Label Defect Highlighting Using Scan Grading and Light Projection
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Solution Overview
Problem
Conventional label printers often produce machine-readable symbology and RFID labels that do not meet verification standards, leading to undetected defects in busy warehouse environments where large quantities are printed quickly.
Innovation Solution
A system comprising a reader, processor, and light projector that scans labels, determines a grade value or encoded information, compares it to predefined thresholds, and highlights defective labels with customizable light patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If label printers operate at high speed to meet production demands, then productivity increases, but manufacturing precision deteriorates leading to defective labels
Solution Approach 1:
The system performs preliminary verification by scanning and grading labels immediately after printing using a reader device. The processor evaluates multiple quality parameters (bar width, space width, reflectance, contrast, defects) before the labels leave the printing station, enabling real-time detection and prevention of defective labels from being used.
Solution Approach 2:
The system implements feedback control by continuously monitoring label quality through scanning and comparison against verification standards. The processor provides real-time feedback on grade values and defect detection, allowing for immediate identification of printing issues and adjustment of printing parameters to maintain quality at high speeds.
2Ease of operation
If conventional label printers operate without verification, then ease of operation is maintained, but reliability deteriorates due to undetected defects
Solution Approach 1:
The label printing system performs self-verification through integrated reader devices that automatically scan and evaluate printed labels against verification standards. The processor autonomously determines grade values and identifies defects without requiring manual inspection, enabling the system to self-monitor and self-correct while maintaining operational simplicity.
3Manufacturing precision
If comprehensive quality verification is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The reader device serves multiple functions: it scans barcodes, measures reflectance, evaluates contrast, detects defects, and determines grade values. The processor integrates multiple verification functions into a single evaluation system that compares all parameters against verification standards, reducing the need for separate specialized devices while maintaining comprehensive quality control.
Data Source
AI summary
A system is disclosed. The system comprises at least one reader configured to scan one or more labels and at least one processor communicatively coupled to the at least one reader. Further, the at least one processor is configured to determine a grade value or encoded information associated with each of the one or more labels based at least on the scanning, compare the determined grade value or the encoded information with a predefined threshold value associated with each of the one or more labels, and determine at least one defective label from the one or more labels, based at least on the comparison, and a light projector communicatively coupled to the at least one processor. Thereafter, the light projector is configured to project one or more light patterns over the at least one defective label to highlight the at least one defective label to a user.