Classifications

• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
  • G06K7/00—Methods or arrangements for sensing record carriers, e.g. for reading patterns
  • G06K7/10—Methods or arrangements for sensing record carriers, e.g. for reading patterns by electromagnetic radiation, e.g. optical sensing; by corpuscular radiation
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
  • G06Q30/00—Commerce
  • G06Q30/02—Marketing; Price estimation or determination; Fundraising
  • G06Q30/0207—Discounts or incentives, e.g. coupons or rebates
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
  • B41F—PRINTING MACHINES OR PRESSES
  • B41F33/00—Indicating, counting, warning, control or safety devices
  • B41F33/0036—Devices for scanning or checking the printed matter for quality control
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
  • G06K19/00—Record carriers for use with machines and with at least a part designed to carry digital markings
  • G06K19/06—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code
  • G06K19/06009—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code with optically detectable marking
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
  • G06K5/00—Methods or arrangements for verifying the correctness of markings on a record carrier; Column detection devices
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
  • G06Q10/00—Administration; Management
  • G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
  • G06Q10/087—Inventory or stock management, e.g. order filling, procurement or balancing against orders
• • G—PHYSICS
  • G06—COMPUTING; CALCULATING OR COUNTING
  • G06V—IMAGE OR VIDEO RECOGNITION OR UNDERSTANDING
  • G06V10/00—Arrangements for image or video recognition or understanding
  • G06V10/98—Detection or correction of errors, e.g. by rescanning the pattern or by human intervention; Evaluation of the quality of the acquired patterns
  • G06V10/993—Evaluation of the quality of the acquired pattern

Definitions

• This invention relates to methods and systems for production line marking of a series of unique identifiers.
• this invention relates to the marking and verification of unique codes, such as promotional codes, on a line of articles.
• Methods and systems for marking of articles for various purposes are known. For example, methods are known for printing identifying symbols and codes on products during production line runs. A run of products may be printed with a Universal Product Code or barcode, identifying for instance the product, a batch number, any expiry date, and the like. These are generic codes, as each product in a run or batch is marked or printed with the same code. In contrast, the printing of unique codes or unique identifiers requires greater control than other forms of code printing on a product. This is because, for example, unique codes linked to a manufacturer's SKU (Stock Keeping Unit) may have an associated (redeemable) value. Consequently, they require stringent control, which is enforced by print producer clients, who pay for each redemption.
• SKU Stock Keeping Unit
• Clients typically require complete digital traceability on every such code issued to a print producer.
• Complete digital traceability means that, from the point of receiving codes, through every process, including printing and verification, an unbroken digital record must be maintained of its journey. This introduces a level of digital control not required when printing generic codes.
• the present invention aims to address these problems and provide improvements upon the known devices and methods.
• one embodiment of a first aspect of the invention can provide a method for verified production line marking of a series of unique identifiers, the method comprising: marking a unique identifier of the series onto an article to form a unique identifier mark; obtaining marking feedback data associated with the unique identifier from said marking; and inspecting the unique identifier mark to obtain inspection data associated with the unique identifier.
• the marking feedback data may, for example, comprise data indicating a status of the marking and the inspection data may, for example, comprise imaging data of the unique identifier mark.
• Obtaining data from marking as well as from inspection facilitates accurate verification of the marking of the identifier.
• the method provides two sources of data for tracing of the unique identifier.
• the data may advantageously be used or combined for corroboration and/or accurate diagnosis of any errors occurring during marking.
• the method may be continuous or repeated, for example in order to provide continuous marking and verification in a production line environment.
• the method is repeated at least ten times, in particular at least twenty times.
• the method may have particular value in the context of rapid production line marking.
• the method is repeated at least once per second, advantageously at least ten times per second, more advantageously at least fifteen times per second.
• the invention embraces a suitable routine for such repetition.
• the marking and inspection may advantageously occur in series.
• the method may comprise marking a plurality of unique identifiers of the series onto a plurality of articles to form a plurality of unique identifier marks, obtaining marking feedback data associated with each unique identifier, and inspecting each unique identifier mark to obtain inspection data associated with each unique identifier.
• the unique identifier may, for example, be a unique code, such as one of a series of unique promotional codes.
• the code is an alphanumeric code, or a barcode, a QR code or the like, or an image in a series of unique identifying images.
• the article to which the identifier is applied may be, for example, a product or item, or a substrate for application to a product or item.
• the marking may be achieved in any suitable manner, for example by printing, or stamping, or embossing, or other known marking techniques.
• the method comprises passing, or making available, marking data for the unique identifier to a marking device for marking the unique identifier onto the article.
• the marking device may be any suitable device, for example, a printing, stamping, or embossing device.
• the marking device may be a printer printing the mark.
• the marking data may comprise a marking command issued to the marking device to mark the unique identifier onto the article.
• the marking data may comprise information representative of said unique identifier or series of unique identifiers, for example one or more glyphs or features thereof.
• the marking feedback data comprise data indicating a status of the marking of the unique identifier.
• the marking feedback data may indicate whether the marking was completed or not, information on any error or malfunction affecting the marking, or simply details required for logging the marking.
• the marking feedback data comprise information about a state of a marking device instructed to mark the unique identifier. For example, possible states may be on/off, functioning/ malfunctioning, or one or more error states.
• the inspection data may in principle be any data obtained by inspection of the unique identifier mark.
• Inspection of the unique identifier mark may, for example, comprise imaging, in particular optical imaging, of the unique identifier mark.
• the inspection data may comprise imaging data, in particular optical imaging data.
• inspection of the unique identifier mark may comprise using an imaging device, for example an optical imaging device, to generate the inspection data.
• the imaging device may be a camera.
• the inspection data may comprise a continuous image stream.
• the inspection data may comprise an image stream, e.g. having a frame rate of at least 20 frames per second (fps), or advantageously at least 100 fps, or even at least 200 fps or at least 250 fps.
• the method may comprise adapting a lighting condition for the article during inspection in dependence on a determined characteristic of the article. For example, certain articles may require stronger or weaker lighting to enhance the usefulness of the inspection data. Determined characteristics of the article may include, for example, the colour or reflectiveness of the article.
• the method comprises storing, logging and/or processing the marking feedback data and/or inspection data for the unique identifier.
• the method comprises processing the inspection data to obtain an inspection result associated with the unique identifier.
• the method may comprise comparing the inspection data to expected data associated with the unique identifier to obtain an inspection result.
• the expected data may relate to an inspection appearance, e.g. visual appearance of the unique identifier mark.
• the inspection appearance may include, for example, one or more of size, shape, colour and orientation of the unique identifier mark.
• the expected data comprises a glyph or feature associated with the unique identifier.
• the expected data may in principle be determined in any suitable manner to obtain an inspection result.
• matrix matching and feature extraction techniques are known in the art for obtaining inspection results by optical character recognition.
• the method comprises subjecting the inspection data to character recognition to obtain an inspection result.
• Processing of the inspection data to obtain the inspection result involves processing capacity and processing time, which together amount to a processing demand.
• Processing demand may be considerable, particularly where optical character recognition is employed. Excessive processing demand can affect the speed of production line marking and/or reduce the accuracy of the inspection result.
• the method may advantageously comprise determining or defining, in particular limiting, the expected data in dependence on data associated with the unique identifier.
• the data associated with the unique identifier comprise or consist of an expected inspection appearance, e.g. a glyph or feature, or one or more glyph or feature combinations, of the unique identifiers in the series.
• the data associated with the unique identifier comprise or consist of an expected inspection appearance, e.g. a glyph or feature, or one or more glyph or feature combinations, of the unique identifier.
• Limiting the expected data can greatly reduce processing demand by restricting the amount of expected data to be parsed, e.g. compared to conventional optical character recognition. Determining the expected data based on data associated with the unique identifier can also facilitate recognition of the unique identifier mark in a continuous image stream, as is desirable in rapid production line marking. In particular, the unique identifier mark may be more quickly identified in the inspection data. Accordingly, a greater amount of inspection data, such as continuous image stream, can be processed. Therefore the need for triggers to begin and end the collection of inspection data can be avoided.
• the method comprises obtaining a continuous image stream, and stitching together portions of the image stream to obtain the inspection data.
• the data associated with the unique identifier may comprise, consist, or be determined in dependence on, marking data for the unique identifier, i.e. data which may also be passed or made available to a marking device for marking the unique identifier onto the article.
• the method comprises: marking a unique identifier of the series onto an article to form a unique identifier mark, the marking comprising passing, or making available, marking data for the unique identifier to a marking device for marking the unique identifier onto the article; obtaining marking feedback data associated with the unique identifier from said marking; and inspecting the unique identifier mark to obtain inspection data associated with the unique identifier, wherein the method comprises comparing the marking data to expected data associated with the unique identifier to obtain an inspection result, the expected data comprising, consisting of, or being determined from, said marking data.
• the expected data comprise, consist of, or are determined in dependence on the marking feedback data.
• the method comprises: marking a unique identifier of the series onto an article to form a unique identifier mark; obtaining marking feedback data associated with the unique identifier from said marking; and inspecting the unique identifier mark to obtain inspection data associated with the unique identifier, wherein the method comprises comparing the marking data to expected data associated with the unique identifier to obtain an inspection result, the expected data comprising, consisting of, or being determined in dependence on, said marking feedback data.
• the expected data determined based on the relevant marking feedback data may reflect that no marking has taken place. Accordingly, the inspection result can confirm that no marking has taken place, whereas without determination of the expected data by the marking feedback data the inspection result would indicate an error and/or require additional processing to recognise a marking failure.
• expected data may comprise, consist of, or be determined in dependence on both marking data and marking feedback data.
• the expected data for example a plurality of potential inspection appearances for the unique identifier
• the expected data may be stored in a look-up table and mapped against associated marking data or marking feedback data values.
• a first appearance for the unique identifier may be associated with error-free marking of the unique identifier and a second appearance may be associated with failed marking of the unique identifier.
• the method may comprise querying a lookup table based upon the marking data or marking feedback data to determine expected data to be compared with the inspection data to obtain an inspection result.
• the method may comprise determining a verification status associated with the unique identifier, based upon the marking feedback data and/or the inspection data.
• the verification status may reflect whether or not the unique identifier has been acceptably marked. Additionally or alternatively, the verification status may reflect whether or not a serious error has occurred that requires a stop of production line marking.
• the verification status may be determined based upon an inspection result as hereinabove described.
• said inspection result is obtained by a comparison of the inspection data with expected data determined in dependence on marking feedback data.
• Such an inspection result advantageously takes into account both marking feedback data and inspection data.
• a further comparison of the inspection result with marking feedback data to obtain an advantageously corroborated verification status may hence be unnecessary.
• corroboration may also be achieved by comparing inspection data or an inspection result with the marking feedback data to obtain the verification status.
• the method may comprise determining and optionally performing one or more actions based upon the verification status.
• the method comprises discarding the article in dependence on a verification status, e.g. a status reflecting a marking error, and/or illegibility and/or absence of marking.
• a verification status e.g. a status reflecting a marking error, and/or illegibility and/or absence of marking.
• the method comprises storing the inspection data in dependence on a verification status, e.g. reflecting a marking error. This enables further analysis of errors, e.g. by an operator, whilst allowing other data to be deleted to save storage space.
• the method comprises stopping further production line marking in dependence on a verification status, e.g. a status reflecting a serious marking error that indicates a fault requiring repair or maintenance. This can prevent continued marking until the error can be checked and resolved.
• a verification status e.g. a status reflecting a serious marking error that indicates a fault requiring repair or maintenance. This can prevent continued marking until the error can be checked and resolved.
• the method is suited to rapid production line marking.
• the method may comprise adapting or modifying a marking device for rapid marking.
• the method comprises overriding a buffering routine of a marking device instructed to execute the marking to enable more rapid marking.
• the method comprises reconfiguring a baud rate of a marking device instructed to execute the marking to enable more rapid marking.
• Processing of the marking data, marking feedback data and inspection data may be performed by a processor.
• the processor may be configured to implement the methods described herein.
• the processor may be a controller configured for controlling the marking and/or inspection.
• the processor or controller may be linked to one or more data storage memories, as may be required.
• the invention embraces a processors configured to perform the methods described herein.
• One embodiment of a second aspect of the invention can provide a processor for verifying and/or controlling production line marking of a series of unique identifiers, the processor comprising: a marking device interface for receiving marking feedback data associated each of a plurality of unique identifiers from a marking device; and an inspection device interface for receiving inspection data associated with each said unique identifier from an inspection device.
• One embodiment of a third aspect of the invention can provide a system for verified production line marking of a series of unique identifiers, the system comprising: a processor; a marking device co-operable with the processor, the marking device being configured for marking unique identifiers onto articles to form unique identifier marks and sending marking feedback data associated with each of a plurality of unique identifiers to the processor; and an inspection device co-operable with the processor, the inspection device being configured for inspecting the unique identifier marks to obtain inspection data associated with each unique identifier, the processor being configured to receive the inspection data from the inspection device.
• the system may suitably comprise a transport means, e.g. a conveyor, for carrying articles from the marking device to the inspection device.
• the system may comprise a line blower.
• the unique identifiers, marking device, marking feedback data, inspection device and inspection data may be, for example, as hereinabove described.
• the processor or system may be configured to implement any of methods described hereinabove.
• the processor or controller may be linked to one or more data storage memories.
• the processor may be a controller configured for controlling the marking device and/or inspection device.
• the controller is configured to send marking data to the marking device, e.g. as hereinabove described.
• the controller controls one or more system modules, for example a transport means or a line blower.
• the processor may advantageously be configured to store or log the marking feedback data and the inspection data.
• the processor is configured to process the inspection data to obtain an inspection result associated with each of the unique identifiers. Such processing may advantageously be as hereinabove described.
• the processor is configured to determine a verification status associated with each unique identifier, based upon the marking feedback data and/or the inspection data. Such determination may advantageously be as hereinabove described.
• the processor is a controller configured for performing one or more actions based upon the verification status, e.g. as hereinabove described.
• processor or controller described herein may suitably comprise a control unit or computational device having one or more electronic processors.
• processors may suitably comprise a control unit or computational device having one or more electronic processors.
• processors may suitably comprise a single processor or controller or alternatively different functions of the processor or controller may be embodied in, or hosted in, different control units or controllers.
• controller or “processor” will be understood to include both a single control unit or processor and a plurality of control units or processors collectively operating to provide any stated functionality.
• a suitable set of instructions may be provided which, when executed, cause said control unit or computational device to implement the techniques specified herein.
• the set of instructions may suitably be embedded in said one or more electronic processors.
• the set of instructions may be provided as software to be executed on said computational device.
• the processor comprises a server system.
• the processor comprises a marking device controller and/or an inspection device controller.
• the processor comprises an optical character recognition module.
• Further aspects of the invention comprise computer programs, computer program applications or computer program code which, when loaded into or run on a computer or processor, cause the computer or processor to become a system, or to carry out methods, according to the aspects described above. The above aspects and embodiments may be combined to provide further aspects and embodiments of the invention.
• Figure 1 is a diagram illustrating steps of a method for verified production line marking according to an embodiment of the invention.
• Figures 2 and 3 are diagrams illustrating systems and apparatus for verified production line marking according to embodiments of the invention.
• Embodiments of the invention can provide methods and systems used to print, verify and manage unique identifiers, in particular unique codes, on articles. They address the needs of both the print producer and their clients by providing ease of use, improved information and control, together with digital traceability of codes. No system known to the inventors provides a complete and integrated solution as in embodiments of the invention. These innovative processes ensure greater accuracy in the printing of unique codes.
• embodiments of the invention use a (pre-generated) set of codes for printing by a print head on a plurality of articles; obtain as marking feedback data from the print head information on the codes actually printed on the articles; and inspect the printed codes with an inspection device in the form of an image recognition system comprising a camera.
• Data is obtained from the print head and the inspection. This data may be stored and/or processed. The availability of two sources of data aids accuracy in verifying and tracing the marking of codes, since corroboration is possible.
• the expected data provided to the image recognition system may simply be the set of codes supplied to the printer.
• the expected data is determined based upon the marking feedback data. Because the marking feedback data from the print head provides information as to what was in fact printed, inspection can then be based on a more accurate set of references, and is therefore itself more accurate and efficient. For example, a code may fail to print. This could lead to high processing demand in the image recognition system to recognise that a code has failed to print. Such processing can be reduced by limiting expected data in the processing step to a list of codes supplied to the printer.
• the print producer receives unique codes from their client (or another source), which are stored and formatted on a secure digital coding (SDC) Server, which acts as a controller/processor.
• SDC secure digital coding
• the server may be configured simply to store this information. However in particularly advantageous embodiments, the server may update each code's status on its database.
• the server also issues or makes available the codes to an Optical Character recognition (OCR) interface.
• OCR Optical Character recognition
• This interface verifies, via an imaging device in the form of an OCR camera, that the correct code has been printed, that it is legible, and in the correct order.
• the codes made available to the OCR interface may be codes that have been updated with the status from the printer, i.e. the OCR interface may be provided with expected data determined on the basis of marking feedback data received from the printer.
• the OCR Interface feeds back its own status for each code to the SDC Server.
• the server may be configured simply to store this information. However in particularly advantageous embodiments, the server may update each code's status on its database based on the status received from the OCR.
• the server is configured to determine a verification status that takes into account the status from the printer and the status from the OCR interface.
• each code is tracked throughout the process such that complete digital traceability is achieved, as well as ensuring legibility of codes.
• the system simplifies the management of codes, as well as the printing process. Additionally, as all information is digitally recorded, reporting and analysis is substantially enhanced.
• Figure 1 is a diagram illustrating steps of a method for verifying production line marking according to an embodiment of the invention.
• the system obtains a series of unique identifiers to be marked on the production line articles (100).
• This may be, for example, a set of unique promotional codes to be applied to a run of products.
• the codes may be alphanumeric, for example a 10 digit or letter string.
• the unique identifiers/codes are made available to a marking device and an inspection device (102). This can be done by a central server, over a network of which the marking and inspection devices form a part.
• the codes may be presented in a sequence, in batches, or in an on-going updated sequence monitored by each device.
• the marking device marks (104) the respective unique identifiers onto articles.
• the marking may be achieved by printing, for example by any of the known ink-jet, laser or other printing methods.
• the substrate may be anything sufficient to allow marking for the article - board may be embossed to be marked, various materials, textiles and papers may be readily printed upon.
• the codes may be printed in the presented sequence, by a print head onto each article as it passes the print head on the conveyor.
• marking feedback data is collected for that marking step (106); this may be any kind of feedback which may be relevant for the system to assess efficiency, errors or the like.
• the feedback may simply be a notification that the printing took place.
• the feedback may comprise data on when the printing was done, to monitor and corroborate timing with later devices.
• the feedback may note printing errors, such as lack of a substrate to print on, a partial mis-print, or a malfunction of the print head.
• the feedback is returned to the server and is used to update the list of codes available to an inspection or verification device (102).
• the inspection or verification device which has access to the sequence of codes, inspects each unique identifier mark as it passes on the line (108).
• a camera may be set up to view each article printed earlier on a conveyor, with the camera taking images of passing substrates on the conveyor.
• the inspection device determines inspection data for each mark - i.e. for each printed code (or even a non-printed substrate, where one is expected), feedback is provided.
• An assessment of the inspection data (1 10) is made by an inspection processor.
• Assessment of the inspection data may, for example, indicate whether the code is present or not, whether the inspection has been made or not, or a more complex assessment of any possible error, such as smudging or partially missing code.
• a comparison is made between expected data (e.g. an image of the code, or an OCR reading of the code determined from the unique identifier information made available by the server) and the result assessed.
• An error report may be logged where a difference is found.
• the inspection processor may, for example, be an OCR Interface for comparing an image with an expected image, or with details of the identifier sequence provided to the inspection device. Additionally or alternatively, the inspection processor may be part of the central server such that assessment of the inspection data is left to a central server, with the marking and inspection devices merely reporting their respective tasks and the data associated with them.
• the verification status may be a consequence of the inspection result and reflects whether or not the unique identifier has been acceptably marked, as well as whether or not a serious error has occurred that requires a stop of production line marking.
• the server is further configured to determine and perform one or more actions based upon the verification status.
• the server discards articles on which a marking error has occurred by activating a line blow module.
• the server also logs and stores inspection data for such articles. Where a serious marking error that indicates a fault requiring repair or maintenance has occurred, the server stops further production line marking.
• the Management Software which controls the entire process, from receiving codes, their formatting, printing and verification, to exporting completed sets back to clients, with full traceability.
• a Printer Interface to enable printing devices to buffer sufficient codes, print at higher speeds, print more accurately, query print status (so that code status can be updated) and provide a universal interface for the different printing devices.
• An OCR Interface to support high visual recognition rates, as well as providing the facility to record errors and predefined events (e.g. a winning code.)
• FIG. 2 illustrates a single print-line installation.
• the SDC server (202) is connected to a printer interface (204) and to an OCR interface (206).
• the printer interface is connected to the printing device (205); these may be considered the marking device.
• the OCR interface is connected to the OCR camera (208), and to the illumination device (214), here an LED lighting device. These components can be considered the inspection device.
• the system also includes production line warning lights (212), line blowing devices (216), speed controllers and conveyor stop/start actuators (218), and a wireless network access point.
• a user print management device (210) can be used to control the network, and to assess the function of the server and the devices, via the wireless network access point.
• FIG. 3 illustrates a multiple print-line configuration. The same components are present, but duplicated for each line, where necessary.
• a single server (302) manages the network, and each line has its own printer interface (304) and printing device (305), OCR interface (306) and OCR camera (308) and lighting.
• the Management Software comprises software and firmware for controlling and managing the entire system, as described earlier, thereby contributing to controller and processor functionality. Additionally, the software improves security by protecting codes through the elimination of unsafe procedures, and restricting access to codes on a "need-to-know" basis. The software also supports complete digital traceability of codes.
• the software necessary to run the system resides on the SDC Server. Firmware and software to run both the Printer and OCR Interfaces are found on these devices.
• the SDC Server and its two associated Interfaces are hardwired into a network.
• the Administrator connects to the network via a Wi-Fi connection and downloads the Administration suite of programmes, comprising three main sections, listed below, onto a PC (or similar device) in their office:
• Factory-floor operators use a dedicated Print Management Device (which comprises an iPad, or similar touch-screen device,) located on the factory floor, and connected to the SDC Server through a fast Wi-Fi connection. They interact with this device in performing their duties. It in turn, records all their actions, which are stored on the SDC Server. A set of warning lights are placed near the production-line. These are directly connected to the SDC Server. In the case of a printing or reading error these errors are returned to the SDC, where they are recorded. The SDC Server then submits the error code to the production-line warning lights, which then display an appropriate warning. This alerts the factory-floor operative to the problem, so that they may take action.
• a dedicated Print Management Device which comprises an iPad, or similar touch-screen device, located on the factory floor, and connected to the SDC Server through a fast Wi-Fi connection. They interact with this device in performing their duties. It in turn, records all their actions, which are stored on the SDC Server.
• a set of warning lights are placed near the production-line. These are
• the print producer's Administrator On receiving an order from the client, the print producer's Administrator will access the system's Administrator section and set up the campaign, responding to screen prompts requesting all relevant information. The Administrator will then download client codes in an encrypted format and allocate them to a campaign. The system will then decrypt the codes internally and perform a checksum calculation on the file to ensure the files uniqueness, eliminating the possibility of duplicate files being sent by the client. This may be important because code / file splitting is carried out by the Management Software and cannot usually be compromised, as there is no manual intervention by the print producer's Administrator. They have no need, or ability to open files, completely removing the risk of error from manually handling and manipulating codes.
• the system then formats the codes into a standard format. Once production has started and the details of the printing-device which will print the codes is known, the system reformats the codes according to printing-device specifications. Sometimes products are available for printing before their codes have been issued (by the client), but because codes are allocated to SKU (Stock Keeping Units) unused codes from other SKUs cannot be used. However, to help reduce costly production delays, the SDC Management Software provides "transfer rules", setup in the Campaign
• Codes are transferred directly from the SDC Server, where they are stored, to the Printer Interface, ready for printing. Factory-floor operatives are exposed to very few codes, only the starting and ending codes of a print-run, thereby reducing security risks associated with code exposure.
• Print-runs may be stopped and unprinted codes reallocated to another print-line and printing- device. All the management of codes is carried out by the system, with no duplicates being printed and full traceability of codes maintained.
• an operative on the factory-floor using a Print Management Device enters a job and campaign number. Details of the print-run are displayed. If correct, the operative signs on the screen to confirm the details. The system records the signature and details of the operative. This provides the ability to query codes (at a later date) and compare statistical data on different print-runs, by any criteria recorded in the system. A PDF copy of the signed job is recorded and forwarded to the Administrator.
• the operator now goes through a "Make Ready” stage where they verify that printing components are ready to print, checking ink levels, heating up the ink and checking on calibrations, for both printing-device, high-speed camera and LED lighting device. Most of these settings are done automatically by the system, although fine adjustments may be required.
• the entire process is controlled and monitored from the Print Management Device. As it is controlled from a single device, significant reduction in setup times are achieved.
• the SDC Server downloads codes ready for printing, so that when the operator is ready, printing can commence with no delays.
• the Printer Interface is a physical box containing hardware, firmware and software, used as an interface between the SDC Server and the printing device. It is placed on, or in close proximity to, the printing device. There is one Printer Interface for every printing device. The functions and aims of the printer interface are:
• the system configures the baud rate to 38,400 baud per second, the maximum achievable using RS232 protocols;
• the system To interrogate the printing device's buffer by monitoring the timing of electrical signals.
• the system detects different states, which it uses to update the code's status (e.g. "printed correctly") and / or provide actionable responses (on errors), such as ejecting product from the line;
• the system To ensure the printing device receives codes correctly and that no duplicate codes are printed. In the case of power loss, the system knows it has sent a code to the printing device (as all codes are managed in the Printer Interface through firmware.) If no status is returned, the system records an "assumed printed” status. It returns this to the SDC Server, where it is recorded. The status of this code is updated by the information feedback by the OCR Interface;
• the Printer Interface is hardwired into the network, which connects it to the SDC server. It connects with the printing device through a variety of different ports, supporting different communication protocols.
• the Printer Interface driver is downloaded from the SDC server which provides updates made available from a cloud server.
• the Printer Interface can digitally update its driver, port configuration and key properties and components, making it a universal interface.
• the Printer Interface is managed using a Print Management Device (which comprises an iPad, or similar touch-screen device,) preferably located at a fixed position on the factory floor, although it can be located anywhere. It connects to the SDC Server through a fast WiFi connection.
• the management of the printing device is controlled through the Printer Interface, which in turn is managed and controlled by the Print Management Device utilizing specially developed software.
• the Print Management Device can control multiple Printer Interfaces, which connect to one printing device.
• the standard configuration of the SDC Server supports up to 24 Printer Interfaces, although this can be extended through hardware and network upgrades on the server.
• Printing devices can be replaced during print runs within a few minutes due to the Printer Interface's ability to reconfigure them with no lengthy setup procedures. It also allows print suppliers to respond rapidly to requests to print unique codes, simply by attaching the Printer Interface to a printing device.
• the Printer Interface is control by software accessed through the Print Management Device found on the factory floor in close proximity to the printing device. Operatives use the Print Management Device to: prepare for the print run, start the print run, interrupt the print run, restart print runs, monitor and manage printing errors, end print runs.
• the interface operates to override a buffering routine in the printer to enhance the speed of the printer. This can be performed by a dedicated control module in the printer interface, either in firmware or in software.
• an error status is sent to the SDC Server.
• the SDC Server records this and then forwards the error onto the production-line warning lights, which displays the appropriate lights according to the error detected.
• the factory-floor operative, on seeing the production lights activated will go to their Print Management Device and by pressing a single key the device will display error details.
• the OCR Interface is a physical box containing hardware, firmware and software, used as an interface between the SDC Server and camera. It is used to store and compare images taken of printed codes by the camera, with codes passed from the SDC Server about codes recently printed by the printing device. This is to ensure the correct codes are printed and that they are legible.
• This interface also incorporates specialised lighting to support the high speed verification process. These lights are interfaced with, and controlled by, the OCR Interface.
• the functions and aims of the OCR interface are:
• a continuous image stream is used as there are no triggers to activate the camera. This continuous stream of images also ensures that no code passes through without being verified.
• ROI Region Of Interest, i.e. the region the camera needs to scan
• Software in the OCR Interface adjusts for these variations automatically, thereby providing great flexibility of application;
• LED Lights housed in a cover/hood positioned either side of the camera, and used to illuminate the ROI to provide constant and consistent illumination of the correct intensity for the material/substrate used in the printing process. These LED lights are necessary to "block” adverse lighting effects from the factory / production environment and ensure no light “seepage” from the LEDs onto the factory-floor.
• the OCR Interface controls lighting intensity variations to best suit the material and substrate that is being printed on. This is done automatically through software;
• the OCR Interface is directly connected to "line-blowers” to eject product and to the production line "speed adjuster control", which it can switch off, thereby stopping the line.
• the region of interest (ROI) may be sub-divided, in order to enhance the speed of code reading.
• the OCR camera may be configured to image several different areas of an incoming article or substrate at once.
• the ROI may be split into three parts; for a linear code this may be a beginning, a mid-section, and an end portion of the code.
• each section may comprise three letters.
• the codes will continue to pass through the imaging area and scroll past the camera; the imaging system will maintain the constant image stream for later stitching, but more duplicates will have to be removed in the stitching stage (or used for additional corroboration of the matching results).
• the OCR Interface is hardwired into the network, which connects it to the SDC server. It connects directly with the high speed, high definition camera and LED lighting devices. It also connects directly with the production "line-blower" and "speed adjuster control". There is one OCR Interface, one camera and two LED lighting devices per production line.
• the OCR Interface is managed and controlled using a Print Management Device, the same device mentioned earlier to control the Printer Interface, as both the Printer and OCR Interface form part of the same production-line and process.
• a Print Management Device the same device mentioned earlier to control the Printer Interface, as both the Printer and OCR Interface form part of the same production-line and process.
• These settings include production-line speed settings, which the OCR Interface controls.
• Campaign and SKU character set tolerances which the OCR Interface uses to accept or reject characters that don't fall within set parameters.
• Preset image requirements i.e. images it must take and store, such as winning codes and quality assurance codes.
• the software analyses the images and provides verification on the printed characters and their legibility. Also during the "Make Ready” stage first automatic and then manually adjustments are made to the lighting level to achieve optimum results.
• the OCR software controls and adjusts the lighting levels to provide the appropriate illumination for the material being used. For example, reflective material such as metalised foil can react badly to intense lighting so a lower lighting level is used to illuminate the material correctly. However, sometimes manual intervention in adjusting illumination levels is required. The factory- floor operative will adjust settings until they have achieved optimum illumination.
• the production warning lights next to the print-line will illuminate, indicating the type of error.
• the Operator using their Print Management Device, can ascertain codes affected and take action quickly without risking the waste of further product.
• the camera takes a continuous stream of images, which the OCR Interface software then stitches together to form a single code which it then compares to codes from the SDC Server of codes recently printed, and which it should expect to read in a specific order.
• the OCR Interface transmits this together with date and time of verification to the SDC Server, where the data is stored.

Applications Claiming Priority (2)

Publications (1)

Family

ID=51454121

Family Applications (1)

Country Status (3)

Families Citing this family (2)

Citations (2)

Family Cites Families (8)

• 2014
  • 2014-07-14 GB GB1412505.8A patent/GB2528261A/en not_active Withdrawn
• 2015
  • 2015-07-14 EP EP15753411.6A patent/EP3170136A1/de not_active Withdrawn
  • 2015-07-14 WO PCT/GB2015/052025 patent/WO2016009188A1/en active Application Filing

Patent Citations (2)

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events