Preparation method of core code integrated color gilding RFID label

Abstract

The application discloses a preparation method of a core code integrated color gilding RFID label, and belongs to the technical field of composite preparation of printing marks and radio frequency identification labels. After a color gilding appearance layer is formed on a continuous label roll, a label position index is generated according to a running position and a dynamic tension strain compensation amount, variable two-dimensional code jet printing, RFID Inlay pasting, die cutting, EPC code writing and online checking are driven, a master control system establishes core code associated information of variable two-dimensional code data, EPC codes and physical label units, and triggers positions and code writing power of a work station are corrected according to core code matching states and radio frequency performance feedback, so that the risks of pasting offset, code error and code string are reduced.

Description

Technical Field

[0001] This invention belongs to the field of composite preparation technology of printed marking and radio frequency identification tags, specifically relating to a method for preparing color hot stamping RFID tags based on integrated core code. Background Technology

[0002] Radio frequency identification (RFID) technology uses radio frequency signals to automatically identify and read / write data on target objects. UHF passive RFID tags have batch reading capabilities and long-range identification distances, and have been applied in scenarios such as logistics tracking, supply chain management, retail settlement, clothing inventory, and product anti-counterfeiting and traceability. High-end product packaging and anti-counterfeiting labels also require eye-catching visual recognition effects. Color hot stamping can create a metallic luster, color gradation, and brand identification patterns on the label surface, and therefore is gradually being combined with RFID tag products.

[0003] Current RFID tag manufacturing typically involves several steps, including faceplate printing, chip or RFID inlay lamination, film protection, die-cutting, chip coding, and finished product inspection. When multiple steps are completed by different equipment or workstations, material conveyor speed, tension fluctuations, workstation offsets, visual inspection errors, and manual handling can all affect the consistency of the physical tag units. Introducing a color hot stamping layer into the metal foil transfer area further introduces issues such as protecting the hot stamping appearance, avoiding misalignment during adhesive application, and avoiding misalignment in the RF antenna area. While sequentially connecting color printing, hot stamping, RFID inlay lamination, and die-cutting can improve process integration, it still cannot guarantee a one-to-one correspondence between the QR code visual code, the EPC code in the RFID chip, and the actual physical tag unit throughout continuous production.

[0004] In conventional manufacturing methods, variable QR codes are often generated by inkjet printers based on batch or serial numbers, while RFID coding is written into the chip by a reader according to a different set of encoding rules. If there is no physical positional reference connecting the inkjet and coding stations, minute offsets in the material during slitting, laminating, bonding, and die-cutting processes can lead to mismatches between the QR code data and the EPC code. Mismatched labels may still appear acceptable in appearance and may individually pass RFID reading, but when consumers scan the QR code, the warehouse system reads the EPC code, or the back-end traceability system compares the data, incorrect codes, missing codes, duplicate codes, or broken traceability chains will appear.

[0005] Furthermore, tension fluctuations during the continuous roll-to-roll fabrication process cause slight elastic expansion and contraction of the flexible continuous tag roll between adjacent workstations. Fixed workstation offsets can only compensate for equipment installation distances, and cannot compensate for positional errors caused by tension changes in the material during real-time conveyor belt operation. The RF antenna at the online coding station also has a certain radiation coverage range. When the center-to-center distance between adjacent physical tag units decreases due to the contraction of the continuous tag roll, adjacent RFID inlays may simultaneously enter areas with higher field strength, increasing the risk of misreading, miswriting, and cross-coding. Summary of the Invention

[0006] The purpose of this invention is to provide a method for manufacturing color hot stamping RFID tags based on integrated core code, which solves the technical problems of difficulty in synchronously integrating the visual effect of color hot stamping and RFID radio frequency function in continuous manufacturing, insufficient matching reliability caused by separate generation of QR code data and EPC code, station positioning drift caused by dynamic tension deformation, and serialization of adjacent physical tag units.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: The method for manufacturing color hot stamping RFID tags based on integrated chip code includes the following steps: Forming a continuous label roll with a colored hot stamping finish; A label position index is generated based on the conveyor position of the continuous label roll, and variable QR code data is generated and printed according to the label position index; Apply adhesive to the RFID Inlay bonding area that avoids the colored hot foil exterior layer, and bond the RFID Inlay according to the label position index; Complete die-cutting and EPC code writing according to the label position index, so that the variable QR code data, EPC code and physical label unit form core code association information; Read the variable QR code data and EPC code, and output qualified winding instructions, abnormal handling instructions or cycle adjustment instructions to the main control system in combination with the RF performance verification results.

[0008] As a preferred technical solution of the present invention, the label position index is formed by the encoder coordinates of the continuous label roll, the offset of the inkjet printing station, the offset of the bonding station, the offset of the die-cutting station, the offset of the coding station, and the visual positioning deviation. When the label position index is transferred between adjacent stations, the trigger position of the target station is updated synchronously.

[0009] As a preferred technical solution of the present invention, the variable QR code data includes a unique label serial number, production batch information, inkjet printing station location information and a verification field. When the main control system prints the variable QR code data, it simultaneously establishes a correspondence between the variable QR code data and the label location index.

[0010] As a preferred technical solution of the present invention, the colored hot stamping appearance layer is formed by cold hot stamping and ultraviolet curing, the transparent protective film covers the colored hot stamping appearance layer and the area where the variable QR code data is located, and forms an avoidance window in the RFID Inlay bonding area.

[0011] As a preferred technical solution of the present invention, the RFID Inlay bonding area forms a bonding adhesive layer through a quantitative adhesive supply mechanism. The visual positioning system collects the edge of the colored hot stamping appearance layer, the positioning mark or the variable QR code data position, and feeds back the bonding position deviation to the main control system to correct the label position index.

[0012] As a preferred technical solution of the present invention, during die-cutting, the avoidance relationship between the die-cutting line and the RFID Inlay, the antenna area and the variable QR code data area is determined according to the label position index, and the position of the physical label unit after die-cutting is transferred to the online coding station.

[0013] As a preferred technical solution of the present invention, the EPC code is generated by mapping the unique serial number of the tag in the variable QR code data. The online coding station reads the variable QR code data to be written to the physical tag unit according to the tag position index, and reads the EPC code after writing to perform consistency verification.

[0014] As a preferred technical solution of the present invention, the core code association information includes the tag position index, variable QR code data, EPC code, writing timestamp, bonding position deviation, die-cutting position deviation and verification status, and the core code association information is stored in the association database of the main control system.

[0015] As a preferred technical solution of the present invention, the radio frequency performance verification result is formed by the reading distance, reading success rate and decoding sensitivity. The main control system combines the core code matching status with the radio frequency performance verification result to determine the tag status.

[0016] As a preferred technical solution of the present invention, when the abnormal ratio of multiple consecutive physical label units reaches a preset abnormal ratio threshold, the main control system reduces the conveyor speed of the continuous label roll, suspends the corresponding workstation or triggers an alarm, and marks, removes or isolates the abnormal labels.

[0017] As a preferred technical solution of the present invention, the layout data of the colored hot stamping surface layer and the antenna area data of the RFID Inlay together form a no-fabrication area. The main control system restricts the metal foil transfer area according to the no-fabrication area, so that the metal foil transfer area avoids the main radiation area of ​​the RFID Inlay.

[0018] As a preferred technical solution of the present invention, the integrated color hot stamping RFID tag is used for anti-counterfeiting labels for high-end product packaging, clothing hang tags, supply chain traceability labels or retail bulk inventory labels. The physical tag unit has both a color hot stamping visual recognition entry and an RFID radio frequency identification entry before leaving the factory.

[0019] In addition, this invention also discloses a color hot stamping RFID tag manufacturing system based on integrated chip code, including a color hot stamping preparation module, a coding module, a laminating module, an RFID inlay bonding module, a die-cutting module, an online coding module, a data verification module, and a main control system; the color hot stamping preparation module outputs a continuous label roll with a color hot stamping outer layer to the coding module; the coding module receives the label position index and variable QR code data from the main control system and outputs the printed continuous label roll to the laminating module; the laminating module receives the printed continuous label roll and outputs a laminated roll with an avoidance window to the RFID inlay bonding module; the RFID inlay bonding module receives the laminated roll with the avoidance window and the label position index from the main control system, applies the RFID inlay to a predetermined bonding area, and outputs a composite roll to the die-cutting module; the die-cutting module die-cuts the composite roll according to the label position index and outputs physical tag units to the online coding module; the online coding module receives the physical tag units, variable QR code data, and EPC code, and writes the EPC code into the RFID inlay. Inlay outputs core code association information to the data verification module; the data verification module reads the variable QR code data and EPC code and outputs the verification status to the main control system; the main control system outputs a qualified winding instruction, an anomaly handling instruction, or a cycle adjustment instruction based on the verification status.

[0020] As a preferred embodiment of the present invention, during the synchronous update of the target station trigger position when the label position index is transferred between adjacent stations, the offset of the bonding station, the offset of the die-cutting station, and the offset of the coding station include dynamic tension strain compensation. The dynamic tension strain compensation is calculated based on the real-time conveyor tension of the continuous label roll between the source station and the target station, the elastic modulus of the continuous label roll, and the cross-sectional area of ​​the continuous label roll. The dynamic tension strain compensation is: ; in, This is the dynamic tension strain compensation amount, in mm; The real-time belt tension of continuous label roll material between the source station and the target station, in N; The reference tension for continuous label rolls, in N; The cross-sectional area of ​​the continuous label roll is in mm². The elastic modulus of continuous label rolls is expressed in MPa. The physical reference span between the source station and the target station is in mm. The main control system superimposes the dynamic tension strain compensation amount into the offset of the bonding station, the offset of the die-cutting station, and the offset of the coding station to correct the trigger position of the target station.

[0021] As a preferred embodiment of the present invention, the online coding station dynamically adjusts the transmit power of the RF antenna based on the updated target station trigger position and dynamic tension strain compensation amount; the main control system calculates the actual center distance between two adjacent physical tag units, which is the actual center distance plus the dynamic tension strain compensation amount corresponding to the latter physical tag unit at the online coding station and minus the dynamic tension strain compensation amount corresponding to the former physical tag unit at the online coding station, based on the designed pitch; when the actual center distance is less than the designed pitch, the main control system reduces the transmit power of the RF antenna according to the power attenuation relationship, and the linear value of the adjusted transmit power is: ; in, The adjusted linear value of the transmit power is expressed in mW. This is the linear value of the reference transmit power, in mW; This is the antenna radiation pattern adjustment coefficient, which is dimensionless. The design pitch for continuous label rolls, in mm; The actual center distance between two adjacent physical tag units is in mm. The main control system converts the adjusted linear value of the transmit power into a dBm control value and then transmits read / write radio frequency signals to the physical tag unit to be written. The adjusted linear value of the transmit power is not lower than the minimum linear value of the transmit power required for the physical tag unit to complete the EPC code writing, so as to reduce the risk of accidentally writing EPC codes to adjacent physical tag units.

[0022] Compared with the prior art, the present invention has the following beneficial effects: This invention utilizes a tag position index that runs through the inkjet printing station, RFID inlay bonding station, die-cutting station, online coding station, and data verification station. This ensures that the visual code position, RFID inlay position, die-cutting boundary, and EPC writing object of the same physical tag unit remain consistent throughout the continuous manufacturing process. It confirms core code consistency from multiple levels—data source, processing location, and final read / write result—thereby reducing the risk of mismatch between QR code data and EPC code. When the tag position index is transferred between adjacent stations, the target station trigger position is updated synchronously, ensuring that inkjet printing trigger, adhesive bonding trigger, die-cutting trigger, and coding trigger all target the same physical tag unit. This reduces cross-station object misalignment caused by equipment spatial distance, visual positioning deviation, and material conveyor belt fluctuations.

[0023] This invention incorporates the elastic expansion and contraction of continuous tag rolls caused by tension changes between the source and target stations into the tag position index through dynamic tension strain compensation. This eliminates the reliance on rigid encoder counting for the target trigger positions at the bonding, die-cutting, and coding stations. When combined with visual positioning deviation feedback, the dynamic tension strain compensation reduces RFID inlay bonding offset, die-cutting boundary offset, and coding object offset caused by tension fluctuations, thereby improving composite positioning accuracy.

[0024] This invention enables the online coding station to shrink the effective coding range when the distance between adjacent physical tag units decreases by calculating the actual center distance and dynamically adjusting the RF antenna transmission power. The online coding station adjusts the RF antenna transmission power according to the updated target station trigger position and dynamic tension strain compensation, ensuring that the physical tag unit to be written can still complete the EPC code writing. The risk of adjacent physical tag units being falsely activated is reduced, thereby suppressing code crosstalk and false writing.

[0025] This invention utilizes a collaborative design between the coated avoidance window and the RFID Inlay bonding area to provide physical protection for the colored hot stamping surface layer and the variable QR code data through a transparent protective film. This simultaneously prevents the transparent protective film from affecting the application of the adhesive and the bonding strength of the RFID Inlay. By restricting the metal foil transfer area through a restricted area on the printing plate, the metal foil transfer area is kept away from the main radiation area of ​​the RFID Inlay, balancing the visual effect of the colored hot stamping with RFID radio frequency performance. The main control system outputs qualified winding instructions, abnormal handling instructions, or cycle adjustment instructions based on the core code matching status and RFID performance verification results. This suppresses the spread of abnormal tags during continuous production, improving the reliability of finished product unwinding. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0027] Figure 1 This is the main flowchart of the preparation method of the present invention.

[0028] Figure 2 This is a flowchart of the label position index transfer and dynamic tension strain compensation sub-process of the present invention.

[0029] Figure 3 This is a flowchart of the dynamic adjustment sub-process of the radio frequency antenna transmit power in this invention.

[0030] Figure 4This is a flowchart of the sub-process for generating and determining the core code association information in this invention. Detailed Implementation

[0031] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the embodiments of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0032] The following is in conjunction with the appendix Figures 1-4 The embodiments of the present invention will be described in detail below.

[0033] The present invention is used to prepare multiple physical tag units on a continuous tag roll. Each physical tag unit has a material position, a visual code position, an RFID Inlay position, a die-cutting boundary, a chip writing object, and a quality verification status during the preparation process.

[0034] Traditional continuous production lines typically process these objects as data within different workstations, with the coding controller, bonding controller, die-cutting controller, and reader only sharing start, stop, or speed signals. While this approach can complete the action of a single workstation, it's difficult to prove that the RFID Inlay currently being written with an EPC code belongs to the physical tag unit whose QR code was previously printed. This invention unifies the triggering reference for multiple workstations to the tag position index, reducing object mismatch at the source.

[0035] The label location index is not simply a serial number. It includes at least the physical label unit number, strip column number, source station encoder coordinates, current station encoder coordinates, target station offset, visual positioning deviation, strip correction deviation, dynamic tension strain compensation, and anomaly marker field. The physical label unit number establishes the logical correspondence between variable QR code data and EPC codes; the strip column number handles situations where multiple rows of side-by-side labels enter different station channels after striping; the source and current station encoder coordinates are used to calculate the conveyor belt distance; the target station offset compensates for the spatial distance between the inkjet head, bonding head, die-cutting blade, and read / write antenna; the visual positioning deviation compensates for the actual offset of the hot stamping edge, QR code, or positioning mark; the dynamic tension strain compensation compensates for the elastic expansion and contraction of the flexible continuous label roll due to tension changes between the source and target stations; and the anomaly marker field transmits inkjet printing defects, bonding deviations, die-cutting deviations, or read / write failures to subsequent stations.

[0036] The main control system can be implemented using an industrial computer, a PLC controller, or a combination of both. The industrial computer processes tag location indexes, variable QR code data, EPC code mapping, associated databases, dynamic tension and strain compensation values, actual center distance, and transmission power control values. The PLC controller drives unwinding, tension control, coding triggering, gluing, bonding, die-cutting, rejection, and rewinding actions. The industrial computer and PLC controller communicate via industrial Ethernet or fieldbus. Communication content is not limited to start / stop commands but also includes tag location indexes, workstation offsets, visual positioning deviations, tension acquisition values, core code association information, and verification status.

[0037] When continuous label rolls pass through the color hot stamping preparation module, both the color graphic layer and the metal foil transfer layer serve as positioning references for subsequent processes. The color graphic layer can contain brand patterns, color blocks, text, or anti-counterfeiting backgrounds. The color hot stamping appearance layer can contain gold, silver, or other metallic patterns. To avoid uncontrollable effects of the metal foil area on the UHF RFID antenna, the main control system imports RFID Inlay antenna area data during the layout design stage and performs avoidance verification between the main antenna radiation area and the metal foil transfer area. If a hot stamping pattern enters the restricted area, the main control system outputs a layout conflict warning, and the hot stamping pattern or the RFID Inlay bonding position is adjusted by the plate-making file.

[0038] After the colored hot stamping finish is completed, a visual inspection device checks the integrity of the hot stamping pattern, edge defects, registration errors, and surface contamination. The visual inspection results are not only a record of appearance quality but also serve as correction input for label position indexing. For example, if the actual position of the hot stamping edge shifts relative to the designed position towards the conveyor belt direction, the coding station can adjust the QR code printing trigger time based on the shift; the RFID inlay bonding station can adjust the adhesive application position based on the shift; and the die-cutting station can adjust the die-cutting trigger position based on the shift. In this way, the appearance layer inspection results are actually used in subsequent processes, rather than forming isolated inspection data with no downstream application.

[0039] The slitting station cuts the finished material into rolls of material suitable for the width of subsequent processing stations. After slitting, each roll of material generates a new edge position and column number. The main control system writes the slitting column number into the label position index, enabling the inkjet printing station to identify the column number corresponding to the current inkjet printing station, the laminating station to determine the corresponding RFID Inlay feeding channel, the die-cutting station to retrieve the die-cutting plate of the corresponding column, and the online coding station to determine which column of physical tag units is covered by the read / write antenna.

[0040] When generating variable QR code data, the main control system prioritizes using the tag's unique serial number as the logical primary key. The tag's unique serial number can be a combination of production batch, date, volume number, column number, and an incrementing sequence number. Variable QR code data can contain plaintext serial numbers, or it can contain a query address, verification field, or data digest converted according to encoding rules. Regardless of the form of the QR code content, the main control system maintains the correspondence between the variable QR code data and the tag location index, and uses this correspondence as input for subsequent EPC code generation and writing.

[0041] After the QR code printing is completed, a visual reader reads the actual content of the QR code. If the read content is inconsistent with the content sent by the main control system, the physical tag unit is marked as having abnormal printing content; if the read content is consistent but the position deviation exceeds the printing position threshold, the physical tag unit is marked as having abnormal printing position. Abnormal printing content usually requires rejection or isolation; abnormal printing position can be determined based on the deviation magnitude to decide whether to continue RFID inlay bonding. The abnormality marker is passed downstream along with the tag position index, so that subsequent workstations do not need to re-determine the source of the abnormality.

[0042] The protective film not only protects the appearance but also participates in subsequent bonding processes. After the transparent protective film covers the colored hot-stamped outer layer and the area containing the variable QR code data, the label surface's scratch resistance is improved, and the QR code is less likely to become unreadable due to friction. With a clearance window set in the RFID inlay bonding area, the adhesive can directly contact the substrate or the intended bonding surface without being blocked by the transparent protective film. The size of the clearance window can be determined based on the RFID inlay outline, the adhesive coating width, and positional deviation tolerance. The clearance window position is controlled by the label position index and verified by a visual positioning system.

[0043] The RFID Inlay bonding station includes an RFID Inlay feeding mechanism, a metering adhesive dispensing mechanism, a bonding roller system, and a vision positioning system. The RFID Inlay feeding mechanism releases a single RFID Inlay based on the tag position index. The metering adhesive dispensing mechanism applies bonding adhesive to the corresponding bonding area. The bonding roller system applies pressure after the RFID Inlay aligns with the continuous tag roll, causing the bonding adhesive to soak the back of the RFID Inlay and the substrate surface. The vision positioning system acquires the position of the RFID Inlay edge or chip area and writes the actual bonding position into the chip code association information.

[0044] When the RFID inlay bonding position deviation is small but has not exceeded the rejection standard, the main control system can allow the physical tag unit to enter the die-cutting and coding station, while increasing the weight of RF performance verification. This processing method can avoid prematurely rejecting tags that may still be qualified, and can also ensure that tags with bonding risks receive stricter judgment at the data verification station. If the RFID inlay bonding position deviation exceeds the rejection standard, the main control system writes a forced anomaly mark in the chip code association information, and the subsequent rejection mechanism performs rejection based on the tag position index.

[0045] The die-cutting station needs to simultaneously consider the appearance boundary, QR code reading area, RFID inlay area, and antenna area. If the die-cutting line is too close to the QR code area, it may cause damage to the QR code edge; if the die-cutting line is too close to the RFID inlay chip or antenna, it may cause a decrease in radio frequency performance or damage to the chip. This invention uses the tag position index and the board's no-go area to jointly control the die-cutting trigger, ensuring that the die-cutting boundary maintains a designed avoidance relationship with the QR code area, RFID inlay area, and antenna area. After die-cutting, the main control system writes the die-cutting position deviation into the chip code association information as input for subsequent quality judgment.

[0046] The online coding station can be located downstream of the die-cutting station, or at a location where RFID inlays can be stably read before or after die-cutting. When the online coding station is located upstream of the die-cutting station, the EPC code is pre-written. After die-cutting, the data verification station still verifies the association between the variable QR code data and the EPC code based on the tag position index. The coding station determines the current object to be written based on the tag position index. The main control system retrieves the variable QR code data according to the tag position index and generates the EPC code according to the preset mapping rules. The mapping rules can make the EPC code sequence field consistent with the tag's unique serial number in the QR code, or the EPC code can include an encoded field converted from the tag's unique serial number. Regardless of the mapping method used, the main control system saves the correspondence before and after mapping.

[0047] After the code writing is completed, the RFID reader reads the EPC code for verification. If the RFID reader cannot read the radio frequency response of the RFID Inlay chip, the physical tag unit is marked as read / write failed; if the EPC code read by the RFID reader does not match the target EPC code, the physical tag unit is marked as EPC inconsistent; if the RFID reader successfully reads the code but the radio frequency performance is below the threshold, the physical tag unit is marked as radio frequency performance risk. All three states—read / write failed, EPC inconsistent, and radio frequency performance risk—enter the data verification station.

[0048] The core code association information can be stored in the local production line database, or synchronized to the plant quality management system. The core code association information at least includes the label position index, variable two-dimensional code data, EPC code, inkjet printing timestamp, laminating timestamp, code writing timestamp, inkjet printing position deviation, laminating position deviation, die-cutting position deviation, dynamic tension strain compensation amount, radio frequency performance data and final disposal result. Since the core code association information uses the unique label serial number or the label position index as the primary key, subsequent quality traceability can query the EPC code from the two-dimensional code entry, and can also query the two-dimensional code data and preparation process parameters from the EPC code entry.

[0049] The data verification station performs dual-entry reading. The visual code reader reads the variable two-dimensional code data on the label surface, and the RFID reader-writer reads the EPC code in the RFID Inlay. The main control system compares the two actual reading results with the expected values in the associated database. Only when the actual two-dimensional code data, the actual EPC data and the label position index of the physical label unit all match, the core code matching state is judged as qualified. If the actual two-dimensional code data is correct but the actual EPC data belongs to an adjacent label, the main control system determines that the core code is mismatched, rather than simply determining that the two-dimensional code is qualified or the RFID is qualified.

[0050] Exception handling may include marking, rejecting, isolated winding and stop alarm. Marking is applicable to labels that require manual re-inspection but are not rejected immediately; rejecting is applicable to labels that have been confirmed to have core code mismatch, read-write failure or appearance damage; isolated winding is applicable to the situation where abnormalities occur continuously in the same continuous label roll and the entire section needs to be rechecked; stop alarm is applicable to the situation where the abnormal ratio continuously exceeds the threshold and may be caused by equipment failure. All exception handling actions are triggered by the label position index, so as to prevent the rejecting mechanism from mistakenly rejecting adjacent qualified labels.

[0051] The cycle feedback of the main control system can adopt a sliding window statistical method. The sliding window contains the quality status and abnormality type of several recent physical label units. If the number of core code mismatches, the number of read-write failures, the number of lamination deviations or the number of radio frequency performance risks in the sliding window reaches the corresponding threshold, the main control system outputs a cycle adjustment instruction. The cycle adjustment instruction can reduce the web running speed, increase the lamination roller pressing holding time, extend the reading time of the RFID reader-writer, increase the exposure time of visual inspection or suspend the corresponding station. The cycle adjustment is not intended to improve the calculation efficiency, but to reduce the continuous spread of abnormal labels in the continuous preparation process.

[0052] The core processing logic of this invention is interdependent. The location index generation logic solves the problem of physical object attribution; the dynamic tension-strain compensation logic solves the problem of deformation compensation across workstations for flexible continuous label rolls; the core code ternary binding logic solves the problem of consistency between QR code data, EPC codes, and physical label units; the writing power adjustment logic solves the problem of code mixing when the center distance between adjacent physical label units shortens; and the verification feedback logic solves the problem of the spread of abnormal labels in continuous production. If the location index generation logic is removed, the core code ternary binding cannot determine the physical object; if the dynamic tension-strain compensation logic is removed, cross-workstation offsets caused by tension fluctuations cannot be promptly triggered at the target workstation; if the writing power adjustment logic is removed, the online writing workstation cannot reduce the risk of miswriting based on changes in the spacing between adjacent labels; if the core code ternary binding logic is removed, the QR code and EPC code can only exist side-by-side and cannot be proven to be consistent; and if the verification feedback logic is removed, abnormal labels may still be generated continuously.

[0053] In engineering implementation, the location index generation logic can be implemented using encoder pulses and workstation offset tables, or it can be dynamically compensated by combining visual positioning results. The dynamic tension-strain compensation logic can be implemented using tension sensors, material parameter tables, and the main control system's calculation module. The chip code ternary binding logic can be implemented using local database tables, or it can be implemented using a combination of the main control system's memory queue and a persistent database. The code writing power adjustment logic can be executed by the RFID reader's power control interface. The verification feedback logic can be implemented using a fixed threshold, or it can be implemented using graded thresholds after production line debugging. Different implementation methods do not change the technical essence of this invention, which uses the same tag location index to connect multiple workstations and form a closed loop of chip code association.

[0054] This invention can also adjust the relative positions of the colored hot foil coating layer and the RFID inlay according to different product layouts. For small-sized labels, the RFID inlay can be placed in the central area of ​​the back of the label, and the colored hot foil coating layer can be placed in the edge area of ​​the front. For long garment hang tags, the RFID inlay can be placed along the length of the hang tag, and the variable QR code data can be located in an area that maintains a distance from the antenna. For gift box seals, the colored hot foil coating layer can be located in the main visual area, and the RFID inlay can be located in the back area of ​​the seal. Regardless of how the product layout changes, the label position index remains the common reference for coding, bonding, die-cutting, coding, and verification.

[0055] To support large-scale production, this invention can generate finished roll information during the winding stage. The finished roll information includes the roll number, unique serial number of the starting label, unique serial number of the ending label, number of qualified labels, number of abnormal labels, location of the isolation label, production time, and equipment number. The finished roll information, together with the core code association information, constitutes a factory traceability record. When the subsequent warehousing system scans the outer packaging code of the finished roll, it can retrieve the core code association status of all physical label units within the finished roll.

[0056] This invention does not require the RFID inlay to use a specific chip model, the QR code to have a specific error correction level, or the adhesive to be a single type. The chip protocol, QR code encoding method, adhesive type, protective film material, and hot stamping method can be adjusted according to the product application scenario. As long as the manufacturing process establishes a traceable correspondence between the variable QR code data, EPC code, and physical tag unit through tag position indexing, and uses the verification status for anomaly handling or cycle feedback, the technical effects of this invention can be achieved.

[0057] The parameters can be categorized into design parameters, equipment calibration parameters, material calibration parameters, and production verification parameters. Design parameters are derived from label layout files, RFID inlay dimension files, QR code area files, and die-cutting line files. Equipment calibration parameters are derived from measurements of the spray nozzle installation position, bonding head installation position, die-cutting blade installation position, reader / writer antenna installation position, and rejection mechanism installation position. Material calibration parameters are derived from the width, thickness, cross-sectional area, elastic modulus, and baseline calibration tension of the continuous label roll. Production verification parameters are derived from online data acquisition results from vision inspection devices, RFID readers / writers, encoders, tension sensors, and tension controllers. The main control system reads the design parameters, equipment calibration parameters, and material calibration parameters before production, and reads the production verification parameters during production, combining these parameters into a label position index.

[0058] During first roll production or changeover production, the main control system can execute a station calibration process. This process involves forming positioning marks on the continuous label roll, sequentially passing them through a coding station, a laminating station, an RFID inlay bonding station, a die-cutting station, an online coding station, and a data verification station. Each station collects the actual position of the positioning marks and calculates the station offset. The station offset is written to a target station offset table. During production, if the visual positioning deviation continues to accumulate in the same direction, the main control system can prompt for recalibration of the station offset. This process provides a calibrable source for the position index, preventing the station offset from being treated as an unexplainable constant.

[0059] The chip code association database can contain a master table and a process table. The master table uses the tag's unique serial number as the primary key and stores variable QR code data, EPC codes, tag location indexes, finished product roll numbers, and final quality status. The process table uses the tag location index and workstation number as a composite primary key and stores inkjet printing results, lamination window results, bonding results, die-cutting results, coding results, coding reading results, RF performance results, and anomaly handling results. The master table is used for quickly tracing the identity of finished products, while the process table is used for tracing the manufacturing process. The master table and process table are linked through the tag's unique serial number and tag location index.

[0060] When the data verification station finds that the QR code cannot be read but the RFID reading is successful, the main control system does not directly classify the tag as qualified because the consumer-end QR code entry is invalid. The physical tag unit can be marked as having a visual code anomaly and enter the rejection or isolation path. When the data verification station finds that the QR code reading is successful but the RFID reading fails, the main control system does not directly classify the tag as a regular visual tag because the product definition requires both RFID entry points. The physical tag unit is marked as having a radio frequency anomaly. When both the QR code and RFID can be read but they do not match, the main control system determines it as a chip code mismatch and prioritizes rejection.

[0061] The shutdown recovery process also uses tag position indexes. After a production line is paused, the continuous tag rolls may experience positional changes during tension release or re-tensioning. Before restarting, the main control system reads the tag position index of the most recently qualified physical tag unit and confirms the physical tag units before and after the current workstation using a visual positioning system or RFID reader. If the current physical tag unit is inconsistent with the associated database record, the main control system performs a no-load positioning or isolates the initial segment until the tag position index matches the actual physical tag unit again. This prevents a segment of products with misaligned core codes after shutdown recovery.

[0062] The timing of the rejection mechanism's action is also calculated using the tag position index. After the data verification station determines that a physical tag unit is unqualified, the main control system calculates the rejection trigger time based on the physical tag unit's current position, the rejection mechanism's position, the conveyor speed, and the rejection mechanism's response time. When the rejection trigger time arrives, the air blower, claw, or isolation guide mechanism activates. If the rejection mechanism fails to respond, the main control system marks the corresponding physical tag unit and adjacent physical tag units within the protection range as requiring review and can switch to the isolation winding path.

[0063] Post-production verification can be performed based on the chip code association information. During sampling verification, the operator scans the QR code on the surface of the finished product label, the system retrieves the associated EPC code, and then an RFID reader reads the EPC code of the same label. If the EPC code corresponding to the QR code matches the actually read EPC code, and the process log shows that the coding, bonding, die-cutting, coding, and verification are all qualified, then the sampling verification passes. If inconsistencies are found during sampling verification, the system can locate adjacent labels in the same time period, the same strip column number, or the same equipment status based on the finished product roll number and label position index, facilitating the isolation of risk areas.

[0064] During roll changeover, the main control system writes the unique serial number of the end label of the previous finished roll, the coordinates of the end encoder, and the end verification status into the roll changeover record, and generates a unique serial number of the start label and a start label position index for the next finished roll. If the bonding quality of the color hot stamping outer layer, variable QR code data, and RFID inlay cannot be guaranteed in the roll changeover joint area, the main control system marks the physical tag units in the joint area as non-finished units and prohibits the online coding station from writing the official EPC code. This roll changeover process can prevent the joint material from entering the qualified take-up path.

[0065] To facilitate a better understanding of the present invention by those skilled in the art, the present invention will be further illustrated below with reference to specific implementation examples.

[0066] Example 1: This example provides a method for manufacturing color hot stamping RFID tags based on integrated chip code. Continuous tag rolls are output by an unwinding mechanism. The continuous tag rolls can be PET film substrates, paper-plastic composite substrates, or other flexible substrates suitable for printing and composite RFID inlays. After the continuous tag rolls enter the color hot stamping preparation module, the color printing unit forms a color graphic layer on the surface of the continuous tag rolls, and the cold stamping unit forms a color hot stamping appearance layer in the predetermined hot stamping area. After the color hot stamping appearance layer is formed, a visual inspection device collects the hot stamping edges, positioning marks, and defect locations, and sends the hot stamping quality signal to the main control system.

[0067] The main control system establishes a label position index for each physical label unit to be prepared. The label position index includes at least the label serial number, source station encoder coordinates, current station coordinates, target station offset, and visual positioning deviation. When continuous label rolls pass through the slitting station, the main control system writes the slitting column number, width, and edge correction deviation into the label position index. The output of the slitting station is not isolated material dimension data, but rather a coordinate source shared by subsequent inkjet printing, lamination, die-cutting, and coding stations.

[0068] At the coding station, the main control system generates variable QR code data based on the label position index. This variable QR code data includes the label's unique serial number, production batch information, coding station position information, and a verification field. The variable QR code data is sent to the variable data printing equipment via the coding controller. The coding controller determines the printing trigger time based on the continuous label roll speed, coding station offset, and label position index. After printing, the vision reader reads the actual content and position of the QR code, and the reading result is sent back to the main control system. If there is a deviation between the actual QR code position and the position indicated by the label position index, the main control system uses this deviation as compensation input for subsequent lamination, die-cutting, and coding.

[0069] When the tag position index is transferred between workstations, the main control system calculates the target workstation trigger position based on the encoder coordinates recorded at the source workstation, the conveyor speed corresponding to the physical tag unit, the recording time at the source workstation, the planned trigger time at the target workstation, and the comprehensive position compensation amount at the target workstation. For example, in a set of debugging calculations, the encoder coordinates recorded at the inkjet printing workstation for the 86th physical tag unit are 120mm, the conveyor speed is 200mm / s, the planned trigger time at the target bonding workstation is 0.3s later than the inkjet printing recording time, and the comprehensive position compensation amount at the target bonding workstation is -0.5mm. Therefore, the target bonding trigger position is 120mm plus 60mm minus 0.5mm, which is 179.5mm. The main control system controls the gluing and RFID Inlay feeding based on the target bonding trigger position, ensuring that the RFID Inlay bonding object matches the physical tag unit for printing the QR code.

[0070] The lamination station is located downstream of the coding station. A transparent protective film covers the colored hot stamping finish and the area containing the variable QR code data, forming a clearance window in the RFID inlay bonding area. This clearance window can be formed from pre-fabricated film or online by the die-cutting mechanism of the lamination station. The outline of the clearance window is determined based on the RFID inlay shape, the adhesive layer width, and the restricted area on the label. The main control system controls the relative position of the clearance window to the physical label unit based on the label position index, ensuring that the clearance window does not cover the subsequent adhesive application area.

[0071] The RFID inlay lamination station receives laminated rolls with clearance windows. A metering adhesive dispensing mechanism applies adhesive within the clearance windows, while the RFID inlay feeding mechanism releases the RFID inlay according to the label position index. The lamination roller system then presses the RFID inlay onto the continuous label roll. A vision positioning system acquires data on the edge of the color-stamped outer layer, positioning marks, or variable QR codes before lamination and calculates the lamination position deviation. This deviation is entered into the label position index for use by the die-cutting and online coding stations.

[0072] The die-cutting station determines the die-cutting boundary according to the tag position index. An avoidance mechanism is established between the die-cutting boundary and the RFID inlay, antenna area, and variable QR code data area to prevent damage to the RFID inlay or the QR code reading area from the die-cutting cutter lines. After die-cutting, the physical tag unit position is updated to the post-die-cut position. The online coding station receives the die-cut physical tag units, retrieves the variable QR code data from the associated database according to the tag position index, and generates or retrieves the corresponding EPC code. After the EPC code is written to the RFID inlay, the online reader reads the contents of the chip's EPC storage area and compares it with the target EPC code.

[0073] The chip code association information includes the tag location index, variable QR code data, EPC code, writing timestamp, bonding position deviation, die-cutting position deviation, and verification status. The data verification station reads the variable QR code data using a vision reader and the EPC code using an RFID reader / writer, comparing the actual reading results with the chip code association information. If the chip code matching status is qualified and the RF performance verification result is qualified, the main control system outputs a qualified winding command; if the chip code matching status is unqualified or the RF performance verification result is unqualified, the main control system outputs an exception handling command.

[0074] Radio frequency (RF) performance verification can establish a quality status based on QR code reading consistency, EPC code matching consistency, and RF performance normalization values. QR code reading consistency indicates whether the visual reader's reading result matches the variable QR code data in the associated database; EPC code matching consistency indicates whether the RFID reader's reading result matches the target EPC code; and RF performance normalization values ​​represent the normalized result of reading distance, reading success rate, or decoding sensitivity relative to a set acceptable range. For example, in a set of verification calculations, if the QR code reading consistency value is 1, the EPC code matching consistency value is 1, the RF performance normalization value is 0.92, the QR code reading consistency weight is 0.3, the EPC code matching consistency weight is 0.4, and the RF performance normalization weight is 0.3, then the quality score is 0.3 + 0.4 + 0.276, resulting in 0.976. If the acceptable threshold is set to 0.95, the physical tag unit is considered acceptable. The specific threshold can be determined based on actual equipment and actual product test data.

[0075] When the quality scores of multiple consecutive physical tag units fall below the pass threshold or the core code matching status fails, the main control system adjusts the conveyor speed based on the difference between the quality scores and the preset pass threshold. If the quality score is lower than the preset pass threshold, the main control system reduces the conveyor speed; if the continuous abnormalities are not eliminated, the main control system triggers a shutdown alarm or isolates the winding. The input to this cycle feedback algorithm is the quality score and verification status output from the data verification station, and the output is a conveyor speed adjustment, alarm, rejection, or isolation command.

[0076] The algorithm interaction process is as follows: The location index generation algorithm outputs the tag location index; the tag location index serves as the common input for the QR code generation and printing algorithm, the RFID Inlay bonding control algorithm, the die-cutting positioning algorithm, and the EPC writing algorithm; the core code three-element binding algorithm outputs the core code association information; the core code association information serves as the input for the data verification algorithm; the data verification algorithm outputs the quality score and verification status; the quality score and verification status serve as the input for the cycle time feedback algorithm; the cycle time feedback algorithm outputs instructions for belt speed adjustment, alarm, rejection, or isolation. The closed-loop termination condition is that the quality scores of a consecutive preset number of physical tag units all reach the preset qualified score threshold and the core code matching status is qualified, or the main control system enters the shutdown alarm state.

[0077] Example 2: This example further specifies the protection of the color hot stamping outer layer and the quality control of RFID Inlay bonding based on Example 1. In this example, the color hot stamping outer layer is formed by cold stamping printing. The hot stamping adhesive is first applied to the predetermined hot stamping area. The metal foil is bonded to the continuous label roll and then cured under ultraviolet light before the untransferred metal foil is peeled off. A transparent protective film covers the color hot stamping outer layer and the area where the variable QR code data is located, avoiding the window corresponding to the RFID Inlay bonding area.

[0078] In this embodiment, the main control system stores the color hot stamping appearance layer layout data, the variable QR code data area, the RFID Inlay antenna area, and the die-cutting boundary. The metal foil transfer area in the layout data overlaps with the RFID Inlay antenna area; areas that overlap or have insufficient spacing are marked as no-fly zones. These no-fly zones are output to the plate-making file and the lamination avoidance control file to prevent the metal foil transfer area from entering the main radiation area of ​​the RFID Inlay.

[0079] Hot melt adhesive can be used as the bonding adhesive. The metering system determines the amount of adhesive to be supplied based on the RFID inlay width, conveyor speed, and target adhesive layer thickness. The bonding roller system applies pressure as the RFID inlay passes the avoidance window, and the vision positioning system detects the center position of the RFID inlay, the edge of the colored hot foil coating layer, and the variable QR code data area. If the deviation of the RFID inlay center position relative to the tag position index exceeds a preset bonding deviation threshold, the main control system marks the corresponding physical tag unit and increases its detection priority in subsequent coding and verification stations.

[0080] For example, under a set of bonding debugging conditions, the target center position of the RFID Inlay is 180mm, the visual positioning system detects the actual center position as 180.15mm, and the bonding position deviation is 0.15mm. If the preset bonding deviation threshold is 0.3mm, the bonding position is qualified; if the actual center position is 180.4mm, the corresponding physical tag unit is marked as a bonding deviation risk unit, and radio frequency performance verification must be performed after coding.

[0081] Example 3: This example, based on Example 1, illustrates the scenario of anti-counterfeiting labels for high-end product packaging and clothing hang tags. The front of the physical label unit includes a colored hot-stamped outer layer and variable QR code data, while the back or interior of the physical label unit is affixed with an RFID inlay. Consumers can access the anti-counterfeiting query page by scanning the variable QR code data, and warehouses or stores can read EPC codes in batches using UHF RFID readers. The backend system receives QR code query records and EPC reading records and confirms whether the two belong to the same physical label unit through the core code association information.

[0082] For apparel hangtags, the colored hot-stamped finish serves as the brand's visual identification area, the variable QR code data acts as a consumer query entry point, and the RFID inlay serves as a store inventory and anti-theft identification entry point. For high-end wines, cosmetics, or gift box packaging, the colored hot-stamped finish enhances packaging recognizability, the RFID inlay facilitates channel circulation identification, and the variable QR code data enables consumer verification. Since the chip code association information is written and verified during the manufacturing process, subsequent circulation stages do not require rebinding the QR code and EPC code.

[0083] Example 4: This example further illustrates the dynamic deformation compensation of flexible substrate and online coding power control during the continuous roll-to-roll preparation process, based on Example 1. The continuous label roll experiences tension fluctuations during multi-station transfer processes including unwinding, printing, laminating, die-cutting, and rewinding. Small speed differences between the unwinding mechanism, traction roller, and rewinding mechanism, as well as changes in the friction of each guide roller, cause a redistribution of mechanical stress within the continuous label roll. When the continuous label roll is in the elastic deformation stage, its physical dimensions in the belt feeding direction undergo slight expansion and contraction with changes in tension. Physical spans exist between the coding station and the RFID Inlay laminating station, die-cutting station, and online coding station. The accumulated elastic deformation within these physical spans affects the tag position index calculated solely based on encoder coordinates. Fixed station offset compensation can compensate for equipment installation position, but it is difficult to compensate for random positioning errors caused by dynamic deformation.

[0084] The fabrication system incorporates a tension sensor installed beneath the guide roller bearing housing between the source and target stations. This sensor continuously monitors the real-time tension of the continuous label roll material as it travels between the source and target stations. The main control system receives the real-time tension signal via an analog-to-digital converter. The signal sampling rate can be set to 2000Hz. The main control system incorporates a composite filtering algorithm combining a moving average filter and a Kalman filter to filter out high-frequency tension noise signals caused by mechanical vibration. The filtered real-time tension is directly used in the calculation of dynamic tension strain compensation.

[0085] Continuous label rolls have fixed geometric dimensions and material mechanical properties. Before the fabrication task is issued, the main control system receives the cross-sectional area and elastic modulus of the continuous label roll. The reference calibration tension is the initial set tension established by the fabrication system under static tension without belt movement. The main control system calls the dynamic tension strain compensation calculation formula to solve for the minute expansion and contraction caused by tension fluctuations. The dynamic tension strain compensation is: ; in, This is the dynamic tension strain compensation amount, in mm; The real-time belt tension of continuous label roll material between the source station and the target station, in N; The reference tension for continuous label rolls, in N; The cross-sectional area of ​​the continuous label roll is in mm². The elastic modulus of continuous label rolls is expressed in MPa. The physical reference span between the source station and the target station is in mm.

[0086] For example, the continuous label roll uses a 0.05mm thick polyethylene terephthalate film as the substrate. After the colored hot stamping finish is formed, a 0.02mm thick transparent protective film is laminated onto the coated roll. The overall physical thickness of the continuous label roll is 0.07mm. The width of the continuous label roll is set to 150mm. The cross-sectional area of ​​the continuous label roll is equal to the product of the physical thickness and the width, calculated to be 10.5mm². The equivalent elastic modulus of the polyethylene terephthalate film and the transparent protective film composite is 3200MPa. The reference calibration tension is set to 50N. The inkjet printing station serves as the source station, the RFID inlay bonding station as the target station, and the physical reference span between the inkjet printing station and the RFID inlay bonding station is 4500mm.

[0087] When the fabrication system processes physical tag unit 0512, the real-time conveyor tension, after being fed back from the tension sensor and filtered, is 62N. The main control system extracts the above physical parameters and substitutes them into the calculation formula. Subtracting the reference calibration tension of 50N from the real-time conveyor tension of 62N yields a tension difference of 12N. The product of the cross-sectional area of ​​10.5mm² and the elastic modulus of 3200MPa is 33600N. Dividing the tension difference of 12N by 33600N yields a strain rate of 0.000357. Multiplying the strain rate of 0.000357 by the physical reference span of 4500mm, the dynamic tension strain compensation is calculated to be 1.607mm. Due to the increased tension, the continuous tag roll stretches, and when physical tag unit 0512 reaches the RFID Inlay bonding station, its actual physical position deviates by 1.607mm from the theoretical position calculated solely based on the encoder coordinates.

[0088] The main control system adds a 1.607mm offset to the bonding position offset of the RFID Inlay bonding station. The updated target station trigger position is delayed by the corresponding time equivalent. The RFID Inlay feeding mechanism triggers with a delay based on the updated target station trigger position. The RFID Inlay is bonded inside the clearance window of the colored hot-stamped outer layer, and the bonding position deviation is controlled within the design tolerance range of 0.1mm. The feedforward compensation mechanism can reduce the composite position drift caused by tension fluctuations, ensuring that the geometric mapping relationship between the variable QR code data and the RFID Inlay on the same physical tag unit is not affected by belt transport disturbances.

[0089] Elastic deformation not only causes a shift in the absolute coordinates of physical tag units but also alters the actual center-to-center distance between adjacent physical tag units. The design pitch of continuous tag rolls is the theoretical spacing specified in the layout document. Minor stretching and contraction cause the actual center-to-center distance to deviate from the design pitch. The RF antenna at the online coding station has a fixed electromagnetic radiation pattern and a specific effective reading range. When the actual center-to-center distance shortens due to reduced tension, two adjacent physical tag units may simultaneously enter the high-field-strength region of the RF antenna. Physical overflow of the RF signal is one of the causes of chip code mismatch and incorrect coding.

[0090] The main control system uses dynamic tension strain compensation to calculate the actual center distance between two adjacent physical tag units. The actual center distance is calculated by adding the dynamic tension strain compensation of the subsequent physical tag unit at the online coding station to the designed pitch, and subtracting the dynamic tension strain compensation of the preceding physical tag unit at the online coding station. The main control system determines the relationship between the actual center distance and the designed pitch in real time. When the actual center distance is less than the designed pitch, it indicates that the continuous tag roll is in a relaxed or elastic recovery contraction state at the online coding station. The main control system then uses the power attenuation relationship to calculate the adjusted linear value of the transmission power. The adjusted linear value of the transmission power is: ; in, The adjusted linear value of the transmit power is expressed in mW. This is the linear value of the reference transmit power, in mW; This is the antenna radiation pattern adjustment coefficient, which is dimensionless. The design pitch for continuous label rolls, in mm; This represents the actual center-to-center distance between two adjacent physical label units, in mm.

[0091] The minimum linear value of the transmission power required to complete the EPC code writing can be pre-calibrated according to the RFID chip specification and stored in the main control system parameter table, or it can be measured during the production line start-up calibration stage.

[0092] For example, the design pitch of the continuous tag roll is 40mm. The reference transmit power set for the online coding module is 31.62mW, corresponding to 15.0dBm. The antenna radiation pattern adjustment coefficient is obtained by calibrating the sidelobe attenuation characteristics of the RFID read / write antenna, and the antenna radiation pattern adjustment coefficient is set to 2.5. When the fabrication system reaches the junction of physical tag unit 0888 and physical tag unit 0889, due to the local tension decrease in the winding mechanism, the tension sensor feedback shows that the belt tension has dropped to 42N. The main control system calculates that the actual center distance between physical tag unit 0888 and physical tag unit 0889 becomes 39.2mm.

[0093] The main control system immediately executes the dynamic adjustment algorithm for transmit power. Subtracting the actual center distance of 39.2mm from the designed pitch of 40mm yields a difference of 0.8mm. Dividing this difference by the designed pitch of 40mm gives a distance reduction ratio of 0.02. Multiplying this ratio by the antenna radiation pattern adjustment coefficient of 2.5 yields a power attenuation factor of 0.05. Subtracting the power attenuation factor of 0.05 from the reference parameter 1 gives an attenuation factor of 0.95. Multiplying the reference transmit power of 31.62mW by the attenuation factor of 0.95 calculates an adjusted transmit power linearity of 30.04mW, which is approximately 14.78dBm.

[0094] The online coding module transmits an RF signal for writing the EPC code to physical tag unit 0888 according to the converted dBm control value. After the transmission power is reduced from 15.0 dBm to approximately 14.78 dBm, the electromagnetic field strength at the edge of the RF antenna radiation is reduced. The adjacent physical tag unit 0889, which was originally close to the misread danger zone corresponding to the reference transmission power due to the shortened center distance, now has its RF energy below the RFID chip's activation threshold after the transmission power is reduced. Physical tag unit 0889 is in a non-responsive state, and the main control system writes the EPC code to physical tag unit 0888. The chip code association information composed of the variable QR code data, EPC code, and physical tag units remains physically isolated and corresponding at the online coding station, reducing the risk of cross-coding between adjacent physical tag units due to belt deformation.

[0095] For example, the main control system internally runs a dynamic tension strain compensation algorithm and continuously verifies the core code matching status and RF performance verification results during production. The total length of the continuous tag roll preparation is set to 20,000m, covering 500,000 physical tag units. The preparation system's operating speed is set to 40m / min. The preparation process is divided into four test phases of equal length. In the first test phase, the dynamic tension strain compensation input is turned off, and the online coding station's RF antenna transmit power adjustment function is also turned off. In the second test phase, only the dynamic tension strain compensation input is turned on to correct the offsets of the bonding station, die-cutting station, and coding station, keeping the reference transmit power unchanged. In the third test phase, the correction of the station position by the dynamic tension strain compensation is turned off, and the RF antenna transmit power is adjusted only through the encoder coordinates and the local errors calculated by the vision system. In the fourth test phase, the dynamic tension strain compensation input for the position update path and the transmit power dynamic adjustment for the power control path are both turned on simultaneously. The data verification module synchronously collects the quality data of each phase and feeds it back to the main control system. The data summary is shown in Table 1.

[0096] Table 1 is a performance comparison table of dynamic tension strain compensation mechanisms; In the first testing phase, the average deviation of the bonding position reached 1.85mm, and the average deviation of the die-cutting position reached 1.92mm. Physical offset under high tension fluctuations caused the RFID inlay to deviate from the avoidance window area set by the transparent protective film. Some RFID inlays were affected by the die-cutting line, resulting in a write error rate of 0.84% ​​and a core code matching pass rate of 96.15%. In the second testing phase, after introducing dynamic tension strain compensation to correct the coordinates, the average bonding position deviation decreased to 0.08mm, and the physical positioning accuracy returned to within the process specification requirements. The write error rate decreased to 0.32%, and the core code matching pass rate increased to 98.74%. The residual errors in the second testing phase mainly originated from the cross-coding phenomenon of adjacent physical tag units caused by pitch shortening. In the third testing phase, the transmit power adjustment was enabled separately, and the error rate was controlled. However, due to the continued drift in the bonding physical position, antenna damage and impedance mismatch still limited the core code matching pass rate.

[0097] In the fourth testing phase, dynamic tension strain compensation was used for both position correction and power adjustment control. The average fit position deviation was reduced to 0.07mm. The avoidance relationship between the die-cutting blade line and the variable QR code data area and the RFID Inlay antenna area remained stable, with an average die-cutting position deviation of 0.10mm. Dynamic adjustment of transmission power reduced the risk of code crosstalk, further reducing the write error rate to 0.01%. The data verification module read the variable QR code data and compared it with the EPC code, confirming a core code matching qualification rate of 99.98%.

[0098] The main control system uses dynamic tension-strain compensation calculation as the underlying feedforward control algorithm. The visual positioning system collects visual positioning deviations from the edges of the color hot stamping outer layer, positioning marks, or variable QR code data positions as closed-loop feedback control data. The main control system periodically merges the feedforward compensation amount and the feedback deviation amount via a bus. When the continuous label roll is in an accelerated, decelerated, or constant-speed preparation state, the coordinates of the physical label unit when it arrives at each station can be dynamically corrected. The compensation model established based on the material constitutive properties reduces the positioning error caused by relying solely on encoder rigidity counting, enabling the core-code integrated color hot stamping RFID tag preparation method to maintain the reliability of finished product roll output under tension fluctuation conditions.

[0099] Comparative Example 1: Comparative Example 1 uses the same continuous label roll, color hot stamping outer layer, RFID Inlay, die-cutting station, and coding station as Example 1. The difference is that the label position indexing mechanism is eliminated. The QR code printing station generates variable QR code data only based on the inkjet printer's own counting. The online coding station writes EPC codes only according to the triggering order of the RFID reader. The inkjet printing position, bonding position, die-cutting position, and coding object do not share the same label position index.

[0100] In Comparative Example 1, when the continuous label roll experiences minor tension fluctuations or edge correction deviations after slitting, the counting and coding station triggering sequences of the inkjet printer may still be correct, but the corresponding physical label units may be misaligned. For example, in 100 consecutive labels, the 51st label is written with the EPC code of the adjacent label due to a delay in the bonding position compensation. The QR code can still be read visually, and the EPC code can also be obtained by RFID reading, but the backend comparison reveals that the serial number in the QR code is inconsistent with the EPC sequence field. For example, under a set of comparative conditions, Example 1 had 0 labels with inconsistent core codes out of 1000 labels, while Comparative Example 1 had 4 labels with inconsistent core codes out of 1000 labels.

[0101] Comparative Example 2: Comparative Example 2 uses the same label position index and core code three-element binding as Example 1, but the difference is that the verification status feedback cycle adjustment is cancelled. The data verification station still reads the variable QR code data and EPC code, and can also identify unqualified labels, but the main control system does not reduce the conveyor speed, suspend the station, or trigger an alarm according to the abnormality ratio; it only records the unqualified labels.

[0102] In Comparative Example 2, if the RFID Inlay feeding mechanism experiences a short-term slippage leading to increased bonding deviation, the data verification station can continuously detect a decline in radio frequency performance. However, due to the lack of cycle time feedback, subsequent physical tag units continue to pass through the bonding and coding stations at the original speed, causing the anomaly to continue to spread. For example, under a set of comparative conditions, Example 1 adjusted the conveyor speed from 30 m / min to 24 m / min after 5 consecutive physical tag units had quality scores below the threshold, and the speed returned to acceptable after 10 tags. Comparative Example 2 maintained a speed of 30 m / min, and 25 consecutive tags showed radio frequency performance below the threshold.

[0103] Comparative Example 3: Comparative Example 3 uses the same continuous label roll, tension acquisition hardware, RFID Inlay bonding station, die-cutting station and online coding station as Example 4. The difference is that the main control system does not calculate the dynamic tension strain compensation amount, but only updates the target station trigger position according to the encoder coordinates and fixed station offset.

[0104] In Comparative Example 3, when the real-time tension of the continuous label roll increased from 50N to 62N, the continuous label roll underwent elastic stretching between the coding station and the RFID Inlay bonding station. Because the target station trigger position did not incorporate dynamic tension strain compensation, the RFID Inlay feeding mechanism still triggered with its original fixed offset, resulting in a positional deviation of approximately 1.607mm between the RFID Inlay and the avoidance window. If the edge margin of the avoidance window is 2mm, this positional deviation will significantly compress the bonding safety distance. If visual positioning errors or tension fluctuation delays are added, the RFID Inlay may partially enter the edge of the hot stamping protective film or approach the die-cutting line, leading to decreased bonding strength, pressure on the antenna area, or insufficient die-cutting avoidance.

[0105] Comparative Example 4: Comparative Example 4 uses the same dynamic tension strain compensation amount as Example 4 to participate in the station position correction. The difference is that the online coding station always uses the reference transmission power and does not dynamically adjust the radio frequency antenna transmission power according to the actual center distance between two adjacent physical tag units.

[0106] In Comparative Example 4, when the continuous tag roll shrinks due to elastic recovery caused by a local decrease in tension, the actual center distance between physical tag unit 0888 and physical tag unit 0889 is shortened from the designed pitch of 40mm to 39.2mm. The online coding station still transmits RF signals at a reference transmission power of 15.0dBm, making it easier for the adjacent physical tag unit 0889 to enter the high field strength edge region of the RF antenna. Even though the trigger position of physical tag unit 0888 has been corrected by dynamic tension strain compensation, adjacent RFID inlays may still be mistakenly activated and participate in the read / write response, resulting in non-unique EPC code writing objects or mixed objects returned by the RFID reader. Compared to Example 4, Comparative Example 4 lacks the linkage control between the actual center distance and the transmission power, leading to a higher risk of code cross-coding.

[0107] In a specific implementation case, a continuous roll of label material enters the color hot stamping preparation module from the unwinding mechanism. The main control system establishes label position indexes for physical label units 0001 to 0100. The encoder accumulates from 0mm. The inkjet printing station, bonding station, die-cutting station, and coding station each have fixed station offsets. When physical label unit 0025 passes through the inkjet printing station, the main control system generates variable QR code data. The inkjet printing controller prints the QR code at a designated trigger position, and the vision reader reads the QR code content and returns the actual printing coordinates.

[0108] When physical tag unit number 0025 arrives at the lamination station, the transparent protective film covers the colored hot-stamped outer layer and the QR code area, and the avoidance window is aligned with the RFID Inlay bonding area. If the vision system detects that the avoidance window is offset by 0.1mm relative to the tag position index, the main control system writes the offset into the target station's comprehensive position compensation amount, and the subsequent bonding trigger position is corrected accordingly.

[0109] When physical tag unit No. 0025 enters the RFID Inlay bonding station, the main control system controls the application of adhesive and the feeding of the RFID Inlay according to the tag position index. After bonding, the vision positioning system reads the center position of the RFID Inlay. If the center position deviation is within the preset bonding deviation threshold, the physical tag unit enters the die-cutting station. The die-cutting station cuts out the finished product outline according to the tag position index, avoiding the RFID Inlay antenna area and the QR code reading area.

[0110] When physical tag unit number 0025 enters the online coding station, the main control system retrieves the corresponding variable QR code data from the associated database and generates the corresponding EPC code. The RFID reader writes the EPC code into the RFID Inlay and then reads the contents of the EPC storage area again. If the read EPC code matches the target EPC code, the coding status is recorded as qualified.

[0111] The data verification station then reads the QR code and EPC code and calculates the quality score. If the QR code reading consistency value is 1, the EPC code matching consistency value is 1, and the RF performance normalization value is 0.92, with weights of 0.3, 0.4, and 0.3 respectively, the quality score is 0.976. If the preset pass score threshold is 0.95, physical tag unit 0025 enters the pass rewinding path.

[0112] If the normalized RF performance value of physical tag units 0026 to 0030 continuously decreases due to bonding deviation, the main control system outputs a cycle time adjustment command based on the quality score. After the conveyor belt speed is reduced, the RFID Inlay bonding station obtains a more stable feeding and rolling time, and the quality score of subsequent physical tag units recovers to above the preset qualified score threshold. The closed loop terminates after the number of consecutive qualified units reaches the preset number.

[0113] In practical implementation, those skilled in the art can adjust the specific substrate, adhesive, hot stamping method, coding equipment, RFID reader / writer protocol, visual inspection device, tension sensor, power control interface, and anomaly handling mechanism without departing from the core data flow and process closed loop of this invention. Any technical solution that associates variable QR code data, EPC code, and physical tag unit core code based on tag position indexing, and feeds back dynamic tension strain compensation or verification status to the continuous manufacturing process, falls within the scope of this invention's technical concept.

Claims

1. A method for preparing integrated color hot stamping RFID tags, characterized in that, Includes the following steps: Forming a continuous label roll with a colored hot stamping finish; A label position index is generated based on the conveyor position of the continuous label roll, and variable QR code data is generated and printed according to the label position index; Apply adhesive to the RFID Inlay bonding area that avoids the colored hot foil exterior layer, and bond the RFID Inlay according to the label position index; Complete die-cutting and EPC code writing according to the label position index, so that the variable QR code data, EPC code and physical label unit form core code association information; Read the variable QR code data and EPC code, and output qualified winding instructions, abnormal handling instructions or cycle adjustment instructions to the main control system in combination with the radio frequency performance verification results; The EPC code is generated by mapping the unique serial number of the tag in the variable QR code data. The online coding station reads the variable QR code data to be written to the physical tag unit according to the tag position index, and reads the EPC code after writing to perform consistency verification.

2. The method for preparing a color hot stamping RFID tag based on integrated chip code as described in claim 1, characterized in that, The label position index is formed by the encoder coordinates of the continuous label roll, the offset of the inkjet printing station, the offset of the bonding station, the offset of the die-cutting station, the offset of the coding station, and the visual positioning deviation. The target station trigger position is updated synchronously when the label position index is transferred between adjacent stations.

3. The method for preparing a color hot stamping RFID tag based on integrated chip code as described in claim 1, characterized in that, The variable QR code data includes the label's unique serial number, production batch information, inkjet printing station location information, and verification fields. When printing the variable QR code data, the main control system simultaneously establishes a correspondence between the variable QR code data and the label location index.

4. The method for preparing a color hot stamping RFID tag based on integrated chip code as described in claim 1, characterized in that, The colored hot stamping finish is formed by cold stamping and UV curing. A transparent protective film covers the colored hot stamping finish and the area where the variable QR code data is located, and forms an avoidance window in the RFID Inlay bonding area.

5. The method for preparing a color hot stamping RFID tag based on integrated chip code as described in claim 1, characterized in that, The RFID Inlay bonding area forms a bonding adhesive layer through a quantitative adhesive supply mechanism. The visual positioning system collects the edge of the colored hot stamping outer layer, the positioning mark or the variable QR code data position, and feeds back the bonding position deviation to the main control system to correct the label position index.

6. The method for preparing a color hot stamping RFID tag based on integrated chip code as described in claim 1, characterized in that, During die-cutting, the avoidance relationship between the die-cutting line and the RFID Inlay, antenna area and variable QR code data area is determined according to the label position index, and the position of the physical label unit after die-cutting is transferred to the online coding station.

7. The method for preparing a color hot stamping RFID tag based on integrated chip code as described in claim 1, characterized in that, The core code association information includes the tag location index, variable QR code data, EPC code, writing timestamp, bonding position deviation, die-cutting position deviation, and verification status. The core code association information is stored in the association database of the main control system.

8. The method for preparing a color hot stamping RFID tag based on integrated chip code as described in claim 1, characterized in that, The RF performance verification result is formed by the reading distance, reading success rate and decoding sensitivity. The main control system combines the chip code matching status with the RF performance verification result to determine the tag status.

9. The method for preparing a color hot stamping RFID tag based on integrated chip code as described in claim 2, characterized in that, During the synchronous update of the target station trigger position when the label position index is transferred between adjacent stations, the offset of the bonding station, the die-cutting station, and the coding station includes dynamic tension strain compensation. The dynamic tension strain compensation is calculated based on the real-time belt tension of the continuous label roll between the source and target stations, the elastic modulus of the continuous label roll, and the cross-sectional area of ​​the continuous label roll. The dynamic tension strain compensation is: ； in, This is the dynamic tension strain compensation amount, in mm; The real-time belt tension of continuous label roll material between the source station and the target station, in N; The reference tension for continuous label rolls, in N; The cross-sectional area of ​​the continuous label roll is in mm². The elastic modulus of continuous label rolls is expressed in MPa. The physical reference span between the source station and the target station is in mm. The main control system superimposes the dynamic tension strain compensation amount into the offset of the bonding station, the offset of the die-cutting station, and the offset of the coding station to correct the trigger position of the target station.

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