Project Summary and Challenge
A steel bar manufacturer located in Ohio required an update to its automated prep line to improve efficiency, reduce errors, and support growing demand. The labeling process relied on a single printer and frequent operator intervention, causing multiple daily downtimes for roll changeovers. Misprints or incorrectly loaded label colors also created a risk of costly relabeling and production delays.
To overcome these limitations, the manufacturer required a fully automated robotic labeling system that functioned within the tight footprint of their existing facility and is capable of labeling steel bars ranging from 1.875” to 7” in diameter.
The Challenge
The legacy labeling process created several obstacles that disrupted efficiency and accuracy:
- Frequent Downtime: A single printer required multiple changeovers for different label sizes, halting production several times a day.
- Label Accuracy Risks: Misprints or incorrectly loaded label colors that identify the type/alloy of product could lead to costly relabeling and delays.
- Space Constraints: The new system needed to fit inside a 72” x 109” enclosed room while still allowing safe operator access.
- Limited Flexibility: The existing setup could not accommodate multiple label sizes or integrate verification technology without operator intervention.
The Solution
To address these challenges, Premier Automation designed a compact robotic labeling cell to eliminate downtime, improve accuracy, and fit within the limited space available. Key elements include:
- Collaborative Robots: A Fanuc CRX-5iA collaborative robot applies labels across multiple bar diameters with flexibility and precision.
- Integrated Vision System: A Cognex In-Sight 2800 camera provides both OCR and color verification, ensuring accurate labels and preventing costly errors.
- Stacked Printer Arrangement: Four Sato printers, mounted in vertically stacked pairs, allowing seamless product changeovers without halting production.
- Operator-Friendly Design: Custom printer stands and a compact cell layout maximized space while maintaining operator accessibility for label loading and rewinding.
The Results
- Reduced Downtime: Multiple printers and automated handling eliminated frequent stoppages for label roll changeovers.
- Improved Label Accuracy: Integrated OCR and color verification ensured correct labels for each alloy type.
- Optimized Use of Space: A compact, stacked printer arrangement custom-made to fit within the tight space while maintaining safe operator access.
- Enhanced Productivity: Automated label application across bar diameters from 1.875” to 7” improved throughput and reduced dependence on manual intervention.
- Operational Reliability: Modern components simplify maintenance and provide long-term support for critical operations
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Driving the future of manufacturing through collaboration
Premier Automation is a proud member of the ARM (Advanced Robotics for Manufacturing) Institute. The ARM Institute aims to be the leading catalyst of robotics innovation and expertise and to accelerate growth in US-based manufacturing and the high-value careers that go arm in arm with this industry change. ARM is dedicated to creating the ecosystem that will drive innovation in robotics.
Premier Automation is an Authorized System Integrator for:
Robotics
Electric