Bi-optical Workstation Full Coverage Scan Zone
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Solution Overview
Problem
Existing dual-window workstations with imager-based readers face challenges in providing full coverage scan zones due to subfields being twisted or skewed, leading to dead areas and reduced reading performance, and require multiple imagers, which increases cost and complexity.
Innovation Solution
The use of a bi-optical workstation with two solid-state imagers and an optical system that splits the field of view into six subfields using fold mirrors to prevent skewing, allowing two imagers to cover all sides of a product with redundant coverage, and positioning optical splitters remotely to reduce manufacturing complexity and improve sensor utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple imagers are used to provide full coverage scan zone, then reading coverage and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The field of view of each imager is segmented into multiple subfields using optical splitters and fold mirrors. Each subfield is directed to cover a specific region of the scan zone. By dividing the viewing coverage into subfields and using fold mirrors to direct each subfield, the patent achieves comprehensive scan zone coverage with fewer imagers, resolving the contradiction between reading coverage and device complexity
Solution Approach 2:
Each imager is designed to perform multiple functions by capturing images from multiple angles through its divided subfields. The same imager unit covers multiple regions of the scan zone that would traditionally require separate imagers, making each imager multi-functional and reducing the total number of imaging components needed
2Area of stationary object
If subfields are twisted or skewed to increase coverage, then scan zone coverage is improved, but reading precision and resolution deteriorate due to dead areas and peripheral clipping
Solution Approach 1:
The patent employs asymmetric optical path design where fold mirrors are positioned at specific angles to direct subfields without twisting or skewing them. This asymmetric arrangement allows each subfield to maintain its geometric integrity and resolution while still achieving comprehensive coverage of the scan zone, eliminating dead areas and peripheral clipping that occur with symmetric twisted subfield arrangements
3Ease of manufacture
If optical splitters are positioned close to imagers to reduce complexity, then manufacturing complexity is reduced, but manufacturing precision requirements increase due to critical alignment tolerances
Solution Approach 1:
The patent positions optical splitters remotely from the imagers along the optical axis, utilizing the third dimension (depth) to resolve the manufacturing contradiction. This remote positioning creates sufficient optical path length that allows for relaxed alignment tolerances while still achieving the desired subfield division and coverage, thereby reducing both manufacturing complexity and precision requirements simultaneously
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
This configuration ensures full coverage of the scan zone with minimal dead areas, maintaining high resolution and efficiency while reducing the number of imagers needed, thus lowering costs and improving reading performance.
Implementation Method 1
an optical system having a plurality of fold mirrors positioned in the optical path to fold the captured return light in at least one of the subfields of view about a respective minor axis substantially parallel to one of the array axes projected onto that minor to resist skewing of the one subfield of view relative to the one window
Data Source
AI summary
A bi-optical, dual window, point-of-transaction workstation images indicia associated with multi-sided products over a full coverage scan zone by splitting each field of view of only two imagers into three subfields that pass through each window and fill the scan zone and minimize dead areas therein. Twisting of the subfields relative to the windows is minimized so that the subfields fit fully with minimal clipping through each window. Splitting of each field of view is remotely performed well away from each imager. The imagers have lens assemblies of substantially the same optical power and are spaced from their respective windows by substantially the same distance.