On-Line Bar Code Verification System

1. Field of the Invention

The present invention relates to the verification and validation of bar code labels printed for identification of products. More particularly, a system is provided for scanning bar codes in real time as printed or passed by a scanner in a production environment allowing verification of the quality of the bar code to a plurality of standards, readability of the bar code and proper encoding of desired data. Scanning is accomplished in a synchronized or free-scan format, with the system providing control outputs for use by a printer or process based on the bar code verification or validation results.

2. Prior Art

Bar codes are extensively used for identification of products sold in the commercial market, process procedures and routings, materials and data indexing, cataloguing and storage, and other data administrative and control activities. The development of low cost systems for printing bar codes, including thermal and laser printer systems, has allowed the use of bar codes to proliferate throughout industry. Numerous standards have been developed for bar code encoding schemes and quality, including UPC/EAN/JAN, CODABAR and IATA, with evaluation criteria, including bar width deviation, ratio calculation, percent decode calculation, encodation check, modcheck calculation, quiet zone check and intercharacter gap (ICG), print contrast (PCS), and decodability grade and reference decode calculations by ANSI. The printing of bar code symbols with assured quality and decodability requires on-line verification and/or validation of the bar codes as printed in real time. Similarly, for bar codes applied to products, verification that labels have not been damaged or degraded or that incorrect labels have not been applied to the goods also requires real time on-line evaluation. Various prior art systems have provided differing levels of verification or decoding of bar codes of different symbologies, however, such systems typically do not provide sufficient flexibility in verification or decoding techniques, require significant calibration inputs or lack sufficient communication and control output capability to provide useful service in real time applications.

It is therefore desirable to provide an on-line verification and validation system which has sufficient flexibility to verify bar code symbols to industry specifications and validate data to ensure actual encoded information is accurate without extensive or repeated calibration of the system. Further, it is desirable to provide a system having flexible control and data outputs for accumulation of historical data and response to inaccurate or unreadable bar code information.

The present invention provides a system employing a non-contact scanner operating under microcomputer control. Synchronized or free-scanning operation of the scanner is controlled by the microcomputer responsive to user inputs based on requirements of the system for which label or bar code analysis is required. Manual function selection and output display for communication to the user provide direct input and output from the microcomputer and a bi-directional communications interface allows data and instruction exchange between the microcomputer and a host for data designation, analysis and record keeping activities. A plurality of programmable field outputs from the microcomputer allows real time control of the process or system being monitored by the invention. Pattern matching is accomplished in a synchronized or free-scan mode selectable by the user. Free-scanning allows detection and analysis of bar codes on an unconstrained basis. Synchronized scanning allows confirmation of fixed process parameters, including presence of bar code labels at designated times in the process to allow a "no read" designation for missing bar codes or labels. Timer capability is provided for "no read" evaluations in the free-scanning mode.

FIG. 1a is a block diagram of an implementation of the present system in a printing or process application for verification/validation of bar codes.

FIG. 1b shows the scanner of the present invention oriented to read "picket fence" oriented bar codes;

FIG. 1c shows the scanner of the present invention oriented to read "ladder" oriented bar codes;

FIG. 2 is a block diagram of an embodiment of the system demonstrating the various input, output and operational elements of the invention.

FIG. 3 is a system flow diagram in block form demonstrating various software elements of the invention.

FIGS. 4a through 4d are flow diagrams for software implementing the free-scan mode.

FIGS. 5a through 5c are flow diagrams for software implementing the synchronized mode of operation of the invention.

Referring to the drawings, FIG. 1 demonstrates the operational environment of the present invention. A printer or other monitored process 10 provides the bar code labels 12 to be monitored by the system. These bar code labels may be present on label stock exiting from a printer, bar code labels applied to packaging present on a conveyor or on the packaging machine for the product itself. Such printers or processes are typically controlled by a host processor 14 which downloads control information to the process and/or bar code information, including symbology definition and data encoded in the bar code. A non-contact scanner 16 is employed in the present invention to observe the bar code. In the embodiment shown in the drawings, a moving beam laser scanner having a visible laser diode light source at 670 nanometers is employed. The scanner communicates with a controller 18 which incorporates an input keypad 20 for operator communication with the device, an LCD display 22 for data output and communication with the operator, and a plurality of function LEDs 24 to identify the operation and status of the invention.

A communications interface 26 is provided between the controller and any host processor for data transmission, as will be described in greater detail subsequently. In addition, a plurality of control outputs 28 are provided in the controller for direct output of control signals to the printer or monitored process. Various functionality for these signals can be provided by the controller responsive to preprogrammed conditions. Those skilled in the art will recognize that the scanner and controller are mountable in a common enclosure, and are shown separately in FIG. 1 merely for convenience.

FIGS. 1b and 1c demonstrate the flexible mounting of the scanner in the present invention using stand 17 to accommodate "picket fence" (1b) and "ladder" (1c) oriented bar codes. The invention provides scanner control, as will be described in greater detail subsequently, which facilitates operation in either mounting position.

As shown in FIG. 2, a microcomputer controls the scanner and receives data input from the scanner. An ENABLE signal activates the scanner, which responds with a START OF SCAN signal. Digital data is then provided for scan results. Analog data is also provided in the embodiment shown in the drawings through a controllable operational amplifier 32, which transmits data to the microcomputer through an analog to digital converter 34.

As previously described, operator interface with the system of the invention is accomplished through a keypad 20. In present embodiments, this keypad comprises a four key membrane switch, providing for separate function inputs to the microcomputer.

Internal communication in the controller is accomplished through a two bus architecture. An ADDRESS BUS operating through an address decoder 36 allows the microcomputer to access system memory, including a program read-only memory (ROM) 38 and a non-volatile random access memory (RAM) 40. Addressable latches 42 allow data output and control for the LCD, a synch LED 44 and field outputs 46 with associated identification LEDs 48 for distribution of external control signals. In the embodiment shown in the drawings, five field outputs are provided employing open collector transistors.

The operational amplifier for analog data input from the scanner is controlled using a gain/offset control 50, also addressed by the ADDRESS BUS. Data transmission to the memories, latches and control circuits is provided employing a DATA BUS.

The present invention operates in a synchronized or free-scan mode for flexibility in adapting to the requirements of a monitored process. For processes in which the bar code labels being scanned appear at a synchronized time, inputs for analog (SYNCA) or digital (SYNCB) signals are provided. Analog synchronization signals are received by an optical isolator 52 and pass through a 120 Hz filter 54 to or gate 56, which provides the SYNC.sub.-- IN signal for use by the microcomputer. Digital synchronization inputs are provided directly through the or gate.

External communication with a host processor or other control system for the process is provided through a standard communications channel. In the embodiment shown in the drawings, a bi-directional serial port employing a standard RS 232 interface 58 is employed.

A basic system flow for software employed in the microprocessor of the invention is shown in FIG. 3. A subroutine for pattern setup 60 allows definition of the symbology employed by the bar codes in the monitored process. The present embodiment employs decoding capability for code 39, CODABAR, interleaved 2 of 5, UPC/EAN including two- and five-digit addenda, Code 128 and Code 93 symbologies. Definition of the pattern is accomplished through direct operator input using the four key interface prompted via menus on the LCD. The embodiment of the invention disclosed in the drawings provides for defining a pattern of up to six scan lines with up to four symbols across each scan line. A total of ten symbols is allowed in the pattern of the present embodiment due to memory and processing limitations. Those skilled in the art will recognize that other combinations of the number scan lines and symbols may be employed.

Each scan line is defined through an input format displayed on the LCD in the form

In this format, the "L #" refers to the particular scan line number, while the "Z Z Z" fields represent the possible four symbols available for the scan line. Exemplary symbol abbreviations for use in the "Z" fields in this format for entry on the keypad are shown in Table 1. Additional definition of subsymbology is accomplished using key inputs on the "Z" field subsequent to input of the symbol abbreviations. Exemplary subsymbology abbreviations are also shown in Table 1. The "Y" field in the format described provides an alpha numeric description of the field indicated by the symbol field selected.

Analysis parameters, which will be discussed in greater detail subsequently, may also be defined by the operator through the key pad/menu display interface. Both pattern setup and analysis parameters are alternately communicated to the invention directly from a host processor using the bi-directional communication interface.

The bidirectional communication interface is established in the subroutine real time output configuration 64, as will be described in greater detail subsequently. Similarly, control of the field outputs is accomplished in a subroutine for output port configuration 62. The five separate field outputs are individually controllable to provide user programmable response to various scanning conditions. For example, failure of a bar code verification step can be programmed to result in a signal on one field output to pause a printer system in response the failure. Similarly, for process control, field outputs can be employed to activate alarms or other communication signals for notifying operators of a verification failure and/or provide real time control of the process to suspend processing or re-route items with failed bar codes.

The external synchronization is managed by the microcomputer through a subroutine synch input 66 and interface with the scanner is accomplished through subroutine scanner data 68.

Control of the scanner and processing of received data is accomplished through a plurality of subroutines, which will be described in greater detail subsequently, generally identified in FIG. 3 as pattern match 70. Downstream functions handled by the microprocessor include bar code analysis 72, which is accomplished in present embodiments using standard ANSI decodability grades A, B, C, D and F and ANSI reference decode calculations, as well as traditional parameters for encodation check, mod check, average bar width deviation, quiet zone, intercharacter gap (ICG), addendum parity (UPC/EAN) and wide-to-narrow ratio evaluation.

Capability of the present invention to provide direct communication with a host processor, as well as direct operator input, allows character validation for the bar codes, as well as bar code verification. Character representations for the bar code being printed or present on marked articles in other monitored processes is either entered manually by an operator using menu directed input or downloaded from the host processor and stored in RAM for access by the microcomputer during bar code analysis.

Outputs to the field outputs resulting from bar code analysis are accomplished through subroutines output port control 74, as defined by parameters established in the output port configuration subroutine. Similarly, real time output subroutines 76 control communication to the host based on the real time output configuration previously established.

Data from scanned patterns is stored by the scan history buffer routines 78 for scan comparison and bar code analysis, as will be described in greater detail subsequently.

As previously described, the present invention allows operation in either synchronized or free-scan modes for bar code detection, verification and validation. The free-scan mode allows operation of the invention in monitoring a process in which appearance of bar codes to be scanned does not occur in a rigidly timed sequence and/or a sync signal is not available. An embodiment of the present invention for this mode is shown in FIGS. 4a-d. Upon entering the free-scan subroutine at block 80, the microcomputer directs a scan 82 by enabling the scanner, as previously described. The scanner provides a start of scan signal for timing purposes, followed by digital data and/or analog data comprising the scan information, which is then decoded at block 84.

As a means for increasing data throughput in the invention, a text recognizer is incorporated in the decode routine for the present invention. Identification of scanned elements having a 5X or larger dimension quickly isolates non-bar code patterns. This type of pattern is typically associated with text, which may be printed on a label adjacent a bar code within the scan path. Prescreening of such greater than 5X elements with decoding significantly increases computation efficiency.

A determination is made if the decoded scan matches any scan line in block 86. If no scan line is matched, the program transitions to subroutine FREE.sub.-- SCAN2 block 88, which is further depicted in FIG. 4d.

In the free-scan mode, a background timer can be employed by the microcomputer to establish a maximum time during the monitored process at which a bar code should appear for scanning. If the background timer is enabled at block 89, the microcomputer determines if the timer has reached the set limit at block 90. If the time limit has been reached, the timer is reinitialized at block 91 and a "no read status" is set at block 92 by the microcomputer. Dependent on the output port configuration and real time output configurations established in the software, a no read status can result in a real time output or communication to the host processor indicating a process failure. If the background timer is not enabled, or the timer has not reached its limit, the program reenters the free-scan routine at block 80. Disabling of the background timer is also useful in cases where symbols being analyzed may be passing the scanner at a rate higher than can be 100% analyzed. The symbols will then be "spot checked" at the fastest rate of analysis. A "no read condition" does not exist for the invention operating in this fashion.

If, upon decoding a scan line, a match is found with any scan line in the pattern in block 86, a determination is made if the match is with the current scan line in block 93. If the match is with the current scan line, a determination is made if the maximum number of scans has been completed for this scan line in block 94.

Definition of a maximum number of scans for evaluation of each scan line provides flexibility for the invention to accommodate differing processing speeds for the symbols or labels being evaluated by the invention. In the present embodiment, the MAXSCANs parameter may be set for values from 1 to 10. When the programmed number of scans are analyzed, the system then assumes that the next successful decode will be on the next symbol or scan line in the pattern.

The setting of maximum number of scans for a scan line, the maximum scans value is calculated to be the most times the scan line can be scanned knowing the speed at which the labels or symbols will pass the scanner, the bar code height, the number of symbols in the scan line, and the symbol analysis calculation time. A setting of 10 on the MAXSCANs parameter provides the maximum advantage of multiple scan averaging for analysis of symbology parameters, while a setting of 1 allows maximum throughput speed for the processed symbols or labels. The MAXSCANs parameter also allows precise control of the number of scans to facilitate flexible orientation of the scanner 1b to read "ladder" or "picket fence" oriented bar codes, as shown in FIGS. 1b and 1c, at the process flow rate.

If the check in block 94 shows the maximum number of scans has been completed, the scan counter is reinitialized at block 96, the data from the scan line is analyzed based on the parameters and symbologies previously established in block 98, averaged with the previous analysis for the scan line at block 100, and the results are placed in the proper scan history buffer in block 102. The analysis conducted in the invention provides standard evaluation of bar code symbols for the various symbologies accommodated by the invention. Table 2 defines the parameters checked for each symbology.

Additional analysis is provided in the invention by defining the number of characters per symbol and/or defining specific data content for the programmed scan lines with a data match mode.

The number of characters per symbol is entered during definition of the pattern, as previously described, and allows definition of 4 through 32 characters. Recognition of the number of characters provides additional data security in the analysis over mere evaluation of the parameters of the symbology.

Similarly, defining a complete data match for symbols in a scan line provides maximum security for the analysis. A data match of the encoded data assures the integrity of the label or bar code sensed by the invention. In the embodiment shown in the drawings, entry of the data to be matched is accomplished by scanning of a data target in response to a prompt on the LCD during the pattern setup previously described.

In the embodiment of the invention described herein, analysis is conducted as a background computing function. Higher security levels enabled by defining the number of characters per symbol and/or data matching allows maximum scan speed by avoiding filtering of the scan data required for standard symbology analysis. Stacking of decoded scan data in RAM 40 allows decoupling of the scan operation and analysis routines described, thereby allowing maximum throughput for the system. Effective scan rate and system throughput for the scanned process/printer output is dependent on total analysis time.

Subroutine SETSTAT2 is then entered at block 104 and all status and variables for real time output from the system are established in block 106, resulting in real time output on the field outputs and/or communication to the host processor.

The status parameters provided for real time output based on the analysis are identified in Table 3.

Activation of the field outputs of the invention based on the analysis results is accomplished responsive to the analysis parameters. The setup subroutine for real time output configuration 64, previously described, allows designation of one or more analysis parameter failures from Table 3 to activate the associated field output. Additional limitations for activation of the field output are selectable to require a number of accumulated failures or consecutive failures to occur prior to activation of the port. The form of signal provided on the field output is also defined. The present embodiment provides four port durations, including per scan, per scan pulse, latch, and latch pulse. The per scan duration updates the output of each port after each scan that decodes a valid scan line. For example, if a port activation has occurred and the next analysis produces results that would not activate the port, the field output will go to the inactive state. The latch mode continues to hold the output port in the active state after an activating occurrence until reset. The per scan pulse mode or latch pulse mode will hold the output in the active state for a length of time specified.

Real time output via communication to the host is similarly defined in the subroutine real time output configuration 64, as previously described, to accommodate the formats shown in Table 4.

Status outputs to the host are defined based on the analysis parameters of Table 3. Standard framing and communications protocols are employed for the transmission.

Return from the subroutine SETSTAT2 is accomplished at block 108 and the microcomputer negates the current scan line active status at block 110. The program then transitions to the FREE.sub.-- SCAN2 routine, which has been previously described.

If the maximum number of scans has not been completed for the present scan line in block 94, the scan data is analyzed in block 112, averaged with the previous analysis for this scan line in block 114, with the results placed in the proper scan history buffer in block 116, and the program transitions to FREE.sub.-- SCAN2.

If a decoded scan does not match the current scan line in block 92, the program transitions to the new pattern subroutine NEW.sub.-- PAT in block 118. The new pattern subroutine is disclosed in FIG. 4c.

If a new pattern is detected, a determination is made if analysis is pending of the pattern with the maximum number of scans not complete in block 120. If the maximum number of scans is not complete, subroutine SETSTAT2, previously described, is entered. Upon return from SETSTAT2 or if the maximum number of scans is not complete, a high security pointer is created for the new pattern scan line in block 122 and the scan line match flag is set in block 124. The pattern data is then analyzed in block 126 as previously described. Data is stored in the proper scan history buffer in block 128 and a determination is made if all scan lines in the pattern have been matched, block 130. If affirmative, the flags and variables for the scan line are reinitialized in block 132. If the scan lines in the pattern are not matched, or upon reinitialization of the flags and variables, a determination is made if maximum number of scans set at 1 in block 134. If not, subroutine FREE.sub.-- SCAN2 is executed for a no read status check, as previously described. If the maximum number of scans is set at 1 in block 134, subroutine SETSTAT2 is again executed and any current scan line active status is negated in block 136, prior to executing subroutine FREE.sub.-- SCAN2.

The final leg of the free-scan subroutine is accomplished if no decode is accomplished in block 84. A RE.sub.-- TRY subroutine is executed in block 138. A determination is made if the RE.sub.-- TRY subroutine has been executed in block 140 and, if not, the FREE.sub.-- SCAN2 subroutine is entered. If the RE.sub.-- TRY subroutine has been executed, a determination is made if the pending analysis is waiting for the maximum number of scans in block 142. If not, subroutine FREE.sub.-- SCAN2 is entered. If the analysis is waiting for MAXSCANs, the RE.sub.-- TRY counter is reinitialized in block 144 and the subroutine SETSTAT2 is executed. Upon return, the current scan line active status is negated in block 110 and subroutine FREE.sub.-- SCAN2 is executed.

As previously described, the free-scan mode allows the present invention to be employed in monitoring bar codes for processes without uniquely timed bar code arrival. The present invention is also employed for systems wherein bar code arrival at the scanner is predictably timed and a synchronizing signal from an external source is available.

FIGS. 5a-c provide a flow diagram for operation of one embodiment of the present invention for synchronized scanning. Triggered by a synch signal from OR gate 56, the microcomputer initiates the routine SYNC.sub.-- IN in block 150. A determination is made if all scan lines have been filled since the previous synch signal was received block 152. If all scan lines had been filled previous to the prior SYNC.sub.-- IN, flags and variables for the synch input are set in block 164. A scan is executed, as previously described, in block 166 and a determination made if the scan can be decoded in block 168. If no decode was present, a scan is reexecuted. If a decode was possible, a determination is made in block 170 if a match with any scan line is present. If no match is present, an additional scan is conducted. If a match is present, the data is analyzed in block 172, as previously described. A determination is then made if MAXSCANs has been set at 1 in block 174 and, if not, the variables for the present scan line are set in block 176. The analysis is stored in the scan history buffer in block 178 and subroutine SCAN2 block 180 is executed.

If MAXSCAN was set to 1 in block 174, the analysis is stored in proper scan history buffer in block 182 and subroutine MUSTSET is executed. Active status for the present scan line is then negated in block 184 and subroutine SCAN2 is executed.

The SCAN2 subroutine is shown in FIG. 5c. A scan is accomplished at block 186 and a determination made if the scan can be decoded at block 188. If the scan cannot be decoded, a determination is made if a retry has just been accomplished, block 190 and, if not, an additional scan is made. If a retry has been accomplished, a determination is made if any active scan line is present, block 192, and, if not, an additional scan is attempted. If an active scan line is present, subroutine MUSTSET is executed and the active status for the present scan line is negated by entering at block 194 on FIG. 5a.

If no analysis was remaining, a NO READ status is set in block 162.

If a successful decode was accomplished in block 188, the retry counter is reinitialized in block 196 and a determination is made if the scan line matches any current scan line block 198. If no current scan line match is made, it is determined if MAXSCANs equal 1, block 200. If not, a determination is made if any active scan line is present, block 202 and if so, subroutine MUSTSET is accomplished. Upon return from subroutine MUSTSET or, if no active scan line was present in block 202, a determination is made if a match with any scan line not yet scanned is present, block 204. If not, a scan is accomplished, block 206, and a decode attempted, block 208. If a decode is successful, the determination of block 204 is again attempted and if the decode is not successful, the scan is reattempted in block 206. If a match with any scan line not yet scanned is accomplished in block 204, analysis is accomplished by entering at point A1.

If a match was accomplished with the current scan line in block 198, a determination is made if the maximum number of scans is at the limit, block 210. If not, the decoded scan line is analyzed, block 212, and averaged with previous analysis for the scan line, block 214. The analysis is then stored in the proper buffer by reentry into FIG. 5a at STORE.sub.-- SP block 216. If the determination was made in block 210 that maximum number of scans is at the limit, the decoded scan is analyzed, block 218, and the results are averaged with previous analysis for the scan line, block 220, results are placed in the proper scan history buffer, block 222, and subroutine MUSTSET is executed prior to negating the active status for the scan line by entering block 194 of the FIG. 5a.

If all scan lines have not been filled in the check at block 152, a determination is made if any analysis has not been completed without the maximum number of scans, block 154. If analysis is indeterminate, a subroutine MUSTSET block 156 is executed. The MUSTSET subroutine is demonstrated in FIG. 5b. A "fill" flag is set for the present scan line in block 158 identifying that element of the patter has been identified and all status and variables are defined for real time output in block 160.

Scanning of bar codes on a synchronized basis, as described, provides high accuracy in timing of the scans to assure proper performance of the scanner in the invention, thereby precluding errors in scanning from appearing as bar code verification or validation errors. In addition, specific identification of a "NO READ status" may be made if a bar code does not appear during the synchronized scan time.

The flexibility of the present invention allows application to numerous bar code production systems wherein verification and/or validation of the data in the bar codes is critical. For example, multi-pass ribbon systems and ribbon saving devices on many bar code printing systems may ultimately result in degradation of the bar codes produced. Consequently, verification of the bar codes printed by such systems on a real time basis is desirable. The present invention provides added capability through the programmable field outputs, which can be easily interfaced to multiple bar code production or usage systems, including allowing activation of alarms to notify operators of the requirement for ribbon changes or unacceptable degradation of the product in multi-pass ribbon systems or malfunctioning of ribbon saving devices, resulting in degraded bar code output. In sophisticated applications of the present system, additional control signals from the field outputs can be applied to switch ribbons or adjust ribbon saving devices to achieve a verifiable product output. ##SPC1##

Having now described the invention as required by the patent statutes, those skilled in the art will recognize modifications and substitutions for the elements and steps of the invention required for specific applications. Such modifications and revisions are within the scope and intent of the present invention as defined in the following claims.