Robotic Pallet Labeling: Four Labels, Two Sides, One Stop

The Challenge and Solution

APPLICATION:

The system needed to be able to print and apply a 5.25” wide x 8” long label and apply a pre-printed barcode label 2.57” wide x 6.5” long to the side of a pallet. The pallet would be stopped on the conveyor and a robot would pick the labels up at the labeler peel point and apply them to two locations on the pallet. Labels needed to be applied at a maximum rate of 3 pallets per minute with an average rate of 2 pallets per minute. The system needed to be able to operate 24/7.

The system integrator would be responsible for the data and signals needed for the print and apply operations. The label data to be printed would be sent in batches.
 

ENVIRONMENT/SPECIAL CONDITIONS:

Temperature controlled factory environment between 65°F to plus 75°F. Small amounts of corrugated dust were present.

Application surface is smooth, dust and moisture free.

Implementation and Results

SOLUTION:

FOX IV recommended the Model 6956L2 labeling system with Zebra print engine, PLC Controls and a robotic interface package and the model 1014 labeling system with digital I/O. Neither unit would have a traditional application device. Rather, the integrator would program an industrial robot on the pallet conveyor line to pick up the labels from each FOX IV system and place them onto the pallet after receiving “label ready” signals from the FOX IV units.

FOX IV’s engineering team designed and stored a label format in the 6956L2. The integrator was responsible for calling up the format and sending the variable data to the printer. The 6956 printed and dispensed the 5.25” x 8” label, which came on the customer’s preferred 3” ID X 12” OD label roll. Then the label was printed and ready to apply, the 6956 sent a signal to the integrators PLC.

The 1014 received a signal from the integrator’s PLC to advance the preprinted 2.75” X 6.5” label when the robotic arm was in place. It sent a “label ready” signal to the PLC when it was finished advancing and was ready to be applied. It held a 3” ID x 10” OD label roll to match the label roll amount on the 6956.

To accommodate user access for maintenance and supply changes, the FOX IV units had opposite orientations, with the 6956L2 having a lower left dispense and the 1014 having a lower right dispense. Both units included warning/fault beacons to alert operators to the status of the units.

EQUIPMENT PROVIDED

6956L2 Label Print and Apply System with 6956L2 Label Print and Apply System with Warning/Fault/Status Beacons

SERVICES PROVIDED:

Designed format for label and stored in the 6956
Factory acceptance testing