Robotic Label Application Head for Metal Bar Bundles
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Solution Overview
Problem
Existing automated labelling systems for bundles of metal bars are inefficient and unsafe, as they require manual intervention to position labels outside the bundle, leading to potential loss and operational complexity due to overlapping bundles.
Innovation Solution
A fully automated system using a robotic arm with a label application head and metal wire, which includes wire processing means and object recognition to automatically fix the label outside the bundle by calculating the distance between the strap and the bundle end, forming annular elements to secure the label.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual positioning of labels is used by operators, then labels can be positioned outside the bundle, but operator safety is compromised and the process is slow
Solution Approach 1:
The system enables automated self-positioning of labels outside the bundle using robotic manipulation and computer vision, eliminating the need for manual operator intervention while maintaining positioning accuracy. The robotic arm with gripper automatically places labels at calculated positions outside the bundle based on visual detection of bundle geometry.
Solution Approach 2:
The patent replaces manual mechanical positioning with an automated system combining computer vision (optical field) and robotic manipulation. The system uses cameras to detect bundle characteristics and automatically calculates optimal label positions, then executes placement through robotic arm movement, substituting human operators with automated mechanical-optical systems.
2Reliability
If manual positioning of labels is used by operators, then labels can be positioned outside the bundle, but the labelling process becomes slow and inefficient
Solution Approach 1:
The system enables automated self-positioning of labels outside the bundle using robotic manipulation and computer vision, eliminating the need for manual operator intervention while maintaining positioning accuracy. The robotic arm with gripper automatically places labels at calculated positions outside the bundle based on visual detection of bundle geometry.
Solution Approach 2:
The patent implements continuous automated operation where the robotic arm continuously picks, positions, and places labels without interruption. The system maintains continuous useful action by coordinating camera detection, position calculation, and robotic placement in an uninterrupted sequence, eliminating the intermittent nature of manual operations.
3Extent of automation
If automated welding systems are used to fix labels, then the process is automated, but the system cannot adapt to different bundle configurations and positions
Solution Approach 1:
The patent employs dynamic positioning where the robotic arm can adapt its movement and placement position based on real-time detection of bundle characteristics. The system dynamically calculates optimal label positions outside the bundle for each unique configuration, allowing the automated system to handle varying bundle sizes, shapes, and orientations while maintaining automated operation.
Solution Approach 2:
The system achieves universality by combining computer vision capabilities with flexible robotic manipulation. The same automated system can handle different bundle configurations (varying numbers of bars, different dimensions, various orientations) by detecting characteristics and adapting placement positions, making the system universally applicable to multiple bundle types without requiring reconfiguration.
4Extent of automation
If labels are positioned at the straps inside the tubular element, then automated positioning is achieved, but labels become hidden when bundles are stacked
Solution Approach 1:
The patent solves the visibility problem by changing the spatial dimension of label placement. Instead of positioning labels in the horizontal plane at the strap level (where they would be hidden under stacked bundles), the system places labels in the vertical dimension outside the bundle envelope. This dimensional shift ensures labels remain visible even when bundles are stacked vertically, while maintaining automated positioning through robotic manipulation.
Data Source
AI summary
Labelling system of bundles (300) of rods or bundles of bars, which bundles (300) comprise one or more straps (302) arranged around the bundle (300).Said system comprises a robotic arm (1), an application head (2) of the label and at least one spool (3) of metal wire, which robotic arm (1) is configured for the movement of said application head (2).Means are also present for activating the rotation of the spool (3), configured to convey the metal wire inside the application head (2).The application head (2) comprises wire processing means, automated object recognition means, and means for gripping/releasing (23) at least one label (4), the processing means being configured to unwind the wire and fix a first end of the wire to a strap (302) of the bundle (300) and to engage a second end of the wire to said label (4).Furthermore, the automated object recognition means comprising identification means of the bundle (300), configured to detect a first section, corresponding to the distance between a strap (302) and an end of the bundle, the wire processing means being configured to execute a cutting of the wire such that the distance between the first end and the second end is greater than said first section.