The counting problem
In most rebar mills, bars are still counted by hand at the cooling bed or bundling station. It is slow, tiring and error-prone, and mistakes reach the customer as short or over-weight bundles. Machine vision solves this by counting every bar automatically.
How it works
An industrial camera, protected from heat and dust, views the bar ends or the cooling bed. An AI model trained on your bar sizes detects each bar and counts it in real time. Results go to the operator screen and, if needed, to your ERP or bundle tags.
Applications in a rebar mill
Beyond counting, the same cameras can measure and inspect:
- Automatic bar counting at the cooling bed
- Bundle counting and verification before dispatch
- Diameter and rib-geometry measurement
- Surface crack and defect detection
- Cut-length verification
What makes a project succeed
Good lighting, a stable camera position and representative training images matter more than the camera brand. That is why every project should start with a feasibility check on real images or video from your line, followed by a short proof-of-concept before full deployment.
Mills that automate counting usually see fewer customer disputes, faster dispatch and better data on production — often recovering the investment quickly.