An issue has arisen in the production line where a worker misaligned the labeling guide, causing the labeling machine to continuously feed labels. Despite numerous adjustments, the problem persists. The label sensor and bottle sensor have both been put into teach mode. Are there any experts who can provide insight and assistance in solving this issue? Thank you. View the label video for more details.
A common issue in labeling machines is the misalignment or lack of detection of the gap between labels by the fork type sensor that detects the label's trailing edge. Additionally, it is important to ensure the bottle sensor accurately detects the presence of a bottle and does not stay on when no bottle is present.Troubleshooting these sensors is essential for optimal machine performance.
In most cases, a fork type sensor is used to detect the trailing edge of a label. If this sensor is misaligned or not detecting the gap between labels, it could be causing the issue. Additionally, check if the bottle sensor is accurately detecting a bottle or if it remains on even when no bottle is present. The label sensor model is Leuze GS 61/6D.2 (without knob volume) and the bottle sensor is a Panasonic FX100. Despite only one glass bottle being detected, the label continues to feed. A video demonstrating this issue with the sensor detection is available. The label sensor is functioning properly, successfully detecting every label and gap.
Attempt to clean the sensor using alcohol, but be sure to avoid using any sharp objects!
I will troubleshoot the labeler to identify any missed settings or potential issues. It appears that I may need to follow the same steps as Parky in inspecting the fork sensor that distinguishes between labels at the end. Additionally, a malfunctioning stop command relay for the motor could be causing the problem.
If the control board of a labeller features LED indicators for inputs and outputs, you can perform simple tests to ensure its functionality. Try passing a bottle across the sensor and observe if the corresponding input reacts. The same test can be done with the label sensor. It's important to identify the type of controller used on the labeller - is it a PLC system or a custom-built one? In my experience, labellers can vary in their controllers, with some having a compact PLC system and others having their own unique controller without indicators.
From what you're describing, it seems that there may be a problem with the sensor's configuration or even a hardware fault. I recommend checking the input-output status, as well as cross-verify the position of the bottle sensor. Sometimes it can be as simple as a problem with the mounting position of the sensors. Also, consider scheduling maintenance to your machine. Regular tune-ups often prevent these type of issues. If everything seems fine, you might want to get your machine thoroughly checked by a technical expert.
It sounds like you've tried a lot of the standard troubleshooting steps already, which leads me to think that there might be a mechanical problem at play. I'd advise checking for any physical deformities in the label applicator component that may be causing the misalignment. In addition, examine the pressure balance on the suction cups if you're using them - improper balance can cause feed problems. Also, keep in mind that label adhesives can build-up over time and cause recurring issues. Regular machine maintenance and cleaning might help. Finally, double-check the label orientation in the hopper. I've seen cases where labels are stocked improperly, causing persistent labeling issues.
I've encountered a similar issue in the past and it turned out to be a problem with the label sensor’s sensitivity. It's possible that even though your label sensor is in teach mode, it still may not be picking up the labels correctly. Try examining the sensitivity settings and adjusting them to see if it makes a difference. Additionally, verify that the labels are not somehow interfering with the sensor. If the problem persists, it might be a good idea to consult with the machine's manufacturer since it could be a more complex issue related to the hardware itself.
From your description, it seems like there could be a problem with the sensor alignment, not just the labeling guide. I would suggest ensuring that the label and bottle sensors are properly aligned with their respective elements. Also, re-check the sensitivity settings of your sensors. Sometimes, too high or too low sensitivity levels can lead to persistent problems like these. Lastly, I'd recommend looking into the possibility of mechanical wear and tear in the system, particularly in the feed mechanism.
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Answer: The issue could be due to misalignment of the labeling guide by a worker, leading to the continuous label feed.
Answer: The label sensor and bottle sensor have been put into teach mode, and numerous adjustments have been made, but the problem persists.
Answer: You can seek assistance from experts in the field who have experience with labeling machines and troubleshooting similar problems.
Answer: Yes, you can view the label video for a better understanding of the problem and to assist experts in diagnosing and resolving the continuous label feeding issue.
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