High-rate label applicator method and apparatus

An auto sort and label (ASL) system comprising:

• a conveyor configured to convey a plurality of articles through the ASL system, the conveyor having a linear conveying direction and a conveyor length extending along said ASL system;
• a sensor array being positioned along the conveyor and extending along the conveyor length and configured to detect and identify each article of the plurality of articles on the conveyor;
• a controller configured to receive sensor data from the sensor array and to determine a gap and/or a pitch between adjacent ones of the articles and configured to control the conveyor to dynamically adjust the gap and/or the pitch between adjacent ones of the articles if the determined gap and/or pitch is not within a predefined gap and/or pitch;
• a label, print, and apply system (LPA) configured to print and apply a label to each article, wherein the LPA is positioned with respect to the conveyor such that the LPA can interact with the articles upon the conveyor as they pass by;
• wherein the conveyor comprises a plurality of individually addressable motorized driven rollers (MDRs) and the controller is configured to individually control the MDRs such that the gap and/or the pitch between adjacent ones of the articles is dynamically adjusted while the articles are conveyed along the linear conveying direction of the conveyor to the LPA to ensure that the label is ready prior to each article arriving at the LPA;
• wherein the controller is configured to select a print string for the LPA as defined by the identity of each article, and wherein the LPA is configured to print and apply labels to each respective article as defined by the respective print strings;
• wherein the controller is configured to verify placement and contents of each respective label upon each article as defined by the sensor data from the sensor array;
• and
• wherein the controller is configured to accept or reject a labeled article for further handling.