Apparatus and method for labeling metal products

Abstract

Apparatus (10) and method for labeling metal products (100) comprising at least one robot (12) mobile between at least one supply unit (11) for supplying a label (50) and a labeling zone (LZ) in which the metal product (100) is positioned; wherein the robot (12) comprises at least one feeding unit (15) configured to selectively feed a thin metal wire (19) continuously, associating it directly with the label (50), at least one welding unit (16) configured to weld an end portion (19a) of the metal wire (19) to the metal product (100), at least one forming unit (17) configured to plastically deform a clamping portion (19b) of the metal wire (19) defining at least one shaped segment (21), and at least one cutting unit (18) configured to selectively cut the metal wire (19) downstream of the shaped segment (21), the apparatus comprising vision means (23) associated with said robot (12) and configured to identify at least said metal product (100) and / or said label (50), to provide said information to a controller, wherein said controller is configured to condition at least the selective movement of said robot (12) in said labeling zone (LZ) according to the information provided by said vision means.

Description

[0001] “APPARATUS AND METHOD FOR LABELING METAL PRODUCTS”

[0002]

[0003] FIELD OF THE INVENTION

[0004] The present invention concerns an apparatus and method for automatically applying a label or tag with metal products made by either hot or cold rolling. Hereafter, such products are generically identified as metal products.

[0005] BACKGROUND OF THE INVENTION

[0006] It is known there is a need to trace metal products obtained in steel plants by associating each one of them with a specific distinctive label, in order to provide specific information relating to each individual metal product, or to each single batch of equivalent metal products, or suchlike.

[0007] The implementation of labeling in the iron and steel industry has multiple problems, such as the variability of the metal products’ surfaces, the high level of dirt, the presence of oxidized portions, the high working temperatures - all factors that do not allow to provide a robust, fast and efficient labeling solution.

[0008] So-called robotic labeling stations are known in which, by means of at least one automatic robot, a corresponding identification label is selectively associated with the metal product to be identified.

[0009] However, there are some types of metal products, such as for example metal wires, flat products or suchlike, which are normally stored in bundles or wound into coils, consolidated by ties, straps or similar binding elements, in which performing labeling is complex. In fact, to date, the labeling of these metal products and their storage conformations can occur in a semi-automated or, sometimes, manual way, with a consequent increase in the time, costs and quality of the labeling of the metal products.

[0010] Furthermore, this known solution does not guarantee that the label will have a substantially univocal positioning with respect to the product bundle or coil with which it is associated, possibly proving difficult to identify in the subsequent steps of the process, particularly if these are automated.

[0011] There is an ever-increasing need to speed up and optimize the steps of labeling products in order to respond to ever-increasing production rates and reduce costs.

[0012] Some known techniques provide to integrate the labels with the metal product by using the “pick and place” technique, that is, picking and positioning, on each occasion and for each metal product, determinate and specific elements that are pre-prepared and conformed to carry out the labeling.

[0013] In some solutions, the “pick and place” technique provides to pick, on each occasion, a cylindrical-shaped pin from a pin delivery station, insert the picked pin into a hole present on the specific printed label, and position the assembly consisting of pin and label on the head surface of the metal product to be labeled. Subsequently, the pin is welded to the metal product and the label is clamped to the pin with a holding element, such as a metal disc or a clip.

[0014] A general drawback of the “pick and place” technique is linked to the specificity of the pre-prepared elements, that is, the fact that for each type of product, or its packaging methodology, a univocal type of pin with corresponding holding element is provided. This specificity limits the possibility of labeling successive batches of products, or packages, which differ from each other, unless there are long and complex tooling steps, with a consequent negative impact on overall productivity.

[0015] The known solution also requires different types of pins and holding elements in the warehouse, with a consequent increase in management and storage costs. Another drawback of this known solution is that it requires many and complex manipulations, with consequent lengthening of production times and costs that affect the general economy of the management of the apparatus, as well as of the machines and production plants in which it is installed.

[0016] In addition, due to the high number of manipulations, different, or in any case complex, robotic manipulation members have to be provided, requiring articulated coordination management between the parts, with a greater risk of errors or uncertain labeling, which normally lead to slowdowns or interruptions in production.

[0017] The “pick and place” technique also involves a considerable expenditure of energy, since it requires many and repeated picking and positioning manipulations for each of the metal products to be labelled.

[0018] JP H0966920 discloses a method and apparatus for automatically attaching a tag to a metal strip.

[0019] There is therefore the need to perfect and provide an apparatus and a method for labeling metal products that can overcome at least one of the disadvantages of the state of the art.

[0020] To do this, it is necessary to solve the technical problem of performing an effective, univocal and repeatable labeling on metal products, such as for example metal wires, flat products or suchlike, stored in bundles or wound into coils, without using determinate and specific elements that are pre-prepared and conformed to carry out the labeling.

[0021] In particular, one purpose of the present invention is to provide an apparatus and to perfect a method for integrating a label, or a tag, substantially automatically, with metal products in a simple and effective maimer, guaranteeing the possibility of labeling successive batches of products, or packages, which differ from each other, avoiding long and complex set-up steps.

[0022] Another purpose of the present invention is to provide an apparatus that provides a limited number of manipulations with reduced production times and costs.

[0023] Another purpose of the present invention is to provide a labeling apparatus and a connected method that allows to obtain labelled metal products in a short time and with a limited energy expenditure.

[0024] The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

[0025] SUMMARY OF THE INVENTION

[0026] The present invention is set forth and characterized in the independent claims. The dependent claims describe other characteristics of the present invention or variants to the main inventive idea.

[0027] In accordance with the above purposes and to resolve the technical problems described above in a new and original way, also achieving considerable advantages compared to the state of the prior art, an apparatus for labeling metal products according to the present invention comprises at least one robot, which is movable at least between a unit for supplying a label and a labeling zone in which the metal product is positioned and in which the label is associated with the latter.

[0028] In accordance with one aspect of the present invention, the robot substantially comprises a feeding unit, a welding unit, a forming unit and a cutting unit. In an advantageous embodiment, the aforementioned operating units are mounted in reciprocal cooperation with each other on a single work tool, the latter being part of an embodiment of the robot.

[0029] In an advantageous solution of the present invention, the forming unit is configured as an interplay between the robot and the feeding unit. In other words, the wire can be fed out of the welding unit at different angles and then pushed to create a required plastic deformations so as to obtain the desired shape.

[0030] According to the present invention, the feeding unit is configured to selectively feed a thin metal wire continuously, associating it directly with the label, for example in association with an attachment part of the label, such as a through hole, a slot or suchlike. In an alternative solution, the thin metal wire can be pushed against the label and can punch a hole and penetrate through the label as it is pushed against it.

[0031] Also according to the present invention, the welding unit is configured to weld an end portion of the metal wire to the metal product, while the forming unit is configured to plastically deform a clamping portion of the metal wire on the opposite side of the label with respect to the welded end portion, defining at least one shaped segment so as to keep said label in place on said metal product after the welding of said end portion to the metal product, and finally the cutting unit is configured to selectively cut the metal wire downstream of the shaped segment. In this way, the label is associated with the metal product by means of a single element, that is, the metal wire, which is first fed continuously so as to be coupled to the label, and subsequently welded with its end directly to the metal product. In this operating condition, the clamping portion of the wire is deformed, that is, that segment of wire that protrudes from the label on the side opposite the end portion which is welded to the metal product.

[0032] Advantageously, the shaped portion is given an “S” or double “S” shape, so as to prevent accidental dissociation, or loosening, between the metal wire and the label. In even more advantageous solutions, the shaped segment is compressed against the label.

[0033] Once the desired deformation condition is reached, the metal wire is cut, in order to free the assembly between the metal product and the label, so that the robot can pick up a new label from the feeding unit and start a new labeling cycle.

[0034] With the solution according to the present invention, it is therefore possible to perform an effective, univocal and repeatable labeling on metal products, such as for example metal wires, flat products or suchlike, stored in bundles or wound into coils, using only the metal wire to be welded and deformed on the label. In other words, the labeling of the metal product is performed without using determinate and specific elements that are pre-prepared and conformed to carry out the labeling.

[0035] With the solution according to the present invention there is the advantage of being able to integrate a label, or a tag, with metal products in a substantially automated maimer, simply and effectively, guaranteeing the possibility of labeling successive batches of products, or packages, which differ from each other, avoiding long and complex set-up steps.

[0036] In fact, neither the metal wire nor its deformation in the clamping portion are conditioned by the type of batch or its packaging conformation, thus being substantially independent of the type of metal product to be labelled.

[0037] Another advantage of the solution according to the present invention is that by using the metal wire only, a limited number of manipulations can be provided, with low production times and costs.

[0038] Another advantage of the solution according to the present invention is that labeled metal products can be obtained in a short time and with limited energy expenditure.

[0039] In accordance with another aspect of the present invention, the apparatus comprises at least vision means, which are associated with the robot through a controller and are configured to identify at least the metal product and condition, by means of said controller, at least the selective movement of the robot in the labeling zone. In particular, the vision means can verify the position of the metal wire’s end with respect to the metal product, send this information to the controller that can provide the commands to the robot for the execution of the welding.

[0040] This advantageous solution allows to optimize the robot’s movement, and the effectiveness of the labeling actions performed in sequence by the operating units provided on that robot.

[0041] For example, the vision means can be configured at least for one or more of the following functions:

[0042] identifying a welding position of the end portion of the metal wire on the metal product; verifying the correct positioning of the label after the welding of the end portion; and, if necessary,

[0043] verifying that the information on the label is compatible with the metal product. It is not excluded that the vision means may be of the type with the functionality of performing quality inspections of the bars / bundles. It is not excluded that the vision means can be programmed so as to also perform quality controls at the end of the labeling process, as well as at the end of each operating step provided. In some advantageous embodiments, the vision means are mounted on board the robot, while in other equally advantageous embodiments, the display means can be mounted in a separate and distinct position with respect to the robot.

[0044] In accordance with another aspect of the present invention, the robot comprises an anthropomorphic arm configured to perform movements with at least three degrees of freedom, and the aforementioned single work tool, the latter associated with the anthropomorphic arm in an articulated maimer.

[0045] DESCRIPTION OF THE DRAWINGS

[0046] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of an embodiment, given as a non-restrictive example with reference to the attached drawings wherein:

[0047] - fig. 1 schematically shows a layout of a labeling apparatus according to the present invention, in a first operating step;

[0048] - fig. 2 schematically shows a layout of the apparatus of fig. 1, in a second operating step;

[0049] - fig. 3 schematically shows an enlarged detail of the apparatus of fig. 1, in a third operating step;

[0050] - fig. 4 schematically shows an enlarged detail of the apparatus of fig. 1, in a fourth operating step;

[0051] - fig. 5 schematically shows an enlarged detail of the apparatus of fig. 1, in a fifth operating step;

[0052] - fig. 6 schematically shows an enlarged detail of the apparatus of fig. 1, in a sixth operating step;

[0053] - fig. 7 schematically shows an enlarged detail of the apparatus of fig. 1, in a seventh operating step;

[0054] - fig. 8 schematically shows a layout of the apparatus of fig. 1, in a final operating step; and

[0055] - fig. 9 shows a detail of the apparatus of fig. 1.

[0056] We must clarify that the phraseology and terminology used in the present description, as well as the figures in the attached drawings also in relation as to how described, have the sole function of better illustrating and explaining the present invention, their purpose being to provide a non-limiting example of the invention itself, since the scope of protection is defined by the claims.

[0057] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can be conveniently combined or incorporated into other embodiments without further clarifications. DESCRIPTION OF AN EMBODIMENT OF THE PRESENT INVENTION

[0058] With reference to the attached drawings, a labeling apparatus 10 according to the present invention is applied to automatically apply a label 50, or tag, to generic metal products made by both hot and cold rolling.

[0059] In the solution shown, the metal products are schematically represented as metal bars grouped in a bundle 100, but it is not excluded that the metal products used can be metal wires, flat products or suchlike, which are normally stored in bundles or wound into coils, consolidated by ties, straps or similar binding elements, of a substantially known type and not shown in the drawings.

[0060] The apparatus 10 according to the present invention is usually effectively installed downstream of either a metal products storage machine or of a line for rolling such metal products, which are of a substantially known type and are not shown in the attached drawings.

[0061] Furthermore, the apparatus 10 according to the present invention finds advantageous, but not limiting, installation in operational association with a supply unit, which in this case is or comprises a printer 11, configured to print or to imprint on a paper or plastic medium a series of data and parameters identifying the metal product present in the bundle 100, or its production batch, the intended use, or other data and parameters required by regulations, by the client or by the manufacturer. This operation defines the label 50. In particular, the label 50 traditionally comprises a through hole 51, the functionality of which will be clarified below. In some operating variants, not shown, the printer 11 can be comprised in the apparatus 10 according to the present invention.

[0062] The apparatus 10 according to the present invention comprises a robot 12, provided mobile between the printer 11 and a labeling zone LZ, in which the bundle 100 is positioned.

[0063] The robot 12 substantially comprises an anthropomorphic arm 13, mobile for example on three, or five, axes and on whose wrist a single work tool 14 is mounted.

[0064] On the work tool 14 there are provided, mounted in reciprocal cooperation with each other, a feeding unit 15, a welding unit 16, a forming unit 17 and a cutting unit 18.

[0065] The feeding unit 15 is configured to selectively feed a metal wire 19 continuously, associating it directly with the hole 51 of the label 50 (fig. 2). According to a variant, the label 50 does not have previously any hole 51, but is the metal wire 19 itself that, when pushed by the feeding unit 15, punches and penetrates through the label 50, creating the hole. In this specific case, the feeding unit 15 is fed by means of a coil 20 of metal wire 19 mounted directly on board the anthropomorphic arm 13 and it can be, for example, of the roller type opposing the metal wire 19 being fed, or by means of other known systems for the continuous feed of a metal wire 19.

[0066] Downstream of the feeding unit 15 there is a pulse encoder wheel 24, which tracks the position of the metal wire 19, while it is fed by the feeding unit 15, so as to both detect and selectively set the length of the metal wire 19 supplied.

[0067] The welding unit 16 is configured to weld an end portion 19a of the metal wire 19 to the metal product in the bundle 100, so as to integrate the reciprocal position thereof (fig. 3). The welding of the end portion 19a can occur selectively or directly on the metal product of the bundle 100, or on the straps or other systems for binding the bundle 100.

[0068] The welding is advantageously carried out by electric arc, with the technique known as MIG / MAG (Metal-arc Inert Gas / Metal-arc Active Gas), although the possibility of different technical choices is not excluded, such as TIG (Tungsten Inert Gas), spot welding or others, depending on the different welding operating conditions and requirements. In an advantageous embodiment, the welding unit 16 can comprise a current supply 25 and a cylinder 26, in this case pneumatic, which has the dual function of moving a welding electrode 27 and transmitting the welding current to the latter.

[0069] The forming unit 17 is configured to plastically deform a clamping portion 19b of the metal wire 19, defining at least one shaped segment 21. In this specific case, the forming unit 17 is defined by the kinematic combination between the work tool 14 and the anthropomorphic arm 13 which, as can be seen in the sequence of figs.

[0070] 4 and 5, move alternately and laterally to the direction of feed of the metal wire 19, folding the latter in its clamping portion 19b to define the shaped segment 21 with a double S-shaped development. This shaped segment 21, once defined, is located on the side of the label 50 opposite the end portion 19a, so as to prevent the label 50 itself from accidentally detaching from to the metal wire 19. Advantageously, the shaped segment 21 can be compressed against the label 50 at the end of the forming, so as to keep the label 50 itself adhering to the metal product bundle 100, avoiding possible snagging, or tearing, in the subsequent operations of manipulating and transporting the bundle 100.

[0071] In alternative embodiments, the forming unit 17 can, instead of exploiting the kinematic combination between the work tool 14 and the anthropomorphic arm 13, comprise a deforming element, not shown, such as for example an eccentric ring nut, a deformation lever or other, mounted directly on the work tool 14.

[0072] The cutting unit 18 is configured to selectively cut the metal wire 19 downstream of the shaped segment 21 and, in the solution shown, is configured in a combined solution with the welding electrode 27, in order to reduce and optimize the spaces. In this solution, the cylinder 26 moves both the cutting unit 18, and the welding electrode 27.

[0073] In the preferred solution schematized in the attached drawings, with the work tool 14 there is also associated a gripping member, or tag holder 22, conformed to at least temporarily hold the label 50 during its transport between the printer 11 and the labeling zone LZ.

[0074] In the solution shown, the tag holder 22 is controlled by the same cylinder 26, which moves the welding electrode 27 and the cutting unit 18.

[0075] Also part of the apparatus 10 according to the present invention is a vision means or camera 23, only schematized in figs, from 1 to 8, which is positioned with respect to the labeling zone LZ so as to identify both the label 50 and also the metal product bundle 100. The camera 23 is connected to a controller, not disclosed in the drawings, that receives the information provided by the camera 23, and consequently condition the selective movement of the work tool 14 by means of the anthropomorphic arm 13 according to the information provided by the camera 23.

[0076] In fact, through the vision control of the camera 23 it is possible, for example, to identify the position and the conformation of the through hole 51, and to condition the movement of the work tool 14 so that the feeding unit 15 continuously feeds the metal wire 19 by making it pass through the through hole 51, substantially without any snagging or possibility of ruining the label 50.

[0077] In the same way, the control carried out by means of the camera 23 allows to identify the position of the weld between the end portion 19a and the bundle 100 with precision and repeatability, but also to verify, upstream of the labeling method, the actual and correct conformation and position of the shaped segment 21, as well as exposure and identifiability of the label 50.

[0078] In the attached drawings, the camera 23 is schematized as an element external to the robot 12, in a so-called stand-alone installation condition, but solutions in which the camera 23 can be integrated with the robot 12, for example mounted on the anthropomorphic arm 13, or with the work tool 14 are not excluded.

[0079] Similarly, solutions that provide two or more cameras 23 disposed with different frames are not excluded, in order to more accurately process the reciprocal positions between the parts and consequently command precise and effective movements of the robot 12.

[0080] The operation of the apparatus 10 described heretofore, which corresponds to the method according to the present invention, comprises the following steps. According to the sequence schematized in figs, from 1 to 8, initially a step of positioning the label 50 is initiated, in which the latter is selectively moved by the robot 12 mobile between the printer and the labeling zone LZ, in which the metal product bundle 100 is positioned.

[0081] Once the camera 23 has verified the correct position of the label, a feeding step is initiated, in which the metal wire 19 is fed by means of the feeding unit 13 so as to directly associate the end portion 19a thereof in the through hole 51 of the label 50. As mentioned, the reciprocal positioning between the feeding unit 13 and the label 50 is conditioned by the detection of the camera 23.

[0082] In succession, a welding step is initiated, in which the end portion 19a is welded directly to the bundle 100 by means of the welding unit 16. This step is also conditioned and controlled by means of the camera 23, which first identifies the desired welding position and then visionly checks the quality of the weld carried out.

[0083] At this point, a shaping step is initiated, in which the same robot 12 acts as a forming unit 17, making the work tool 14 alternately oscillate to define the shaped segment 21; once this shaping is finished, the metal wire 19 is cut by the cutting unit 18, in a corresponding cutting step.

[0084] At the end of this step, the labelled bundle 100 is evacuated, leaving room for a new bundle 100 to be labelled; at the same time, the robot 12 is brought into cooperation with the printer 11 to pick up a new label 50. A new labeling cycle is then initiated.

[0085] It is clear that modifications and / or additions of parts may be made to the apparatus 10 and to the method as described heretofore, without thereby departing from the field and scope of the present invention, as defined by the claims.

[0086] It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art will be able to achieve other equivalent forms of apparatus and method for labeling metal products, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.

[0087] In the following claims, the sole purpose of the references in brackets is to facilitate their reading and they must not be considered as restrictive factors with regard to the field of protection defined by the claims.

Claims

CLAIMS1. Labeling apparatus (10) for labeling metal products (100) comprising at least one robot (12) mobile between at least one supply unit (11) for supplying a label (50) and a labeling zone (LZ) in which said metal product (100) is positioned, characterized in that said robot (12) comprises at least one feeding unit (15) configured for continuously feeding a thin metal wire (19) associating it directly with said label (50), at least one welding unit (16) configured to weld an end portion (19a) of said metal wire (19) to said metal product (100), at least one forming unit (17) configured to plastically deform a clamping portion (19b) of said metal wire (19) defining at least one shaped segment (21) so as to keep said label (50) in place on said metal product (100) after the welding of said end portion (19a) to the metal product (100), and at least one cutting unit (18) configured for cutting said metal wire (19) downstream of said shaped segment (21) and in that the apparatus comprises at least vision means (23) associated with said robot (12) and configured to identify at least said metal product (100) and / or said label (50), to provide said information to a controller, wherein said controller is configured to condition at least the selective movement of said robot (12) in said labeling zone (LZ) according to the information provided by said vision means.

2. Labeling apparatus (10) as in claim 1, characterized in that said vision means (23) are configured at least for one or more of the following functions:- identifying a specific welding position of said end portion (19a) of said metal wire (19) to said metal product (100);- verifying the correct position of said label (50) after welding of said end portion (19a) of said metal wire (19) to said metal product (100); and- verifying that the information reported on said label (50) is compatible with said metal product (100).

3. Labeling apparatus (10) as in one or the other of the previous claims, characterized in that said vision means (23) are mounted in a separate and distinct position with respect to said robot (12).

4. Labeling apparatus (10) as in claim 1 or 2, characterized in that said vision means (23) are mounted on board said robot (12).

5. Labeling apparatus (10) as in one or the other of the previous claims, characterized in that said robot (12) comprises an anthropomorphic arm (13) anda single work tool (14) associated with said anthropomorphic arm (13) in an articulated maimer.

6. Labeling apparatus (10) as in claim 5, characterized in that said feeding unit (15), said welding unit (16), said forming unit (17) and said cutting unit (18) are mounted in reciprocal cooperation with each other on said single work tool (14).

7. Labeling apparatus (10) as in claim 5 or 6, characterized in that said anthropomorphic arm (13) is configured to perform movements with at least three degrees of freedom.

8. Method for labeling metal products (100) comprising at least one step of positioning a label (50) on said metal product (100), by means of a robot (12) mobile between at least one supply unit (11) for supplying said label (50) and a labeling zone (LZ) in which said metal product (100) is positioned, characterized in that it comprises, in sequence, at least one feeding step in which, by means of a feeding unit (15) of said robot (12), a metal wire (19) is selectively fed continuously, associating it directly with said label (50), at least one welding step in which, by means of a welding unit (16) of said robot (12), an end portion (19a) of said metal wire (19) is welded to said metal product (100), at least one shaping step in which, by means of a forming unit (17) of said robot (12), a clamping portion (19b) of said metal wire (19) is plastically deformed defining at least one shaped segment (21) so as to keep said label (50) in place on said metal product (100) after the welding of said end portion (19a) to the metal product (100), and at least one cutting step in which, by means of a cutting unit (18) of said robot (12), said metal wire (19) is selectively cut downstream of said shaped segment (21), and further comprising at least one vision step in which, by means of vision means (23) associated with said robot (12), at least said metal product (100) is identified to condition, by means of a controller, at least the selective movement of said robot (12) in said labeling zone (LZ).

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