Bespoke Helmet Labeling System

APPLICATION

The customer wanted to place a 1.12” x 0.5” pre-printed brand label to a specific location on the outside of their helmets as well as a 5.75” x 2.25” contoured label that had variable text to the curved inside back of the helmet.

The final system needed to be both semi-automatic operator triggered and automatically triggered via PLC for future robotic integration. Helmets would be placed manually prior to planned robotic automation. The helmets had to be precisely positioned and labeled each time.The operator activates the labeling system using two finger triggers. The 1914 applies the logo label to the outside of the helmet while the 6957 prints and applies the interior contoured label. Remoted control panels make it easier to operate the labeling equipment.

The system was required to have safety lock-outs for manual operation and sit low to the floor. The customer would supply a motorized height adjustment so the operator could raise or lower the entire system for ergonomic purposes.

ENVIRONMENT/SPECIAL CONDITIONS:

Temperature controlled factory environment.

SOLUTION

FOX IV designed a labeling station including a 1914 label applicator and 6957 printer-applicator with rotary actuator and custom applicator pad. The labeling systems could apply labels independently or simultaneously. HMI control panels were remoted to an operator accessible panel, and the labeling units were mounted to a staging table.

The labeling station table featured a positioning fixture for two different sized helmets, a safety trigger for semi-automatic labeling, and a low profile. The safety trigger required the operator to place a finger from each hand onto signaling devices simultaneously for the labeling to occur.

The 1914 label applicator placed a label on a small raised area on the exterior of the helmet while the 6957 printer-applicator printed the variable information on the contoured label, fed it onto a custom-designed flexible applicator pad, and applied it to the rear interior of the helmet.
 

EQUIPMENT PROVIDED

FOX IV 1914 Label Applicator

•  Allen-Bradley PLC Control
• Remoted HMI
• Pneumatic Cylinder Assembly
• I/O Control Packaging

FOX IV 6957 Label Print and Apply

• 203 DPI Zebra Print Engine
• Allen-Bradley PLC
• Remoted HMI
• Custom Flexible Applicator Pad
• Rotary Actuator
• I/O Interface Package

Product Labeling Table with Positioning Fixture
Safety Application Triggers
Operator Panel
 

SERVICES PROVIDED:

Integration Services
Factory Acceptance Testing
 

WHY FOX IV

The FOX IV helmet labeling system:

• Consistently and accurately applies labels to both the exterior and interior of the helmets.
• Labels two different product sizes, making it flexible.
• Accommodates future automation.
• Prioritizes operator safety.

The implementation of the FOX IV system not only met the customer's requirements but also enhanced the accuracy of their labeling process. This innovative solution ultimately supported their goals:

• Ability to grow with needs
• Accurate and secure label application
• Reduce rework
• Operator safety

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