Barcode Scanner With Multi-Camera Array for Packaging Film
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Solution Overview
Problem
Existing barcode scanners in the packaging industry have limited fields of view and require operator intervention, making them prone to bypassing and errors, especially when scanning packaging film with varying barcode locations and sizes.
Innovation Solution
A fixed scanner housing with multiple cameras arranged in a linear array, capable of capturing high-speed images and coordinated to read barcodes across the entire width of the film path, ensuring all barcodes are scanned regardless of their position, and integrated with a film storage device to prevent bypassing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single barcode scanner with limited field of view is used, then the device complexity is low, but the scanning reliability deteriorates because barcodes are not always in the same place on the film
Solution Approach 1:
The patent divides the scanning system into multiple cameras arranged in an array, where each camera covers a specific segment of the film width. This segmentation allows the system to maintain high scanning reliability across the entire film width while keeping each individual camera unit relatively simple, thus resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The patent transitions from a single-point scanning approach to a multi-point parallel scanning approach by arranging cameras across the width of the film. This dimensional expansion from one camera to multiple cameras allows simultaneous coverage of the entire film width, improving reliability without requiring complex mechanical movement or positioning systems.
2Area of stationary object
If a movable scanner is used to track barcodes on film, then the field of view is improved, but the ease of operation deteriorates due to required operator function
Solution Approach 1:
The patent implements an automatic scanning system where multiple cameras simultaneously capture barcodes across the film width without requiring operator intervention. The system self-adjusts and self-optimizes by coordinating camera readings, eliminating the need for operators to manually track or position a scanner, thus improving ease of operation while maintaining a wide effective field of view.
3Ease of operation
If handheld scanners are used for barcode reading, then the ease of operation is improved, but the reliability deteriorates because the system can be easily bypassed
Solution Approach 1:
The patent uses multiple cameras positioned across the film width, each monitoring a specific zone. This segmentation creates multiple independent detection points that must all be satisfied for proper operation, making it difficult to bypass the system with simple workarounds like taped barcodes, while the automated system remains easy to operate through coordination of the camera array.
Solution Approach 2:
The patent introduces a coordination system that acts as an intermediary between multiple cameras and the control system. This intermediary coordinates readings from all cameras and verifies proper scanning, creating a robust verification layer that prevents bypassing while maintaining automated ease of operation, thus resolving the contradiction between ease of operation and system security.
4Device complexity
If off-the-shelf scanners with limited field of view are mounted to packaging machines, then the device complexity is low, but the productivity deteriorates due to operator function requirements
Solution Approach 1:
The patent expands from a single-camera vertical scanning approach to a multi-camera horizontal array that covers the entire film width simultaneously. This dimensional change enables parallel scanning of multiple potential barcode locations, dramatically improving productivity by eliminating the need for operator intervention to reposition scanners, while the modular camera array keeps individual unit complexity manageable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides reliable and automatic barcode scanning, reducing operator errors and ensuring correct product identification and packaging, even with varying film widths and barcode positions, thereby enhancing packaging accuracy and security.
Implementation Method 1
each camera having a charged coupling device to provide a signal indicative of a barcode exposed to one or more of the cameras
Data Source
AI summary
An assembly to deliver packaging film, having a barcode, to a packaging machine (10). Associated with the packaging machine (10) is a splicing machine (17) that joins film from rolls (14, 15) for delivery to the machine (10). A barcode scanner (19) extends transversely of the film, with the scanner (19) including a plurality of cameras (29). Once a barcode is detected, as an example ten images will be decoded and if six “readings” give the same result, then it can be assumed that the barcode has been correctly decoded.