the gap sensor ) has detected a label edge,
current feed is set to be the total distance N , required to feed and if N , was set to be an amount larger than the longest
a single possible pitch of label stock which may be utilised in
maylabel
label
. The betotal
already distance
known whenN ,therequired
pitch ofto thefeedlabel
a single
web 25 conjunctionpasses
processing with thefromlabelling machine
step S35 to stepat S36
step where
S33, then
the
Lp is less than the distance between the gap sensor and the distance as measured by the encoder remaining in the
label peel beak . In such cases , the trailing edge of next label
to be dispensed during the label feed will have already current label feed N , is set to be the distance E , through
passed the gap sensor. which the label stock should be moved to align a label edge
However, if the total distance N , required to feed a single 30 withProcessing
the labelling
then peel
passesbeak
to .step S37 . If a label edge has not
label is not already known then N is set to an amount larger been detected by the label position sensor 52 , processing
than the longest possible pitch of label stock which may be passes directly from step S35 to step S37 .
utilised in conjunction with the labelling machine . For At step S37 a check is carried out to determine whether
example , in some embodiments N , is set to 500 mm . The
total distance N , required to feed a single label is not already 35 the number of steps remaining in the current feed is equal to
zero . If this is the case processing passes to step S38 where
known when the pitch of the label web Lp is greater than the the feed ends.
distance between the gap sensor and the label peel beak . In If this is not the case , processing passes to step S39 where
such cases , the trailing edge of next label to be dispensed a check is carried out to determine whether the number of
during the label feed will not yet have passed the gap sensor.
Only when the trailing edge of next label to be dispensed 40 steps remaining in the current label feed N, is less than or
equal to the number of steps No required to decelerate the
during the label feed passes the gap sensor will the remain label stock . If this is the case , processing passes to step S40
ing distance the label stock has to be advanced to dispense where a deceleration step rate is determined . In alternative
the next label be known .
Processing passes from step S33 to step S34 where a embodiments which include an encoder which outputs a
number of steps Na required to decelerate the label stock 45 signal which can be used by the controller to determine an
amount of movement of the label stock along the label web
from its current speed to rest is determined . Dmax is the path
maximum deceleration of the label stock which can be (e.g. an encoder which monitors rotation of a print
roller
achieved using the take up stepper motor. The maximum whether ), at step S39 , a check is carried out to determine
deceleration may be determined in any appropriate way 50 based upon the distance remaining in the current label feed N,g
known in the art. For example, it may be determined as the distancethes required
output of the encoder is less than or equal to
to decelerate the label stock . If this
described in PCT application WO2010/018368 which is is the case , processing passes to step S40 where a decelera
incorporated herein by reference. The linear distances tion step rate is determined . Once it has been determined by
through which the label stock is moved to decelerate from a
current linear speed Veto a target linear speed U, is given by the controller that the distance remaining in the current label
the familiar equation: 55 feed N , based upon the output of the encoder is equal to the
U2-V2-2D mars (28 ) distance s required to decelerate the label stock, the con
troller enters a deceleration mode in which the distance
where s represents distance . remaining in the current label feed N , is converted by the
Given that the target linear speed U, is zero , and rear- controller to a number of steps N , remaining in the current
ranging equation ( 28 ) , the following expression for the 60 label feed ( which is equal to the number of steps No required
linear distance s can be derived : for the deceleration of the label stock) . Subsequent control
of the movement of the label stock by the controller in
deceleration mode is based upon the number of steps N
S =
V? ( 29 ) remaining in the current label feed and not on the signal
2Dmd
max 65 output by the encoder.
The deceleration step rate is determined by determining
the lowest rate Crt at which the motor can be caused to step ,
US 10,988,276 B2
115 116
given the limitation of the maximum possible deceleration Equation 39 can be rearranged to give equation ( 31 ) , viz :
Dmax and the current step rate Cy . It is determined using
equation ( 31 ) :
( 31 )
( 31 )
5 C= ( Cond
Crundt
revolution *
??,
-2Dmax N revolution * ??,
Nrrevolution
Cr + 1 CZ 2Dmax??
Nrevolution (Cr:#d :) ?? , (N revolution *. )2
(Nrevolution* ) - 2Dmax Nrevolution *
=
, ( ??,02
nd ??, ( N revolution * )2
Equation (31 ) is based upon equation ( 28 ) which can be 10 (Nrevolution * )2 - 2DmaxNrevolution* ( ??,02
expressed as follows:
(N revolution* )2 2Dmax Nrevolution * · Ad (N revolution* )2 = =
Vc + 12 =v2-2Dmax (32)
where V is the current linear label stock speed ; 15
?? ,
C7 – 2D max Nrevolution :: Cr +1 =
cz 2Dmax??
Nrevolution
,
Vch is the new linear label stock speed ; and
Sw is the linear distance through which the label stock is
moved in a single step. Referring back to FIG . 34 , having determined a step rate
Equation ( 32 ) can be rearranged to give : to effect deceleration at step S40 , processing passes to step
20 S51 , which is described in further detail below .
V6+1=VV.2-2Dmax Sw (33 ) If the check of step S39 determines that the number of
The linear distance Sw through which the label stock is steps remaining in the current label feed N , is not less than
moved in a single step is given by equation (34 ) : or equal to the number of steps Na required to decelerate the
label stock , (or that the distance N , remaining in the current
25 label feed is not less than or equal to the distance s required
?? , ( 34)
to decelerate the label stock ) processing passes to step S41 .
Sw = The check of step S39 is required to ensure proper
Nrevolution operation where the target speed V, and consequently the
target step rate M, varies during movement of the label
The new linear label stock speed can be related to a step 30 thestock . If it were the case that the target step rate did not vary,
check of step 39 need not be carried out .
rate using equation ( 35 ) : At step S41 a check is carried out to determine whether
the current step rate is too fast. This check determines
Cr+ 1adt ( 35 ) 35 whether the inequality of equation ( 40 ) is true:
Vc+1 Nrevolution
=
C- > M , (40 )
If this is the case , processing passes from step S41 to step
Equation ( 35 ) can be rearranged to give : S42 , where a step rate to effect deceleration is calculated
using equation (31 ) set out above . Processing passes from
40 step S42 to step S43 where a check is carried out to
Cr+ 1 = Vc + 1 ??,
Nr
revolution ( 36 ) determine whether the step rate determined at step S42 is
less than the target step rate M , if this is the case , the step rate
is set to be equal to the target step rate M, at step S44 .
Substituting equation ( 33 ) into equation ( 36 ) gives :
Processing passes from step S44 to step S51 , otherwise,
45 processing passes directly from step S43 to step S51 .
If the check of step S41 indicates that the step rate is not
too high, processing passes from step S41 to step S45 . At
Cr+1 = V V2 – 2Dmax Sw Nrevolution ( 37 ) step S45 a check is carried out to determine whether it is
AD possible to accelerate the label stock , and still have a
50 sufficient number of steps to decelerate the label stock to
rest, given the number of steps N , remaining in the current
The current linear label stock speed V is related to the feed. This is determined by determining whether the number
current step rate by equation (38 ) : of steps N , remaining in the current feed is greater than or
equal to one more than the number of steps required to
55 decelerate the label stock to rest if the label stock is
Vc =
C , ?? , ( 38 ) accelerated . If this is not the case , it is determined that the
Nrevolution label stock should not be accelerated , and processing passes
to step S46 where the step rate is set to remain constant,
Substituting equations (34 ) and ( 38 ) into equation (37 ) before processing passes to step S51 .
gives : 60 In alternative embodiments which include an encoder
which outputs a signal which can be used by the controller
to determine an amount of movement of the label stock
( 39 ) along the label web path (e.g. an encoder which monitors
Cr+ 1 =
// Cr.ndt
revolution
2Dmax ad
Nrevolution
Nrevolution
?? ,
rotation of a print roller ), at step S45 a check is carried out
65 to determine whether it is possible to accelerate the label
stock , and still have a sufficient distance to decelerate the
label stock to rest , given the distance measured by the
US 10,988,276 B2
117 118
encoder N , remaining in the current feed . In order to achieve take up spool ) by a distance Ed . The encoder can also output
this the controller may convert the distance N , remaining in a second type of pulse which is indicative of the label stock
the current feed into an equivalent number of remaining retreating backward along the label web path (i.e. towards
steps of the motor (based upon the diameter of the take up the supply spool ) by a distance Ed .
spool ) and determine whether the remaining number of steps 5 At step E3 the controller processes the signal received
is greater than or equal to one more than the number of steps from the encoder and determines whether the signal is
required to decelerate the label stock to rest if the label stock indicative of the label stock advancing forward along the
is accelerated . If this is not the case , it is determined that the
label stock should not be accelerated , and processing passes label signal
web path (i.e. towards the take up spool ) or whether the
is indicative of the label stock retreating backward
to step S46 where the step rate is set to remain constant, 10 along the label web path ( i.e. towards the supply spool ) . In
before processing passes to step S51 . this embodiment , if the encoder outputs the first type of
If the check of step S45 is satisfied (i.e. acceleration can pulse then the label
be carried out while still allowing sufficient steps for decel cessing passes to stepstock has advanced forward and pro
E4 . If the encoder outputs the second
eration of the label stock to rest ), processing passes from
step S45 to step S47 . Here a check is carried out to determine 15 type of pulse then the label stock has retreated backward and
whether the current step rate is less than a target step rate . If processing passes to step E5 .
this is the case , a step rate to effect acceleration is calculated At step E4 the controller sets the value of the distance N 8
at step S48 , according to equation ( 41 ) : remaining in the current feed to be equal to the current value
of the distance N , remaining in the current feed minus
20 distance Ed
(41 ) At step E5 the controller sets the value of the distance N ,
Cr +13 C} + 2AmaxN??revolution
, remaining in the current feed to be equal to the current value
of the distance N , remaining in the current feed plus distance
E?After either steps E4 and E5 processing returns to step E1 .
where Amax is the maximum possible acceleration . 25
It can be seen that equation (41 ) has a similar form to Various features of the labelling machine have been
equation (31 ) and its derivation therefore has the general described above . In some cases , exemplary components ,
form set out above . configurations and methods suitable for realising these par
Processing passes from step S48 to step S49 where a ticular features have been described . However in many cases
check is carried out to determine whether the step rate Ch+ 1 30 the skilled person will know of other components, configu
calculated at step S48 exceeds the target step rate M,. If this rations and methods which can similarly be used to realise
is the case , the step rate Cr+ 1 is set to be equal to the target the particular features which are described . Many of these
step rate at step S50 , before processing passes from step S50 components, configurations and methods will be known to
to step S51 . If the step rate Cr+ 1 calculated at step S48 does the skilled person from the common general knowledge. It
not exceed the target step rate M , processing passes directly 35 is envisaged that such alternative components, configura
from step S49 to step S51 . At step S51 the motor is caused tions and methods can be implemented in the described
to turn one step at the determined step rate . embodiments without difficulty given the disclosure pre
If the check of step S47 determines that the current step sented herein .
While references have been made herein to a controller or
rate is not too slow , processing passes from step S47 to step
S52 . It is known (given operation of steps S41 and 547 that 40 controllers it will be appreciated that control functionality
the step rate is equal to the target step rate , and the motor is described herein can be provided by one or more controllers.
turned through one step at that step rate at step S52 . Such controllers can take any suitable form . For example
control may be provided by one or more appropriately
Processing passes from each of steps S51 and S52 to step programmed
S53 where the number of steps remaining in the current feed microprocessors (having associated storage for
N , is decremented by one , before processing returns to step 45 program code , such storage including volatile and / or non
S34 . volatile storage ) . Alternatively or additionally control may
In alternative embodiments which include an encoder be provided by other control hardware such as , but not
which outputs a signal which can be used by the controller limited to , application specific integrated circuits ( ASICS )
to determine an amount of movement of the label stock and / or one or more appropriately configured field program
along the label web path (e.g. an encoder which monitors 50 mable gate arrays ( FPGAs).
rotation of a print roller ), if the label stock is not being Where angles have been specified herein, such angles are
decelerated (i.e. if the distance remaining in the current label measured in radians although modifications to use other
feed N , based upon the output of the encoder is greater than angular measurements will be apparent to the skilled person .
the distance s required to decelerate the label stock) then step While various embodiments of labelling machine ( s ) have
S53 is omitted such that processing passes back to step S34 . 55 been described herein, it will be appreciated that this
In such embodiments an encoder increment /decrement rou- description is in all respects illustrative, not restrictive .
tine shown schematically in a flow chart of FIG . 35 is Various modifications will be apparent to the skilled person
processed concurrently with the routine shown schemati- without departing from the spirit and scope of the invention.
cally in the flow chart of FIG . 34 .
Referring to FIG . 35 , at step E1 the controller monitors 60 The invention claimed is :
the encoder. At step E2 the controller waits until an update 1. A labelling machine comprising:
from the encoder is available . If an update from the encoder a supply spool support for supporting a supply spool
is available ( e.g. if the encoder has output a signal which is comprising a label stock comprising a web and a
indicative of movement), processing passes to step E3 . plurality of spaced labels attached to the web and which
In this particular embodiment the encoder can output a 65 are separable from the web ;
first type of pulse which is indicative of the label stock a take -up spool support adapted to take up a portion of the
advancing forward along the label web path ( i.e. towards the web ;
US 10,988,276 B2
119 120
a motive means configured to propel the web along a web 13. A labelling machine according to claim 10 , wherein
path from the supply spool support to the take -up spool the controller is configured to control the motive means
support; and /or detect a feature of the label stock based on whether
a sensor comprising a transmitter portion and a receiver at least one of the selected sensor signal, a first order
portion, the receiver portion comprising a plurality of 5 derivative
derivative of
of the
the selected
selected sensor
sensor signal
signal and a second
exhibit order
a predeter
receivers, the transmitter portion and the receiver por mined signature , wherein the predetermined signature is a
tion being configured to receive a portion of the label predetermined temporal pattern in the values of said at least
stock therebetween , and the plurality of receivers each one of the selected sensor signal , the first order derivative of
configured to produce a respective sensor signal which
is a function of a property of a portion of the label stock 10 the selected sensor signal and the second order derivative of
at a plurality of positions spaced from one another in a the selected sensor signal.
14. A labelling machine according to claim 1 , wherein the
direction non -parallel to the web path ; and controller is further configured to select one of the sensor
a controller configured to monitor each of the sensor signals produced by the receivers based on a predetermined
signals produced by the plurality of receivers and to
select one of the sensor signals produced by the plu- 15 criteria and wherein the predetermined criteria is selected
rality of receivers based on said monitoring of each of from the group consisting of:
a sensor signal which exceeds a predetermined threshold
the sensor signals produced by the plurality of receiv for a greatest proportion of a monitoring time ,
ers .
2. A labelling machine according to claim 1 , wherein the a sensor signal which is less than a predetermined thresh
controller is configured to control the motive means based 20 old for a greatest proportion of a monitoring time ,
upon a change in the selected sensor signal in order to a sensor signal which is the first sensor signal to exceed
position a target portion of the label stock at a desired a predetermined threshold during a monitoring time,
location along the web path . a sensor signal which is the last sensor signal to exceed a
3. A labelling machine according to claim 2 , wherein the predetermined threshold during a monitoring time ,
target portion of the label stock is a leading edge of a label 25 a sensor signal which is the first sensor signal to be less
and the desired location along the web path is an edge of a than a predetermined threshold during a monitoring
labelling peel beak . time, and
4. A labelling machine according to claim 1 , wherein the a sensor signal which is the last sensor signal to be less
controller is configured to detect a feature of the label stock 30 than a predetermined threshold during a monitoring
time.
based upon a change in the selected sensor signal . 15. A method of operating a labelling machine , the
5. A labelling machine according to claim 4 , wherein the
transmitter portion comprises an electromagnetic radiation labelling a
machine comprising:
supply spool support for supporting a supply spool
source and the receiver portion comprises an electromag comprising a label stock comprising a web and a
netic radiation detector.
6. A labelling machine according to claim 5 , wherein the 35 plurality of spaced labels attached to the web and which
transmitter portion is configured to produce a beam of are separable from the web ;
electromagnetic radiation which has a power density or a take -up spool support adapted to take up a portion of the
intensity which is substantially the same at said plurality of web ;
positions . a motive means,
7. A labelling machine according to claim 5 , wherein the 40 aa controller
sensor
, and
comprising a transmitter portion and a receiver
electromagnetic radiation source comprises a plurality of portion, wherein the receiver portion of the sensor
light emitting diodes arranged in a substantially linear further comprises a plurality of receivers;
formation .
8. A labelling machine according to claim 1 , wherein the 45 the motivecomprising
the method
means
:
propelling the web along a web path
transmitter portion comprises a plurality of transmitters . from the supply spool support towards the take up
9. A labelling machine according to claim 8 , wherein each spool support ;
of the plurality of transmitters and the plurality of receivers the transmitter portion and the receiver portion receiving
form part of a sensor pair, each sensor pair comprising a a portion of the label stock therebetween ;
transmitter and a receiver.
10. A labelling machine according to claim 1 , wherein the 50 thesensor plurality of receivers each producing a respective
signal which is a function of a property of a
portion of the label stock comprises the web and attached portion of the label stock at a plurality of positions
labels of the plurality of attached labels . spaced from one another in a direction non -parallel to
11. A labelling machine according to claim 10 , wherein the web path ;
the controller is configured to control the motive means the controller monitoring each of the sensor signals pro
and / or detect a feature of the label stock based upon a first 55 duced by the plurality of receivers ; and
order or a second order differential of the selected sensor
signal. the controller selecting one of the sensor signals produced
12. A labelling machine according to claim 10 , wherein by the plurality of receivers based on said monitoring
the controller is configured to control the motive means of each of the sensor signals produced by the plurality
and / or detect a feature of the label stock based on whether 60 of receivers.
at least one of the selected sensor signal, a first order motive 16. A labelling machine according to claim 1 , wherein the
derivative of the selected sensor signal and a second order take - up means spool
comprises a motor configured to rotate the
support .
derivative of the selected sensor signal , have a predeter
mined relationship with a threshold value .

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USO10988276B2

( 12) United States Patent ( 10 ) Patent No.: US 10,988,276 B2

( 30 ) Foreign Application Priority Data

132 130a 130

Yr2 ??r1 'a 20

82a 80a 88 78 76a

28b 80a 82d

324 330 To 324 322 324

410a 414 426 30 408

Speed /step rate

X -V7 -y. (4) d, 2 ( 11 )

centre of roller 32 , and the distance pz between the centre of

In order to calculate the total length L of the web path 20

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