Pre-encoded RFID Tags for High-Speed Packaging Lines
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Solution Overview
Problem
The application of radio frequency identification (RFID) tags to corrugated boxes is inefficient, causing disruptions and waste in high-speed production lines due to difficulties in encoding, inspecting, and managing the tags, leading to high rejection rates and additional costs.
Innovation Solution
A business-to-business portal coordinates the ordering, encoding, and application of RFID tags independently of packaging production, allowing for pre-encoded and tested tags to be applied in a separate offline operation, reducing downtime and waste, and optimizing the supply chain through real-time status and scheduling data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If RFID tags are encoded and applied to corrugated boxes at the time the boxes are filled, then the goods can be tracked and inventoried, but the product filling lines experience interruptions and slowdowns
Solution Approach 1:
The patent applies preliminary action by pre-encoding RFID tags with electronic product codes before applying them to corrugated boxes. Tags are prepared in advance with valid EPCs, so that when they are applied to boxes during high-speed filling operations, no encoding time is needed on the production line. This separates the encoding operation from the filling operation, maintaining both tracking capability and production speed.
2Productivity
If RFID tags are applied to boxes during high-speed manufacture, then production speed is maintained, but there is insufficient time for inspecting tag functionality leading to high rejection rates
Solution Approach 1:
The system performs preliminary encoding and validation of RFID tags before they are applied to boxes. Tags are pre-encoded with electronic product codes and validated in advance, ensuring functionality is confirmed before application. This eliminates the need for time-consuming inspection during high-speed box manufacture while maintaining tag reliability.
Solution Approach 2:
The tag encoding and validation system operates autonomously to prepare tags before application. The system self-manages the encoding process, validation, and sequencing of tags without requiring manual inspection or intervention during the high-speed box manufacturing process, allowing the production line to maintain full speed while ensuring tag functionality.
3Ease of manufacture
If RFID tags are encoded after being applied to boxes, then the encoding can be done separately, but the radio frequency field positioning becomes more difficult and yields decrease
Solution Approach 1:
The patent applies preliminary action by encoding RFID tags before they are applied to boxes rather than after application. This pre-encoding approach allows for controlled, precise RF field positioning in a stationary setup, achieving higher encoding yields. The pre-encoded tags are then simply applied to boxes during high-speed production without requiring additional encoding operations.
4Reliability
If encoding and inspection requirements are imposed on box manufacture, then tag quality is ensured, but production time increases and waste is generated
Solution Approach 1:
The system performs all encoding and inspection operations on RFID tags in advance, before the tags are applied to boxes. This preliminary preparation ensures tag quality through proper encoding and validation, while the actual box production process is not delayed since tags are already ready for application. Defective tags are identified and removed before application, preventing waste of box production time and materials.
Data Source
AI summary
A system is provided in which electronic tags are pre-encoded and mounted on a continuous web for subsequent application to packaging at a packaging supplier plant. A B2B portal provides the information needed to coordinate the pre-encoding of the electronic tags with the packaging manufacture according to a goods packager's requirements.