Labeling apparatus with web registration, web cutting and carrier mechanisms, and methods thereof

An apparatus, comprising:

• (a) a web supply configured to supply a web of material;
• (b) a rotatable drum configured to receive the web of material, the drum including an outer surface;
• (c) a first drive mechanism coupled to the drum and configured to continuously rotate the drum and advance the outer surface thereof at a first predetermined rate;
• (d) a second drive mechanism configured to continuously advance the web of material at a second predetermined rate, wherein the first and second predetermined rates are different from one another;
• (e) a cutter mechanism configured to sever a segment from the web of material at a predetermined rotational position of the drum while at least a portion of the web of material engages the outer surface of the drum;
• and
• (f) a controller configured to dynamically control at least one of the first and second drive mechanisms such that a predetermined length of material is advanced forward of the predetermined rotational position of the drum as such time as the drum is positioned at the predetermined rotational position.

A labeling apparatus, comprising:

• (a) a web supply configured to supply a web of label material, the label material including indicia disposed at predetermined positions thereon;
• (b) a rotatable drum configured to receive the web of material, the drum including an outer surface providing a source of attraction for the web of label material;
• (c) a registration sensor configured to detect the indicia on the web of label material;
• (d) a first drive mechanism coupled to the drum and configured to rotate the drum at a first predetermined rate;
• (e) a second drive mechanism coupled to the web supply and configured to supply the web of label material at a second predetermined rate, wherein the first predetermined rate is greater than the second predetermined rate, and wherein the attraction of the web of label material to the drum is the sole source of tension between the web supply and the drum;
• (f) a stationary knife disposed proximate the drum at a stationary position;
• (g) a rotating knife coupled to the drum and configured to engage the stationary knife when the drum is disposed at a predetermined rotational position;
• and
• (h) a controller, coupled to the first and second drive mechanisms and the registration sensor, the controller configured to control at least one of the first and second predetermined rates such that a desired length of label material is advanced forward of the rotating knife on the drum as the rotating knife engages the stationary knife at the predetermined rotational position of the drum and thereby severs the desired length of label material from the web of material.

A method of severing segments of predetermined length from a web of material, the method comprising:

• (a) advancing a web of material toward a rotating drum;
• (b) attracting the web of material into engagement with the outer surface of the drum;
• (c) severing a segment from the web of material while at least a portion of the web of material engages the outer surface of the drum;
• and
• (d) rotating the drum and advancing the outer surface thereof at a rate greater than the rate at which the web of material is advanced from the web supply, wherein the attraction of the web of material to the drum is the sole source of tension between the web supply and the drum.

A method of severing segments of predetermined length from a web of material, the method comprising:

• (a) continuously rotating a drum at a first predetermined rate;
• (b) continuously advancing a web of material at a second predetermined rate such that the web of material engages an outer surface of the drum, wherein the first and second predetermined rates are different;
• (c) severing a segment from the web of material at a predetermined rotational position of the drum and as at least a portion of the web of material engages the outer surface of the drum;
• and
• (d) dynamically controlling at least one of the first and second predetermined rates such that a predetermined length of material is advanced forward of the predetermined rotational position of the drum as such time as the drum is positioned at the predetermined rotational position.

An apparatus, comprising:

• (a) a hub configured to rotate about a first axis;
• (b) a fixed guide including an article engaging surface;
• (c) an article carrier configured to receive and transfer an article along the article engaging surface of the guide, the article carrier operatively coupled to the hub through a pivotal coupling that defines a second axis substantially parallel to and separated from the first axis;
• and
• (d) a camming mechanism operatively coupled between the article carrier and the hub and configured to pivot the article carrier about the second axis in response to rotation of the hub about the first axis and thereby vary the angular velocity of the article carrier relative to that of the hub.

An apparatus, comprising:

• (a) a first station configured to process articles with a first predetermined transport parameter;
• (b) a second station configured to process articles with a second predetermined transport parameter;
• (c) a fixed guide including an article receiving surface extending from proximate the first station to proximate the second station;
• and
• (d) a carrier mechanism configured to transport articles along the article receiving surface of the guide and between the first and second stations, the carrier mechanism including:
• (1) a hub configured to rotate about a first axis;
• (2) an article carrier configured to receive and transport an article along the article engaging surface of the guide, the article carrier operatively coupled to the hub through a pivotal coupling that defines a second axis substantially parallel to and separated from the first axis;
• and
• (3) a camming mechanism coupled to the article carrier to controllably pivot the article carrier about the second axis during rotation of the hub about the first axis and thereby vary the angular velocity of the article carrier relative to that of the hub, the camming mechanism configured to controllably pivot the article carrier to a first angular position about the second axis when the hub is oriented at a first angular position about the first axis based upon the first predetermined transport parameter of the first station, and to controllably pivot the article carrier to a second angular position about the second axis when the hub is oriented at a second angular position about the first axis based upon the second predetermined transport parameter of the second station.

A method of transporting an article between a first station configured to process articles with a first predetermined transport parameter and a second station configured to process articles with a second predetermined transport parameter, the method comprising:

• (a) receiving an article proximate the first station with an article carrier pivotably coupled to a rotating hub on a carrier mechanism, the hub configured to rotate about a first axis, and the article carrier operatively coupled to the hub through a pivotal coupling that defines a second axis substantially parallel to and separated from the first axis;
• (b) transporting the article along an article receiving surface of a fixed guide to the second station;
• and
• (c) while transporting the article between the first and second stations, controllably pivoting the article carrier about the second axis during rotation of the hub about the first axis to match a predetermined carrier parameter for the article carrier respectively with the first and second predetermined transport parameters when the article is disposed at the first and second stations.