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The Evolution of Barcode Scanning in Logistics Automation

 

Barcodes have played a pivotal role in revolutionizing supply chains since the 1970s. Traditional LED and laser scanners have been the go-to solution for reading barcodes, but with advancements in technology, new possibilities have emerged.

Here, I explore the limitations of traditional scanners and the rise of camera-based barcode scanners empowered by image analysis systems. I will delve into the intricate operations performed by these scanners and their superior efficiency in barcode location and decoding. Additionally, I will discuss the ongoing research in computer vision-based barcode reading techniques and the broader impact of machine vision in logistics beyond barcode scanning.

The limitations of traditional scanners

Traditional barcode readers operate by shining LED or laser light across a barcode, with the reflected beam detected by a photoelectric cell. While simple and effective in their time, these scanners have certain limitations that hinder their performance and restrict their application range. They require prior knowledge of barcode location, struggle with complex scenes, and are unable to read multiple barcodes simultaneously. Moreover, low-quality barcodes pose challenges, potentially leading to losses in time, money, and reputation.

The rise of camera-based barcode scanners

Camera-based barcode scanners, empowered by image analysis systems, have emerged as a game-changer in logistics automation. These scanners perform intricate operations, starting with image acquisition and preprocessing. Images are converted to grayscale, noise is reduced, and barcode edges are enhanced using various filters. Binarization is then applied, isolating black and white pixels for decoding. Unlike traditional scanners, image-based barcode scanners excel in barcode location and decoding. They eliminate the need for prior knowledge of barcode position and can locate and extract multiple barcodes in a single image.

The advantages of optical barcode scanners

As technology progresses, optical barcode scanners are gradually replacing LED and laser-based solutions, offering superior efficiency and performance. Computer vision-based barcode reading techniques have sparked extensive research, addressing challenges in both location and decoding steps. Barcode localization, the most intricate part, involves detecting and extracting barcodes accurately despite illumination variations, rotation, perspective distortion, or camera focus issues. Researchers continually refine barcode extraction techniques, using mathematical morphology and additional preprocessing steps for precise recognition.

Beyond barcode scanning: the impact of machine vision in logistic

The impact of machine vision in logistics extends beyond barcode scanning. Robot-operated warehouses, such as those employed by Amazon, rely on 2D barcodes to navigate shelves efficiently. Drones equipped with computer vision capabilities open new possibilities for delivery services, enabling autonomous and accurate package handling.

Machine vision technology is revolutionizing the way logistics operations are conducted, enhancing efficiency, accuracy, and overall customer experience.

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Key Considerations for Choosing the Right RFID Tag for Your Traceability Application

Choosing an RFID tag for your traceability application can be difficult given the huge variation of tags available today. Here are four main factors to keep in mind when selecting a tag, which will greatly contribute to the success of your RFID project.  

 

Choose tag type: I like to start with tags and work backward. Tags come in many shapes and sizes – from paper labels to hang tags, pucks, and even glass capsules and reusable data bolts. First, think about where you want to mount your tag. It is important that it does not interfere with your current product or production process. If you plan to tag a metal product, using a metal-mount style tag will give you the best results.

Assess the required read range: Think about how much range you need between your RFID readers and your tags. Remember that the shorter your range, the more options you will have when selecting a suitable frequency. While all frequencies work for short ranges, long ranges require HF (High Frequency) or even UHF (Ultra High Frequency) products. As a rule of thumb, it is best to keep your reading range as short as possible for the most reliable results.

 

Consider the environment: RFID tags are designed to withstand high temperatures, chemicals, water, and moisture. If your environment involves any of these conditions, you will want a tag that is up to the challenge and will remain functional.

 

Choose the data storage option: RFID tags can be read only or read/write, so think about what kind of data you want to store on your tags. Do you want your tag to be a simple license plate tied back to a centralized database, or do you want to store process/status data directly on the tag? RFID gives you a choice and now is the time to think about what and how much data you want to maximize the benefit of RFID for your process.

 

So now that you have thought about tag type, read range, environment, and data, you already have a promising idea of which tags will work in your application. The final step is to get price quotes and get started with your project. This is a wonderful time to ask the RFID experts for more recommendations and ask about on-site testing to make sure your tags are a great fit for your application. It is also an excellent time to collect recommendations for which reader will pair best with your tag and application.

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The Benefits of Mobile Handheld and Stationary Code Readers

Ensuring reliable traceability of products and assembly is critical in industries such as automotive, pharmaceuticals, and electronics. Code readers are essential in achieving this, with stationary and mobile handheld readers being the two most popular options. In what situations is it more appropriate to use one type over the other?

Stationary optical ID sensors

Stationary optical ID sensors offer simple and reliable code reading, making them an excellent option for ensuring traceability. They can read various codes, including barcodes, 2D codes, and DMC codes, and are permanently installed in the plant. Additionally, with their standardized automation and IT interfaces, the information readout can be passed on to the PLC or IT systems. Some variants also come with an IO-Link interface for extremely simple integration. The modern solution offers additional condition monitoring information, such as vibration, temperature, code quality, and operating time, making them a unique multi-talent within optical identification.

Portable code readers

Portable code readers provide maximum freedom of movement and can quickly and reliably read common 1D, 2D, and stacked barcodes on documents and directly on items. Various applications use them for controlling supply processes, production control, component tracking, quality control, and inventory. The wireless variants of handheld code readers with Bluetooth technology allow users to move around freely within a range of up to 100 meters around the base station. They also have a reliable read confirmation system via acoustic signal, LEDs, and a light spot projected onto the read code. Furthermore, the ergonomic design and highly visible laser marking frames ensure fatigue-free work.

Both stationary and mobile handheld barcode readers play an essential role in ensuring reliable traceability of products and assembly in various industries. Choosing the right type of barcode reader for your application is crucial to ensure optimal performance and efficiency. While stationary code readers are ideal for constant scanning in production lines, mobile handheld readers offer flexibility and reliability for various applications. Regardless of your choice, both devices offer simple operation and standardized automation and IT interfaces, making them essential tools for businesses that rely on efficient code reading.

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Considerations When Picking UHF RFID

If you’ve attempted to implement an ultra-high frequency (UHF) RFID system into your facility, you might have run into some headaches in the process of getting things to work properly. If you are looking to implement UHF RFID, but haven’t had the chance to set things up yet, then this blog might be beneficial to keep in mind during the process.

UHF RFID and what it can do

UHF RFID is a long-range system with a focus on gaining visibility in the supply chain or manufacturing process. It can track multiple ID tags in a set area/distance (depending on the read/write head you select). The RFID field is emitted by an antenna that propagates an electromagnetic field, which will “ping and power up” a tag with data saved on it. Commonly, warehouses use it for logistics, supply chain tracking, warehouse pallet tracking, equipment tracking, or even for luggage tracking. As amazing as this technology sounds, there are environmental factors that can cause the system to not work to its full potential.

Factors affecting RFID system performance

Different materials or environments can affect the performance of your RFID system. Each tag antenna is set to a specific frequency, and some materials or environments can influence the radiation pattern. This can be something as simple as the material on which the tag is mounted to something more complex, such as how the signal is going to bounce off the walls or the ground. Below are some common issues people run into when implementing RFID.

    • Absorption: Absorption occurs when an object in the field absorbs part of the radio frequency energy emitted from the reader antenna. Cardboard, conductive liquids, and tissue (human bodies or animals) are examples of materials that can absorb some of the RF energy. One way to think of this is to imagine a sound booth in a recording studio. The booth is covered in foam to absorb sound. This is a similar philosophy for UHF RFID. You need to consider materials that absorb that energy.
    • Reflection: When there are distortions of the RF field, reflection can occur. As you may imagine, certain materials, such as metals, can cause the waves emitted from the antenna to distort or “reflect” in ways that cause performance losses. This could be metal machinery or fixings between the reader and the tags, a group of metal pipes, and mounting on metal containers. If you choose to do a deeper dive, there are other performance factors that can be impacted by the path of the signal, such as zones in which the tag can’t be reached (even if the tag is in the reader’s field), or the tag and the reader are not aligned properly.
    • Detuning: Detuning occurs when the radio frequency between the tag and reader is changed in the process. Since you pair specific readers to specific tags at a specific frequency, you don’t want your environment to cause a change in the specific frequencies. Certain materials, such as cardboard, metals, tissue, and plastics, can cause an impedance that can “un-match” your reader and tags based on the RF not matching up.

Luckily for you, many companies who specialize in RFID can help ensure you pick the right system for your application. Some will even go visit your site to evaluate the environment and materials that will be involved in the process and recommend the right readers, antennas, tags, and accessories for you.

Although not all UHF RFID applications seem complex, there are many small things that can affect the entire operation. When you are picking your system, make sure you keep in mind some of these effects, and if you are unsure, call in a professional for some assistance.

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Securing Your Supply Chain and Beefing Up Traceability

 

Snake oil is one of the most maligned products in all of history. Synonymous with cure-alls and quackery, it is a useless rip-off, right? Well, no, it’s actually high in the Omega 3’s, EPA, and DHA.

Snake oil fell from prominence because it was all too easy for charlatans to brew up fake oil and pass it off as the genuine article, with sometimes dangerous outcomes.

Today’s customers are smarter than ever and waking up with ever-evolving knockoffs. We are more aware of fake reviews and fake products. Brands that can prove their products are genuine can command higher prices and forge long-standing customer relationships. This starts with securing your supply chain and beefing up traceability.

Securing your brand

Many roads lead to Rome and no single technology will be the one silver bullet to secure your supply chain. That said, RFID technology is likely to play an important role. RFID allows for multi-read without a line of sight, making it a great choice in both production and warehouse/logistics environments. Perhaps more importantly, RFID tags can be encrypted. This adds protection against would-be cheats. The ability to both read and write provides additional flexibility for tracking and tracing in production.

RFID is not the only traceability solution and smart companies will use a combination of technologies to secure their brands. We’ve seen holograms on baseball cards and QR codes on underwear. We’ve seen authorized retailer programs … and RFID on coffee cups and medical devices. As you think through the various options, it’s worth keeping in mind the following 4 questions:

      1. Is the technology secure? Does it support modern cryptographic methods?
      2. Does the solution add value – i.e. improve current processes?
      3. Is the technology future-proof?
      4. Is the technology robust?

Any technology that answers yes to these questions will be well-suited to meet this new market. Brands that stay ahead of the curve will grow and those who fall behind the curve risk ending up in the dustbin – right next to the snake oil.

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IO-Link Changeover: ID Without RFID – Hub ID

When looking at flexible manufacturing, what first comes to mind are the challenges of handling product changeovers. It is more and more common for manufacturers to produce multiple products on the same production line, as well as to perform multiple operations in the same space.

Accomplishing this and making these machines more flexible requires changing machine parts to allow for different stages in the production cycle. These interchangeable parts are all throughout a plant: die changes, tooling changes, fixture changes, end-of-arm tooling, and more.

When swapping out these interchangeable parts it is crucial you can identify what tooling is in place and ensure that it is correct.

ID without RFID

When it comes to identifying assets in manufacturing today, typically the first option companies consider is Radio-Frequency Identification (RFID). Understandably so, as this is a great solution, especially when tooling does not need an electrical connection. It also allows additional information beyond just identification to be read and written on the tag on the asset.

It is more and more common in changeover applications for tooling, fixtures, dies, or end-of-arm tooling to require some sort of electrical connection for power, communication, I/O, etc. If this is the case, using RFID may be redundant, depending on the overall application. Let’s consider identifying these changeable parts without incurring additional costs such as RFID or barcode readers.

Hub ID with IO-Link

In changeover applications that use IO-Link, the most common devices used on the physical tooling are IO-Link hubs. IO-Link system architectures are very customizable, allowing great flexibility to different varieties of tooling when changeover is needed. Using a single IO-Link port on an IO-Link master block, a standard prox cable, and hub(s), there is the capability of up to: 

    • 30 Digital Inputs/Outputs or
    • 14 Digital Inputs/Outputs and Valve Manifold Control or
    • 8 Digital Inputs/Outputs and 4 Analog Voltage/Current Signals or
    • 8 Analog Input Signals (Voltage/Current, Pt Sensor, and Thermocouple)

When using a setup like this, an IO-Link 1.1 hub (or any IO-Link 1.1 device) can store unique identification data. This is done via the Serial Number Parameter and/or Application Specific Tag Parameter. They act as a 16- or 32-byte memory location for customizable alphanumeric information. This allows for tooling to have any name stored within that memory location. For example, Fixture 44, Die 12, Tool 78, EOAT 123, etc. Once there is a connection, the controller can request the identification data from the tool to ensure it is using the correct tool for the upcoming process.

By using IO-Link, there are a plethora of options for changeover tooling design, regardless of various I/O requirements. Also, you can identify your tooling without adding RFID or any other redundant hardware. Even so, in the growing world of Industry 4.0 and the Industrial Internet of Things, is this enough information to be getting from your tooling?

In addition to the diagnostics and parameter setting benefits of IO-Link, there are now hub options with condition monitoring capabilities. These allow for even more information from your tooling and fixtures like:

    • Vibration detection
    • Internal temperature monitoring
    • Voltage and current monitoring
    • Operating hours counter

Flexible manufacturing is no doubt a challenge and there are many more things to consider for die, tooling and fixture changes, and end-of-arm tooling outside of just ID. Thankfully, there are many solutions within the IO-Link toolbox.

For your next changeover, I recommend checking out Non-Contact Inductive Couplers Provide Wiring Advantages, Added Flexibility and Cost Savings Over Industrial Multi-Pin Connectors for a great solution for non-contact connectivity that can work directly with Hub ID.

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Using LoRaWan in Industrial Environments?

What are LoRa and LoRaWan? How are they used and are they beneficial in industrial environments?

LoRa vs LoRaWan 

LoRa, which stands for “long range,” is the physical communication layer used by many devices. Although it has a long range, its bandwidth is minuscule compared to a WIFI network. It’s been used to collect weather data from multiple weather stations simultaneously from kilometers away and with minimal battery power.

LoRaWan, which stands for “long range wide area network,” is a protocol that runs on the LoRa communication layer. When a location has no cellphone reception or WIFI/Internet access, LoRaWan can travel kilometers with packets of data consistently with minimal investment.

Benefits of LoRa and LoRaWan

LoRa and LoRaWan technology make it possible to add hundreds of non-timed critical sensors to one LoRaWan gateway. Due to the bandwidth limitations, packets of data need to be sent routinely. A good example of differentiation is sending an instant text message with your phone versus sending a picture that might take more time.

Using LoRaWan serves as a perfect solution for the instantaneous inventory of bulk and measurable stock. Being able to do this will drastically enhance purchasing power and improve overhead reduction. It also eliminates the cost and troubleshooting of wiring, in addition to avoiding cellphone service charges.

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Know Your RFID Frequency Basics

In 2008, I purchased my first toll road RFID transponder, letting me drive through and pay my toll without stopping at a booth. This was my first real-life exposure to RFID, and it was magical. Back then, all I knew was that RFID stood for “radio frequency identification” and that it exchanged data between a transmitter and receiver using radio waves. That’s enough for a highway driver, but you’ll need more information to use RFID in an industrial automation setting. So here are some basics on what makes up an RFID system and the uses of different radio frequencies.

At a minimum, an RFID system comprises a tag, an antenna, and a processor. Tags, also known as data carriers, can be active or passive. Active tags have a built-in power source, and passive tags are powered by the electromagnetic field emitted by the antenna and are dormant otherwise. Active tags have a much longer range than passive tags. But passive tags are most commonly used in industrial RFID applications due to lower component costs and no maintenance requirements.

Low frequency (LF), high frequency (HF), ultra-high frequency (UHF)

The next big topic is the different frequency ranges used by RFID: low frequency (LF), high frequency (HF), and ultra-high frequency (UHF). What do they mean? LF systems operate at a frequency range of 125…135 kHz, HF systems operate at 13.56 MHz, and UHF systems operate at a frequency range of 840…960 MHz. This tells you that the systems are not compatible with each other and that you must choose the tag, antenna, and processor unit from a single system for it to work properly. This also means that the LF, HF, and UHF systems will not interfere with each other, so you can install different types of RFID systems in a plant without running a risk of interference or crosstalk issues between them or any other radio communications technology.

 

Choosing the correct system frequency?

How do you choose the correct system frequency? The main difference between LF/HF systems and UHF systems is the coupling between the tags and the antenna/processor. LF and HF RFID systems use inductive coupling, where an inductive coil on the antenna head is energized to generate an inductive field. When a tag is present in that inductive field, it will be energized and begin communications back and forth. Using the specifications of the tag and the antenna/processor, it is easy to determine the read/write range or the air gap between the tag and the antenna head.

The downside of using LF/HF RFID technology based on inductive coupling is that the read/write range is relatively short, and it’s dependent on the physical size of the coils in the antenna head and the tag. The bigger the antenna and tag combination, the greater the read/write distance or the air gap between the antenna and the tag. The best LF and HF RFID uses are in close-range part tracking and production control where you need to read/write data to a single tag at a time.

UHF RFID systems use electromagnetic wave coupling to transmit power and data over radio waves between the antenna and the tag. The Federal Communications Commission strictly regulates the power level and frequency range of the radio waves, and there are different frequency range specifications depending on the country or region where the UHF RFID system is being used. In the United States, the frequency is limited to a range between 902 and 928MHz. Europe, China, and Japan have different operating range specifications based on their regulations, so you must select the correct frequency range based on the system’s location.

Using radio waves enables UHF RFID systems to achieve a much greater read/write range than inductive coupling-based RFID systems. UHF RFID read/write distance range varies based on transmission power, environmental interference, and the size of the UHF RFID tag, but can be as large as 6 meters or 20 feet. Environmental interferences such as metal structures or liquids, including human bodies, can deflect or absorb radio waves and significantly impact the performance and reliability of a UHF RFID system. UHF RFID systems are great at detecting multiple tags at greater distances, making them well suited for traceability and intralogistics applications. They are not well suited for single tag detection applications, especially if surrounded by metal structures.

Because of the impact an environment has on UHF signals, it is advisable to conduct a full feasibility study by the vendor of the UHF RFID system before the system solution is purchased to ensure that the system will meet the application requirements. This includes bringing in the equipment needed, such as tags, antennas, processors, and mounting brackets to the point of use to ensure reliable transmission of data between the tag and the antenna and testing the system performance in normal working conditions. Performing a feasibility study reduces the risk of the system not meeting the customer’s expectations or application requirements.

Selecting an industrial RFID system

There are other factors to consider when selecting an industrial RFID system, but this summary is a good place to start:

    • Most industrial RFID applications use passive RFID tags due to their lower component costs and no battery replacement needs.
    • For applications requiring short distance and single tag detection, LF or HF RFID systems are recommended.
    • For applications where long-distance and multi-tag detection is needed, UHF RFID systems are recommended.
    • If you are considering UHF, a feasibility study is highly recommended to ensure that the UHF RFID system will perform as intended and meet your requirements.

Click here to browse our library of Automation Insights blogs related to RFID.

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Lithium Ion Battery Manufacturing – RFID is on a Roll

With more and more consumers setting their sights on ‘Drive Electric,’ manufacturers must prepare themselves for alternative solutions to combustion engines. This change will no doubt require an alternative automation strategy for our electric futures.

The battery

The driving force behind these new electric vehicles is, of course, the battery. With this new wave of electric vehicles, the lithium ion battery manufacturing sector is growing exponentially, creating a significant need for traceability and tracking throughout the manufacturing processes.

Battery manufacturing is classified into three major production areas:

    1. Electrode manufacturing
    2. Cell assembly
    3. Finishing formation, aging and testing

These processes require flexible and efficient automation solutions to produce high quality batteries effectively. As such, there are numerous areas that can benefit from RFID and/or code reading solutions. One of the biggest of these is the electrode manufacturing process, specifically on the individual mother and daughter electrode rolls. This is a great application for UHF (Ultra-High Frequency) RFID.

The Need for RFID

The electrode formation process involves numerous production steps, including mixing, coating, calendaring, drying, slitting and vacuum drying. Each machine process generally begins with unwinding turrets and ends with winding ones. A roll-to-roll process.

Two of the three primary components of the lithium ion battery, both the anode and cathode electrode, are produced on rolls and require identification, process step validation and full traceability all the way through the plant.

During the slitting process both larger mother rolls are unwound and sliced into multiple, smaller daughter rolls. These mother and daughter rolls must also be tracked and traced through the remaining processes, into storage and ultimately, into a battery cell.

Solution

Working with our battery customers and understanding their process needs, a UHF RFID tag was developed specifically to withstand the electrode production environment. Having a tag that can withstand a high temperature range is crucial, particularly in the vacuum drying lines. This tag is capable of surviving cycling applications with temperatures up to 235 °C. Its small form factor is ideal for recess mounting in the anode and cathode roll cores with an operating range reaching 4 meters.

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The tag embedded in the roll core paired with an RFID processor and UHF antenna provides all the necessary hardware in supporting battery plants to achieve their desired objective of tracking all production steps. Customers not only have the option of obtaining read/writes, via fixed antennas at the turrets, but also handheld ones for all storage locations — from goods receiving to daughter coil storage racks within a plant.

This UHF RFID system allows for tracking from the initial electrode coils from goods received in the warehouse, through the multiple machines in the electrode manufacturing process, into the storage areas, and to the battery cell assembly going in the electric vehicle — ultimately linking all battery cells back to a particular daughter roll, and back to its initial mother roll. RFID is on a Roll!