Multiple Challenges Conquered for Paint Mask Application
An RFID tag manufacturer reached out to FOX IV regarding an RFID encode/print/apply system and a paint mask label applicator for a large machinery manufacturer. The company was referred to FOX IV from the label printer manufacturer, SATO, who knew of FOX IV's ability to customize labeling solutions.
The project would be lead by an integrator using the RFID tag manufacturer's closed-cell RFID tags. The integrator would incorporate the labeling systems into a labeling station where metal cylindrical parts would be placed on a short conveyor by a robotic arm, indexed under the labeling systems, then removed by the robotic arm and replaced with the next part.
The project would be lead by an integrator using the RFID tag manufacturer's closed-cell RFID tags. The integrator would incorporate the labeling systems into a labeling station where metal cylindrical parts would be placed on a short conveyor by a robotic arm, indexed under the labeling systems, then removed by the robotic arm and replaced with the next part.
The Challenge and Solution
Application:
The end-user needed to encode, print, and apply a closed-cell foam RFID tag to a metal cylinder and apply a separate paint mask label over the RFID tag to protect the printed barcode from being painted over. The RFID tag was 2.75" wide by .75" long. Because it was a closed-cell foam tag, it was much thicker than standard label or tag stock. The paint mask label, also 2.75" widex .75" wide, had to be accurately placed on top of the RFID label.
The average production rate was 2 pieces per minute, with a maximum rate of 3 per minute, 24 hours/day, 7 days/week.
 RFID Tag Applied to Cylinder |
Paint Mask Label on Cylinder
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Environmental Conditions:
The temperature in the end-user's facility could reach temperatures near or above 110°F. Additionally, due to the industrial nature of the manufacturing process, the atmosphere was both dusty and oily.
Implementation and Results
Solution:
Several requirements regarding this application presented challenges:1. The RFID tag's thickness: Due to the closed-cell foam construction of the RFID tag, the tags were thicker than the maximum thickness of standard printing mechanisms.
2. The environment: Label applicators and label stocks do not perform well in extreme heat and dirty environments. Heat can cause adhesive ooze, which leads to peeling issues. Dust and oil on label stock create poor print quality and accelerated wear on
the labeling equipment.
FOX IV provided a modified SATO-based RFID label print-and-apply system to encode, print, and apply a barcoded RFID label to the metal parts. The modification accommodated the thick tag. A FOX IV label applicator was provided to apply the clear paint mask label.2. The environment: Label applicators and label stocks do not perform well in extreme heat and dirty environments. Heat can cause adhesive ooze, which leads to peeling issues. Dust and oil on label stock create poor print quality and accelerated wear on
the labeling equipment.
Additionally, both units had stainless steel enclosures to address the temperatures and environmental issues. The enclosures included compact air-conditioning units, positive pressure, and retractable doors to allow the applicator to extend while minimizing contamination and maintaining optimal temperatures.
 Sliding Applicator Door on Enclosure |
 Air Conditioning Unit |
 Painted Parts with RFID Tag |
 Closed-cell foam RFID Tags |