The Rebars (Reinforced Bars) are manufactured at New Bar Mill (NBM) in various dimensions viz., 10mm, 12mm and 16mm in diameters. The Rebars are generally sold in units of 12 meters each. As there is presently no mechanism of counting the bars, they are sold based on weight, from the plant to the distributors.
The challenge is these Rebars are difficult to be counted manually at the plant, due to their high volume in numbers. The rate of production of Rebars is also high and thus there is a requirement to develop a method that will automatically count the Rebars quickly. Additionally, Rebars cannot always remain at the same level when they are strapped in a bundle. They are sometimes jutting out from the main bundle which adds to inconvenience. The Rebars are counted manually at distributors end when they form sub-bundles, which are then passed on to the Dealers. The Rebars finally get sold in the retail market in numbers.
Presently, an estimate of the number of Rebars in a bundle is made based on the weight of the bundle coupled with the diameter and length of Rebars. This has an error margin of (+/-) 10%. The requirement is to count the EXACT number of Rebars in a bundle, to allow sale of Rebars from the plant, on the basis of numbers and also to prevent pilferage during transport. The counting of the Rebars may be done prior to or after the strapping of the bundles. The device or system developed should be able to count the number of Rebars in a few seconds. It should also be able to provide information for being printed on the tags.