Online Data Validator for Printing Unit Barcode Verification
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Solution Overview
Problem
Existing barcode verification technologies integrated into printing units face limitations such as requiring third-party scanners, contact-based CCD scanners that accumulate debris, and the need for external computers for data processing, leading to performance issues and increased costs.
Innovation Solution
A compact, two-dimensional online data validator integrated within the printing unit, featuring a digital imaging system with a camera module, mirror module, and light source module, which captures and grades barcodes in real-time without contact, allowing for self-correction of barcode print quality and reducing system footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If third party barcode scanners are mounted to the front of the printing unit, then barcode reading capability is achieved, but system footprint increases and performance is limited
Solution Approach 1:
The patent combines the barcode verification system with the printing unit by integrating the camera module, light source module, and processor directly into the printing unit's housing. This merging eliminates the need for separate third-party scanners, reducing system footprint while maintaining barcode reading and verification capabilities.
Solution Approach 2:
The integrated system performs multiple functions: it acts as both a printing unit and a barcode verifier. The camera module captures images, the light source module illuminates the barcode, and the processor verifies the barcode, all within the same device that performs printing operations, achieving multi-functionality in a single unit.
2Ease of operation
If contact-based CCD scanners are used, then barcode scanning is enabled, but dirt and debris accumulate on the scanner affecting measurement accuracy
Solution Approach 1:
The patent introduces an optical intermediary system using a camera module and light source module that captures and illuminates the barcode from a distance, eliminating the need for direct contact between the scanner and the printed media. This intermediary optical path prevents dirt and debris accumulation on the scanning surface while maintaining scanning capability.
Solution Approach 2:
The patent replaces the mechanical contact-based CCD scanner with an optical imaging system using a camera module. This substitution eliminates mechanical contact with the printed media, preventing dirt and debris accumulation while maintaining barcode scanning and verification capabilities.
3Extent of automation
If external laptop or desktop computer is used for data processing, then data processing capability is achieved, but system cost and footprint increase
Solution Approach 1:
The patent merges the data processing functions into the printing unit by integrating a processor that receives images from the camera module, verifies barcodes, and communicates results. This eliminates the need for external computers, reducing system footprint and complexity while maintaining full data processing capability.
Solution Approach 2:
The printing unit performs its own data processing functions through the integrated processor, which verifies barcodes and communicates verification results without requiring external computer assistance. This self-service capability reduces system complexity and eliminates the need for additional external devices.
4Adaptability or versatility
If add-on approach is used for barcode verification, then verification capability is added, but setup procedures become lengthy and location restrictions are imposed
Solution Approach 1:
The patent merges the barcode verification system with the printing unit's native components, allowing the verification to occur at the printing location without requiring separate add-on equipment. This integration eliminates location restrictions and reduces setup time by using the printing unit's own camera, light source, and processor.
Solution Approach 2:
The system performs preliminary barcode verification during the printing process itself, rather than requiring separate post-printing setup and verification steps. The camera module captures images during printing, and the processor verifies barcodes in real-time, eliminating lengthy setup procedures and location restrictions.
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
Enables efficient barcode verification and correction during printing, eliminating debris accumulation, reducing setup time, and integrating barcode detection and processing within the printing unit, thus improving barcode quality and reducing costs.
Implementation Method 1
a light source module providing uniform and flattened illumination on the media
Implementation Method 2
a mirror module reflecting the images to the optical lens
Data Source
AI summary
An online data validator is a digital imaging system integrated onto the front side of a printing unit wherein an exit of the printing unit is set on the same side close to the online data validator for a media exiting therefrom. The online data validator comprises a controller facilitating communication with a printing unit controller and controlling overall operation of the online data validator functions; a camera module including a sensor PCB and an optical lens, wherein the sensor PCB contains a camera sensor for capturing 2D digital images of moving labels; and a light source module including a lightbar, a lightbar PCB, a Fresnel lens and a window for providing uniform and flattened illumination on the media.