Feeder Control System Using Line-Scan Camera for Integrity Verification
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Solution Overview
Problem
Existing document handling systems face challenges in accurately and efficiently verifying the integrity of mailings, including limited information from Optical Mark Recognition (OMR) and bar-coding methods, difficulty in reading three-dimensional characters, high costs due to the need for new readers with new symbology, and inefficiencies with multiple area-scanning cameras and lighting issues, which hinder real-time decoding and increase operational complexity.
Innovation Solution
A feeder control system utilizing a line-scan camera with OCR techniques for rapid scanning and decoding, leveraging Regions of Interest (ROI) and data indexing to provide integrity verification, system control, and reporting, while being interoperable with multiple machine manufacturers and legacy equipment, allowing for simultaneous scanning and decoding, and utilizing a single line-scan camera to read multiple symbologies and improve lighting conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If OMR marks are used for integrity verification, then basic information can be read by a light probe, but the work piece is disfigured with permanent markings
Solution Approach 1:
The patent uses a camera to capture an optical image (copy) of the work piece containing the OMR mark, rather than directly reading the mark with a probe. This copying approach allows the mark to remain on the work piece without causing disfigurement, as the information is transferred to a digital image for processing
Solution Approach 2:
The patent replaces the mechanical light probe reading system with an optical imaging system using a camera. This substitution eliminates the need for direct contact or close proximity reading, allowing the work piece to pass through without being disfigured while still enabling integrity verification through image processing
2Loss of information
If bar-coding method is used for integrity verification, then more detailed information can be obtained, but the work piece is disfigured and recipient feels like just a number
Solution Approach 1:
The camera captures an optical copy of the work piece that includes any existing bar codes or other markings. This allows the system to read detailed information from these marks without requiring new disfiguring marks to be placed on the work piece
Solution Approach 2:
The imaging system is designed to be universal, capable of reading multiple types of symbologies (OMR, bar codes, text, etc.) from a single optical image. This eliminates the need for specialized readers for each mark type, reducing the need for additional work piece disfigurement with multiple mark types
3Object-affected harmful factors
If area-scanning cameras are used to scan document areas, then existing information can be utilized for verification, but the scanning speed is slow and requires waiting for entire area to be scanned
Solution Approach 1:
The patent divides the scanned image into multiple regions of interest (ROIs) that can be processed simultaneously. By segmenting the image processing task, the system can extract and verify critical information from different areas of the document in parallel, significantly improving scanning speed while maintaining accuracy
Solution Approach 2:
The system performs preliminary processing of the optical image by identifying and extracting regions of interest before full verification. This preliminary action allows the system to quickly locate and read critical information such as OMR marks, bar codes, or text in specific areas without waiting to process the entire image, thereby improving throughput
4Measurement precision
If multiple area-scanning cameras are used for each targeted area, then information can be captured, but the system complexity and cost increase significantly
Solution Approach 1:
The patent employs a single multi-functional imaging system that can capture and process multiple types of information (OMR marks, bar codes, text, images) from a single optical image. This universal approach eliminates the need for multiple specialized cameras, reducing system complexity while maintaining the ability to verify information from all targeted areas
Solution Approach 2:
The patent combines multiple information capture functions into a single camera system. By merging the capabilities of what would otherwise require separate cameras (OMR reading, bar code scanning, text recognition, image capture) into one unified imaging device, the system reduces complexity and cost while maintaining comprehensive verification capabilities
5Measurement precision
If ring light is used to illuminate embossed characters, then contrast is improved, but precise positioning is required and shadowing problems occur
Solution Approach 1:
The patent changes the lighting parameters by using diffuse illumination instead of direct ring light. This parameter change in the lighting approach eliminates the need for precise positioning and shadow avoidance, allowing embossed characters to be captured clearly without the operational difficulties of traditional ring light positioning
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 system enables high-speed, accurate integrity verification and reporting, reducing the need for multiple cameras and new readers, improving accuracy, and allowing for real-time feedback, thus enhancing operational efficiency and reducing costs by ensuring only necessary equipment is used and minimizing reprints.
Implementation Method 1
a line-scan camera with OCR techniques for rapid scanning and decoding
Implementation Method 2
line-scan camera with OCR techniques for rapid scanning and decoding
Data Source
AI summary
A feeder control system and method are disclosed. The system includes a feeder information detector, and a feeder information leverager to provide integrity verification, system control and/or reporting. The method includes the steps of detecting feeder information, and leveraging the feeder information to provide integrity verification, system control and/or reporting.