Multi-Stream RFID Tag Applicator With Verification
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Solution Overview
Problem
Existing RFID applicators are costly and inflexible, often mismanaging identifiers by assigning the same unique number to multiple tags or missing coding altogether, and lack adaptability to multiple product lines, necessitating an economically viable and adaptable solution.
Innovation Solution
A modular RFID tag applicator system that includes a spool system for guiding RFID tags, an RFID programmer for programming, an RFID reader for verification, and an applicator member for proper tag placement or rejection, along with a camera for substrate detection and a controller for managing the process, allowing for efficient programming and placement of RFID tags on cardboard blanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing RFID applicators are used, then RFID tags can be applied to products, but the system is costly and inflexible, unable to adapt to multiple product lines
Solution Approach 1:
The RFID applicator system is designed with universal components that can handle multiple product lines. The applicator head, spool system, and control mechanisms are configured to accommodate different tag types, substrate materials, and product configurations without requiring complete system redesign, thereby achieving multi-functionality while controlling complexity
Solution Approach 2:
The system incorporates adjustable and reconfigurable elements such as variable spool speeds, programmable applicator positions, and flexible tape routing that allow dynamic adaptation to different product lines. These dynamic features enable the system to be reconfigured for various applications without permanent modifications
2Reliability
If existing RFID applicators are used, then tagging can be performed, but identifier mismanagement occurs with duplicate EPC assignments or missing coding
Solution Approach 1:
The system incorporates an RFID reader that provides real-time feedback on tag programming status and EPC uniqueness. The reader verifies each programmed tag's response and communicates with the controller to detect duplicate EPC values or programming failures, enabling immediate correction before tags are applied to products
Solution Approach 2:
The RFID programmer is positioned to program tags before they reach the applicator point, and the reader verifies programming immediately afterward. This preliminary programming and verification sequence ensures that all tags are properly coded with unique EPC values before being applied to substrates, preventing identifier mismanagement
3Ease of manufacture
If traditional RFID applicator systems are used, then tagging can be performed, but the system is economically unviable due to high costs
Solution Approach 1:
The system replaces complex mechanical tag application mechanisms with a tape-based delivery system where tags are mounted on a moving tape from a spool. The applicator uses a simple roller to press tags onto substrates, eliminating the need for complex mechanical pick-and-place mechanisms while maintaining high tagging speeds
Solution Approach 2:
The tape-fed tag delivery system is self-feeding, requiring minimal mechanical intervention. The spool automatically feeds tape through the programming and application zones, and the applicator roller automatically transfers tags to substrates as they pass by, reducing the need for complex control mechanisms and lowering system cost
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 ensures accurate and efficient programming of RFID tags, preventing misassignment and adapting to various product lines by rejecting improperly coded tags and accelerating the process, thereby reducing costs and improving management efficiency.
Implementation Method 1
an RFID programmer operatively connected to the spool system to send a programming signal to each of the tags passing through the spool system
Implementation Method 2
an RFID reader operatively connected to the spool system for reading return signals from programmed RFID tags
Data Source
AI summary
A radio frequency identification (RFID) tag applicator including a spool system for holding and guiding a tape including a plurality of RFID tags from a first spool to a second spool, an RFID programmer coupled to spool system to send a programming signal to each of the tags passing from the first spool to the second spool, an RFID reader coupled to the spool system for reading a return signal from a programmed RFID tag in order to reject or accept the programmed tag, and an applicator member operatively coupled to the RFID reader to cause an RFID tag to peel away from the tape onto a passing substrate if the RFID tag is accepted by the RFID reader or pass to the second spool if rejected.