Challenge
The labeling machine had to place labels accurately at line speed, handle several product sizes and label formats, and catch missing or misaligned labels before products moved on.
Solution
The labeler now runs in step with the production line. The PLC controls labeling speed and position, using Schneider Electric stepper drives and an Altivar variable-speed drive. The control system is built on a Delta DVP PLC with a Wecon HMI.
Product settings, including label length, dispense length, speeds and gate and stepper delays, are stored in a product table on the HMI. Sensors detect bottles, labels and the gate position, and the system flags missing or misaligned labels. The HMI shows real-time status and alarms, and the system logs production data.
Scope of work
- Delta PLC programming
- Wecon HMI with Main, Settings, Calibration and Alarms screens
- Labeling speed, position and line synchronization
- Stepper-drive control for label dispensing
- Product table for sizes and label formats
- Bottle, label and gate sensors
- Missing and misaligned label detection
- Data logging and production tracking
Result
The labeler switches between products by loading their stored settings, places labels in step with the line, and flags missing or misaligned labels before the products move on.
