RFID Tag Embedding in Race Bibs via Thermal Welding
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Solution Overview
Problem
The existing methods for manufacturing race bibs with programmable RFID tags are labor-intensive and prone to errors, requiring manual programming and matching of tags with competitor numbers, which can lead to tracking system failures if incorrectly applied.
Innovation Solution
A race bib design that integrates a programmable RFID tag between two layers, where the competitor number is printed on one layer and encoded into the tag using a combined printer and RFID reader, allowing for simultaneous printing and encoding, and the layers are thermally welded or adhesively secured together, ensuring the tag is embedded and protected within the bib.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual programming and matching of RFID tags with competitor numbers is used, then flexibility in assigning tags is maintained, but labor intensity and error rate increase significantly
Solution Approach 1:
The patent combines the RFID tag programming function and the competitor number printing function into a single integrated system. The RFID reader and digital printer are controlled by a common controller that automatically matches tags with competitor numbers, eliminating the need for separate manual programming and matching operations. This merging of functions directly reduces labor intensity while maintaining automation.
Solution Approach 2:
The system enables self-service automation where the integrated RFID reader and digital printer automatically perform tag programming and competitor number assignment without human intervention. The controller autonomously matches tags with competitor numbers by reading competitor numbers from the bib and programming the corresponding RFID tags, making the system self-sufficient and eliminating manual labor.
2Productivity
If manual matching of RFID tags with competitor numbers is performed, then flexibility in error correction is maintained, but time consumption and productivity decrease
Solution Approach 1:
The integrated system enables continuous operation where the RFID tag programming and competitor number printing occur simultaneously in a single pass through the assembly line. The controller continuously reads competitor numbers from the bib and programs the corresponding RFID tags without interruption, maintaining continuous productive action and eliminating time losses associated with manual matching operations.
Solution Approach 2:
The system performs preliminary programming of RFID tags with competitor numbers during the bib assembly process itself, before the bibs are distributed to competitors. By integrating the programming function into the assembly line, the system prepares the RFID tags in advance with the correct competitor information, eliminating subsequent time-consuming manual matching and programming operations.
3Manufacturing precision
If RFID tags are manually attached to bibs, then placement flexibility is maintained, but manufacturing precision and error rate worsen
Solution Approach 1:
The patent merges the RFID tag attachment process with the competitor number printing and tag programming processes into a single integrated operation. The RFID tags are automatically positioned and attached to the bib in the correct location while the competitor number is being printed and the tag is being programmed, ensuring precise placement without adding separate complex attachment steps.
Solution Approach 2:
The system replaces manual mechanical attachment operations with an automated mechanism controlled by the integrated controller. The RFID tags are automatically positioned and attached to the bib using a mechanical attachment mechanism that ensures precise and consistent placement, eliminating the variability and errors associated with manual attachment while maintaining simplicity through integration.
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
This method significantly reduces the labor required for programming and matching RFID tags with competitor numbers, preventing errors and ensuring accurate tracking during races by embedding the tag within the bib, thus enhancing efficiency and accuracy.
Implementation Method 1
the RFID tag will be activated and the time the competitor passed each antenna will be recorded stored in a computer system
Implementation Method 2
the layers are thermally welded or adhesively secured together, ensuring the tag is embedded and protected within the bib
Implementation Method 3
The RFID tag assembly is detachably engageable with the mounting film via an adhesive layer
Data Source
AI summary
A race bib and a method of assembling the same. The bib includes a first and second layers with a programmable tag embedded between them. Indicia are provided on a first surface or a second surface of the first layer. A backer is positionable between the tag and the first or second layers. During assembly, a competitor number is printed on the first layer with an ink printer, a tag number correlating to or corresponding to the competitor number is encoded into the tag with a RFID tag printer. The printing and encoding can be accomplished by a combined printer. Alternatively, an optical scanner reads the printed competitor number and transmits the same to the tag printer. The second layer overlays the first layer and is thermally welded or adhesively secured to the first layer.