NSF-Funded Student Design Projects:
Label Dispenser/Applicator
(Team: Laura Bibik, Kola Kolicaj, Ted Kuzmanov, Keith Lewis
(Advisors: Dr. Robert Erlandson, Dr. Evgeny Rivin, Mr. David Sant)

Problem/Need:  Commercially available labeling and dispensing devices are expensive and require cognitive and mechanical skills, such as removing the label from the device and aligning the label correctly on the envelope, that are beyond the capacity of many users. After analyzing the process that workers at the Western Wayne Skills Center (Livonia, MI) were using to complete their labeling tasks, the team decided that a re-designed labeling system should have the following properties:

*  The device should accommodate self-adhesive labels mounted on sheets and rolls
*  The device should be capable of labeling four different sizes of envelopes: pamphlet, standard letter, half sheet, and full size letter
*  Setup and adjustments for different sizes of labels and envelopes should be simple and easy

Also, the device:

*  should be within a close range of the operator
*  should require minimal physical input
*  must be kept low to the table and must accommodate both left- and right-handed users
*  should utilize visual contrasts to aid in envelope alignment processes

Project Description:

After researching existing patented and patent-pending products, the team agreed on a final design, which incorporates a friction label clamping mechanism, a pressure roller mechanism, an adjustable envelope guide, optical sensors and limit switches, push button operation, a timing pulley label transfer system, a moveable hinged ramp, and a sheet metal sharp edge. In addition, controller electronics were added in an effort to "error-proof" the labeling process. The electronics, which were designed by Mr. David Sant, were included to perform/enable the following sequence:

*  Detect that the envelope is properly in position as indicated by the optical sensors mounted in the envelope guide
*  If this condition is satisfied, the actuator button (a single switch) is enabled
*  Pushing the actuator button activates the labeling sequence
*  An optical sensor mounted on the side of the envelope guide indicates the end of the labeling sequence when the envelope passes through the sensor's beam, thus stopping the motor and allowing the user to remove the envelope
*  The sequence is repeated until all the labels are removed from the sheet. At this point the controller should return the clip to start position when the reset button has been pressed
*  The clip assembly stops at the base starting position when the limit switch on the lower pulley standoff is actuated. A rear limit switch was also incorporated as a safety feature to stop the system if an optical sensor fails.

Operating the Labeler

1.  The operator places an envelope into the guide, assuring that the upper right hand corner is seated tightly. When the envelope is seated properly, a green indicator light on the controller box will signal that the device is enabled. If it is not seated properly, the light on the controller box will turn red.

2.  When the envelope is properly seated, the operator presses the actuator button to start the process.

3.  As the label is dispensed, the envelope is pushed out of the guide. The completion of the operation is signaled when the indicator on the controller turns from green to red. Then the envelope can be removed from the guide as the label is pressed on.

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