Dual-Chassis Barcode Scanner Layout for Long-Range Imaging
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Solution Overview
Problem
Industrial scanners face challenges in providing effective illumination and aiming over a wide range of fields of view due to constraints in chassis size, leading to reduced scanning efficiency and potential mechanical damage.
Innovation Solution
A compact high-performance autofocus barcode scanner design featuring a dual-chassis system with near and far imaging systems, illumination, and aiming systems positioned adjacent to the chassis, utilizing a rigid-flexible printed circuit board to reduce size and enhance alignment accuracy, allowing for larger optics and improved illumination across multiple fields of view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If larger optics are used to meet performance requirements for long-range scanning, then scanning capability is improved, but the overall dimensions of the housing and chassis increase
Solution Approach 1:
The patent divides the scanner into separate first and second chassis, each housing different optical systems. The first chassis contains the near imaging system and first illumination system, while the second chassis contains the far imaging system and second illumination system. This segmentation allows each chassis to be optimized independently, enabling long-range scanning capability without requiring a single large housing to accommodate all components.
2Productivity
If larger optics are used to improve long-range scanning, then optical performance is improved, but mechanical securing forces increase and may damage the chassis
Solution Approach 1:
By separating the optical systems into two distinct chassis, the mechanical loads and securing forces are distributed across separate structural assemblies. Each chassis supports only its designated optical system, preventing the accumulation of excessive mechanical forces that would occur if all large optics were mounted in a single chassis.
3Area of stationary object
If compact imaging systems are used to reduce size, then housing dimensions are reduced, but alignment precision of optics becomes more difficult to maintain
Solution Approach 1:
The patent creates separate optical modules in distinct chassis, allowing each module to be aligned and calibrated independently before final assembly. This modular approach maintains alignment precision by preventing the cumulative alignment errors that would occur in a fully integrated compact design, while still achieving reduced overall dimensions through efficient spatial arrangement.
Solution Approach 2:
The patent introduces separate chassis as intermediary structures between the optical systems and the final assembled unit. These chassis serve as stable mounting platforms with built-in alignment features, facilitating precise optical alignment during manufacturing and assembly while maintaining compact final dimensions.
4Device complexity
If a single chassis is used to house all systems, then device complexity is reduced, but illumination and aiming effectiveness decreases across wide field of view
Solution Approach 1:
The patent divides the illumination systems into separate first and second illumination systems, each dedicated to specific imaging ranges. The first illumination system serves the near imaging system, while the second illumination system serves the far imaging system. This segmentation allows each illumination system to be optimized for its specific range, maintaining high illumination effectiveness across the entire wide field of view.
Solution Approach 2:
Each chassis is designed to house multiple functional systems simultaneously - the first chassis contains both the near imaging system and first illumination system, while the second chassis contains the far imaging system and second illumination system. This multi-functionality approach maintains device complexity at acceptable levels while achieving superior illumination effectiveness through dedicated illumination paths.
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 design achieves broad autofocus distances with reduced dimensional requirements, improved illumination, and accurate aiming patterns, enhancing scanning efficiency and reducing mechanical stress on the scanner.
Implementation Method 1
near imaging optics to capture at least one image of an object appearing in a field of view (FOV) onto an imaging plane
Implementation Method 2
near imaging optics to capture at least one image of an object appearing in a field of view (FOV) onto an imaging plane along a near imaging axis
Implementation Method 3
far imaging optics to capture at least one image of an object appearing in a FOV onto an imaging plane along a far imaging axis
Implementation Method 4
far imaging optics to capture at least one image of an object appearing in a FOV onto an imaging plane along a far imaging axis
Implementation Method 5
illumination system including illumination optics to provide illumination to the FOV of each of the near imaging optics and the far imaging optics
Implementation Method 6
aiming system including an aiming path cavity in the first chassis and an aiming light source disposed in a cavity of the second chassis with the aiming system configured to provide an aiming pattern along an aiming axis
Data Source
AI summary
A scan engine for capturing at least one image of an object appearing in an imaging field of view (FOV) is provided that includes an imaging system, illumination system, aiming system, and a first and second chassis. The imaging system includes a lens holder and at least one lens disposed within the lens holder and both a far imaging system and a near imaging system for capturing images across multiple fields of view at different distances. The illumination system and aiming system are physically positioned to provide illumination of a target in the near and/or far fields of view, and provide an aiming pattern to the near and/or far fields of view.