Abstract:
An automated system for the processing of radio frequency identification (RFID) tags. The automated system allows for the simultaneous processing of multiple individual tags through the use of multiple processing stations. A table is provided that is capable of moving the individual tags from one processing station to the next. Tables are also provided for receiving unprocessed tags for input into the system and processed tags for packaging. Individual tags are moved between the tables by a transfer mechanism.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a system and method for manufacturing radio frequency identification (RFID) tags. The present invention also relates to a system and method for high throughput quality control testing of RFID tags. 
     BACKGROUND OF THE INVENTION 
     Radio frequency identification (RFID) tags have a wide variety of applications, especially in the transportation field. RFID tags have a variety of uses, including toll collection, security access, parking, and vehicle tracking. First generation RFID tags, such as described in U.S. patent application Ser. No. 10/246,456, were typically encased in a hard plastic, making them bulky and expensive to manufacture. Label-based RFID tags, such as described in U.S. patent application Ser. No. 11/349,093, were developed to overcome the physical limitations of the hard cased tags. Label-based tags are thin, flexible and may be assembled in sheets, making them easier and less expensive to manufacture. However, for proper testing of label-based tags, the tags need to be separated for individual testing of their radio frequency (RF) response using large anechoic chambers. Testing of label-based tags in this manner requires significant time and precludes high-volume production. 
     Various systems have been derived for testing or producing tags, such as those shown in U.S. Pat. No. 6,487,681 to Tuttle et al., U.S. Pat. No. 6,951,596 to Green et al. and U.S. Pat. No. 6,104,291 to Beauvillier et al. However, there is a need in the art for a high-throughput method for the testing and production of individual RFID tags. It is further a need in the art to have a testing and production system that is as automated as possible, to reduce production time and manufacturing costs, yet is highly reliable and efficient. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a high-volume system and method for manufacturing RFID tags. The system and method of the present invention allow for automated testing, programming, labeling, sorting and packaging of RFID tags with minimal operator intervention. The tags are tested to assure that they meet specifications for use in free space or when mounted (typically on a windshield) on a vehicle. Tags that are non-operational or substandard are eliminated from use. The tested tags are automatically packed in groups for shipment. A computer based audit system provides data on the tags that have been packed. 
     The present invention is the next generation design for the production of label-based RFID tags. The system of the invention incorporates advanced RF resonant cavity technology to greatly reduce the footprint and space requirements of the testing equipment. Previous apparatuses for testing RFID tags have been constrained by the large size of the anechoic RF chambers used for RF testing of tags. The use of RF resonant cavities allows for a more compact RFID tag testing apparatus. 
     The present invention allows for high-volume processing of tags through its multiple station design. The tags in the system undergo multiple tests as they move sequentially from one station to the next, allowing for parallel testing and processing of multiple tags. As many tags are able to be processed at once, the cycle time of production is greatly reduced. 
     The present invention is designed for efficient operator use by placing the load and unload ports and the control console so as to minimize the travel required by the operator. Once a tag enters the system, no operator intervention is required unless the operator is alerted to a problem in the system. Because of the design of the present invention, the operator may easily and efficiently input more unprocessed tags into the system, while removing processed and packaged tags and monitoring the system for any incidents. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A  and B are overview diagrams of an embodiment of the RFID tag processing system of the present invention. 
         FIG. 2  is diagram of a typical RFID tag as produced by the system of the present invention. 
         FIG. 3  is a system diagram showing the processing steps for producing RFID tags. 
         FIG. 4  is a detailed perspective view of an embodiment of one of the input tables used the RFID tag processing system of  FIG. 1 . 
         FIG. 5A  is a detailed perspective view of the pick and place transfer mechanism used in the RFID tag processing system of  FIG. 1 . 
         FIG. 5B  is a detailed perspective view of the carriage mechanism shown in  FIG. 5A . 
         FIG. 5C  is a schematic showing the operation of the pick place transfer mechanism of  FIG. 5A . 
         FIG. 6  is a detailed view of a nest of the main table. 
         FIG. 7  is a detailed view of the main table used in the RFID tag processing system of  FIG. 1 . 
         FIGS. 8A  and B are diagrams of preferred resonant cavities for use with the present invention. 
         FIG. 9  is a detailed view of an RF testing station used in the RFID tag processing system of  FIG. 1 . 
         FIGS. 10A-C  are detailed views of the label applicator used in the RFID tag processing system of  FIG. 1 . 
         FIG. 11  is a detailed view of the machine vision apparatus used in the RFID tag processing system of  FIG. 1 . 
         FIG. 12  is a detailed view of the output transfer mechanism used in the system of  FIG. 1 . 
         FIG. 13  is a detailed view of the output table used in the RFID tag processing system of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIGS. 1A  and B are overall diagrams of the tag production apparatus  3  in accordance with the preferred embodiment of the present invention. The apparatus  3  includes a tag processing system  10 , mounted to a bench  5  and surrounded by an enclosure  9 . The tag processing system  10  essentially has an input table  12 , main table  14 , output table  16 , and transfer devices  41 ,  127 . 
     In general operation of the system  10 , label-based tags  20  are loaded on the input table  12  ( FIG. 4 ). Transfer device  40  ( FIG. 5 ) is used to transfer the tags  20  to the main table  14  ( FIG. 6 ), where they are tested, programmed and labeled at various automated work stations  52 - 66  that are positioned about the table  14 . After the tags are processed, they are transferred by another transfer device  41  to the output table  16 , where they are packaged into labeled boxes  18 , for shipping. The operation of the entire system  10  is monitored and controlled by a master controller  1012 , located in the base  5  of the system  10 , which the operator can communicate with through an interface terminal  19 . 
     The system and method of the present invention are designed for the high throughput production of label-based RFID tags. Examples of label-based tags include the eGo and SeGo tags sold by Transcore, Ltd. and as described in U.S. patent application Ser. No. 11/349,093. A non-limiting example of a label-based tag  20  that may be produced by the present invention is shown in  FIG. 2 . The RFID tag  20  shown in  FIG. 2  is an example of a tag that has been tested and labeled according to the present invention. The tag has an application specific integrated circuit (ASIC)  22  (which, may include, for instance, a processor and memory), and an optional barcode  25  which may be added when the tag  20  is labeled. Optional customer graphics and printed information may also be added when the tag  20  is labeled. The tag  20  preferably has one chamfered corner  28  to allow for orientation of the tag  20 . 
       FIG. 3  is a system diagram giving an overview of the production of label-based RFID tags using the system  10  of the present invention. After an order for tags is received, pre-assembled panels of blank label-based RFID tags  1002  are obtained for further processing. The tags  20  in the panels have been pre-assembled with an ASIC  22  and have a pre-cut chamfer so that they each have a chamfered corner  28  upon removal from the panel. The tags  20  may be pre-assembled in panels of 60 tags arranged in a 5 by 12 array, although different panel configurations can be used. 
     A production database  1008  is provided that stores information to be written to the tags  20  and specifications for the testing and labeling of the tags  20 . That information is obtained by the order processing computer  1006  from sales orders  1004  and stored to the production database  1008 . The production database  1008  is a centrally located database in the production facility that communicates with the work stations  52 - 66  and with the master controller  1012  of all of the automated tag processing systems  10  in the production facility. After customer specifications are written to the production database  1008 , it becomes the central information center for all data regarding production and testing of tags  20 . 
     The production facility also has one or more sample tester computers  1036  for testing finished tag  20  samples taken after production. Those finished tag samples undergo individual testing using established protocols and equipment such as anechoic chambers. The sample tester receives the test parameters from the production database  1008  and use these parameters to establish general quality control tests. After each sample is tested, the sample tester computer  1036  provides test result data to the production database  1008 , allowing for real time quality control monitoring. 
     The production database  1008  provides customer specifications and quality control data to the master controller  1012 . As the tags  20  being processed undergo the various tests of the system  10 , the master controller  1012  records the results of each individual tag  20  in the production database  1008 . Based on information from the database  1008 , the master controller  1012  controls how the tags are programmed, tested, and labeled at the various work stations  52 - 66 . The master controller  1012  also controls whether a tag should be removed from the system as failures or as a sample. The master controller  1012  controls the overall processing operation, such as rotation of the tables, operation of the transfer mechanisms, etc. The master controller  1012  communicates these instructions through the automation controller  1038 , which communicates directly with the various components of the system regarding the action required for the specific tag  20  being processed. 
     The preferred embodiments of the automated system and method for producing RFID tags will now be described. Steps in the automated process will be referred to by the reference numbers shown in  FIG. 3 . Other components of the system of the invention and other steps of the method of the invention are also contemplated. For instance, the order of the components of the system of the invention may be changed, and hence the steps of the method may also be changed, without departing from the spirit or scope of the invention as set forth herein. 
     The first step  1016  of the process is to separate the panels of tags into individual tags, preferably manually, and load the tags  20  onto the input table  12 , which is shown in  FIG. 4 . The input table  12  generally includes a number of bins  32 , for loading the tags. The preassembled RFID tags  20  are loaded into the bins  32  on the input table  12 . The tags  20  are preferably stacked  30  so that each tag is turned 180 degrees from the tag just below it in the stack. This allows for more even stacking and allows for more tags to be stacked per bin. In addition, the staggered stacking prevents the tags from sticking to one another, so that a single tag is removed when a tag is to be retrieved from the bin  32 . Staggering the tags also causes the surfaces of the tags to remain horizontally level, allowing them to be easily picked up by the transfer device  40 . Alternated stacking is especially preferred when the tags have a non-uniform thickness, such as when the ASIC  22  protrudes from one or both sides of the tag. 
     The bins  32  have two elongated projections  31  extending along opposite sides of its base. The projections  31  mate with corresponding slots  34  in the top surface  36  of the input table  12 . Accordingly, the bins  32  can be quickly removed and replaced for filling with tags  20 , but are also firmly secured to the table surface  36 . An opening  35  is positioned beneath each of the bins  32 . This opening  35  corresponds to an opening in the bottom of each bin (not visible), which allows a sensor  37 , to detect whether the bin  32  contains any tags  20 . Preferably, the sensor  37  detecting whether or not the bin is empty is placed below the bin of tags being transferred to the main table  14 . It is also contemplated that one or more sensors in other locations may be employed. The bins  32  are specifically sized to the size of tags  20  being processed. 
     The top surface  36  of the input table  12  is interchangeable, allowing for differently size bins  32  to accommodate differently sized tags. One or more thumbscrews  38  affix the top surface  36  to the base  33 , making it possible to change the top surface  36  without the use of tools. Preferably, the input table  12  can accommodate 10 bins  32 , with each bin capable of holding about 60 tags. Alternatively, bins of different sizes can all have a standard size base that is received by the table  12 , so that the top surface  36  need not be interchanged to accommodate various sizes of tags  20 . 
     The input table  12  is preferably circular in shape so as to allow for the easy rotation of the bins  32  from one position to the next. A drive  39 , rotates the input table  12  to various positions that allow the tags  20  to be accessed by the system  10 . The drive  39 , is preferably a motor which is controlled by the automation controller  1038 . The input table  12  is rotated so that each bin  32  of tags  20  to be processed is successively moved into the proper position to be loaded and transported to the main table  14 . When the bin  32  being drawn from becomes empty, this is detected by the sensor  37  which signals to the automation controller  1038  to rotate the input table  12 , bringing the next bin  32  into position and eventually bringing the empty bin  32  back around to a location where the operator can refill it. 
     It is also contemplated that the input table  12  may be a table capable of containing boxes filled with individual tags. In this alternate embodiment, the design of the input table  12  is very similar to that of the output table  16 , which is shown in  FIG. 13 . With this embodiment of the invention, boxes may be received containing stacks of individual tags that are placed directly onto the input table  12 , eliminating the need to separate the tags from panels and stack them into bins for processing. 
     Turning to  FIG. 5A , a transfer device  40  is used to individually transfer the tags  20  from the input table  12  to the main table  14 . The transfer mechanism of  FIG. 5  is preferably a pick and place mechanism that includes a carriage mechanism  41  which is mounted to an arm  42  by the cable track brackets  43 . The movement of the carriage  41  along the arm  42  is powered by a power source  113 . The arm  42  is mounted to the top surface  7  by a bracket  47 . As the carriage  41  moves along the arm  42 , it passes over a visual orientation camera  46 . The visual orientation camera  46  is protected by a glass shield  101  held by a mount  103 . A light source  105  illuminates the tag as it is transported over the visual orientation camera  46 . The carriage then passes over a fail bin  48 , sitting on a bin holder  107  which is mounted to the top surface  7  by the bin holder mount  109 . A stop bracket  111 , stops the carriage  41  at the proper point for delivering the tag  20  to the main table  14 . In one embodiment of the invention, the bracket  111  may hit a push switch on the carriage  41  to stop its motion. 
     A close up view of the carriage mechanism  41  is shown in  FIG. 5B . The carriage  41  is mounted to the cable track bracket  43  by a mount  45 . The carriage  41  has a pair of vacuum suction cups  44 , that enable it to pick up a single tag to be transferred. The suction cups  44  are attached to a suction cup bracket  51  containing a sensor plate  53  which detects whether or not a tag  20  has been picked up. 
       FIG. 5C  is a schematic diagramming how the tag is transferred. At the position marked I in  FIG. 5C , the suction cup bracket  51  descends into the bin  32  until the suction cups  44  contact a tag  20 . A vacuum is applied to the suction cups  44  to pick up one tag  20 . The suction cup bracket  51  is then raised from the bin  32  and the carriage  41  moves along the arm  42  towards the main table  14  as shown in  FIGS. 1 and 5 . Preferably, the arm  42  is kept stationary and only the carriage  41  moves in order to deliver the tag  20 . The motion of the carriage  41  is controlled by the automation controller  1038 . The motion of the carriage is stopped if the bin  32  is sensed to be empty or if the security features of the system are activated. 
     As the tag is transported, its orientation  1018  is verified and, if necessary, corrected. Here, the carriage passes over a machine vision camera  46 , as shown in position II of  FIG. 5C . While the tag  20  is illuminated by the light source  105 , the camera  46  determines its orientation by detecting the position of its chamfered corner  28 . If the tag  20  is not correctly orientated, the sensor plate  53  rotates with respect to the carriage  41  until the tag  20  is in the proper position. If the tag  20  is upside down, or if its orientation cannot be determined, the tag  20  is dropped into the fail bin  48  and another tag is retrieved for processing. As shown in position III of  FIG. 5C , once the tag is determined to be properly oriented, it is carried to the main table  14 , where the suction cups lower it into a nest  50  at the first station of the main table  14 . The tag  20  is released into the nest  50  by releasing the vacuum at the suction cups  44 . 
       FIGS. 6A  and B are respectively a top view and a cross-section view of a nest  50  of the main table  14 . A nest  50  consists primarily of a tag recess  61  surrounded by a frame  63 . It is preferred that the frame be made of an acetal resin polymer such as Delrin® (DuPont Corp.), although other polymers are also contemplated. The frame  63  is held to the main table by a series of screws  69 . The bottom surface  71  of the tag recess is preferably a glass plate to simulate the windshield on which the tag  20  will eventually be mounted. It is also contemplated that the bottom surface  71  may be made up of plexiglass or similar material. As shown, the tag  20 , sits within the recess  61 . Having the tag  20  within a recess  61  prevents its accidental movement and allows it to remain correctly aligned with the various workstations  52 - 66 . It is also contemplated that various other shapes for the nest  50  and the recess  61  can be used, such as a recess  61  without rounded corners. 
     As shown in  FIG. 7 , the main table  14  has eight stations, though it is contemplated that the main table may have more or fewer stations as proper testing requires. The eight stations include: Input station  52 , RF Sensitivity test station  54 , Phase-lock loop test station  56 , Programming/locking station  58  (not shown in  FIG. 6 ), Labeling station  60 , Machine vision station  62 , RF verification station  64 , and an Output station  66 . The main table  14  is preferably circular in shape and rotated by a drive  115  that is controlled by the automation controller  1038 . The main table  14  is mounted to the top surface  7  through a series of brackets  117 . The automated controller  1038  causes the drive  115  to turn the table so that a new tag  20  is moved to the next station for further processing. 
     Stations  54 ,  56 ,  58  and  64  involve RF testing of the tags  20 . Accordingly, those stations are provided with an aluminum RF resonant cavity  68 , which is shown in  FIGS. 8A and 8B . The resonant cavities  68  are small and eliminate the need for a large anechoic chambers, allowing for the compact size of the invention. The resonant cavities  68  do not require an RF shielded enclosure as they focus the RF energy only to the area around the opening. It is preferred that a cylindrical resonant cavity be used in the RF stations of the invention as the cylindrical shape allows for the emulation of a far-field measurement. It is also contemplated that resonant cavities of varying sizes may be used. The cavity is preferably manufactured by Electrodynamics (New Mexico). 
     The resonant cavity  68  at each station is tuned to a predetermined frequency. Preferably, the RF stations  54 ,  56 ,  58  and  64  are tuned so that testing will occur with at least three different frequencies during the processing of the tag  20 . For example, the stations may be tuned so that station  54  is tuned to a first frequency, stations  56  and  58  are tuned to a second frequency and station  64  is tuned to a third frequency. The tag is tested at several different frequencies in its operating frequency range to assure that it will be operational throughout that range. A frequency range of 902 to 928 MHz is preferred, although other frequency ranges used with RFID tags are contemplated. 
     An exemplary diagram of an RF testing station is shown in  FIG. 9 . One tag is tested at a time at each RF test station by simulating a far field measurement corresponding to the resonant cavity technique. A solenoid  70  is attached to an extending arm  72  which is mounted to a support bracket  74 . The resonant cavity  68  is mounted to the support bracket by a brace  119 . As the table indexes, the tag  20  to be tested, located in a nest  50  on the table, moves underneath the solenoid  70 . The extending arm descends the RF interrogator  70  into the nest  50 , placing the RF testing station in the testing position. A foam pad at the bottom of the solenoid presses the tag  20  against the bottom surface  71  of the nest  50 . The tag  20  is pressed against the bottom surface  71  as it will not function unless pressed against a surface, simulating its application to a windshield of a vehicle. An ionizer  121 , may also be present to counteract any electrostatic discharge generated by the tag and the mechanical movements of the apparatus. After the necessary RF tests are performed, the station returns to the position shown in  FIG. 9 , allowing the main table  14  to index the tested tag  20  to a new station. 
     An RF signal is conductively transmitted into the resonant cavity  68  by a coaxial cable which attaches to port  123  as shown in  FIG. 8 . A magnetic field propagates horizontally around the cavity while an electric field propagates vertically thru the cavity. There are RF readers located underneath the main table  14  in the base of the system that send read/write commands for the testing and programming of the tag. The RF readers are controlled by the master controller  1012 . 
     The various RF stations of the invention are calibrated against control tags. A set of pre-assembled tags to be used with the present invention may be measured in an anechoic chamber to simulate free-space performance. Tags with the desired performance characteristics are then chosen and designated as control tags. These test or “golden” tags are then used to calibrate all of the RF test stations in the automated tag tester  10 . 
     The transfer mechanism  40  delivers the tag  20  from the input table  12  to the nest  50  of the first station, input station  52 . After the tag is received by the main table  14  at the input station  52 , the table then indexes, so that the tag  20  proceeds to the RF sensitivity test station  54 . For the sensitivity test step  1020  of  FIG. 3 , the tag  20  is pressed against a glass plate or other substrate to simulate the environment in which the tag  20  will be used, i.e., a windshield. The stored tag ID is read and sent to the master controller  1012 , where it is verified against the historical information stored in the production database  1008  using a high power read command. The tag  20  is read and written to using commands sent by the master controller  1012 . 
     All tags are identified and tracked by the system through their ID. Any tags that are detected as having “no ID” or those with an ID that is a duplicate of another tag, will fail and will proceed through the remaining stations  56 ,  58 ,  60 ,  62  and  64  without further testing and is subsequently discarded. A step attenuation sensitivity test may also be performed. 
     The RF sensitivity test station  54  measures the ability to be able to read data in the tag and write data to the tag to configure tag operation. The manufactured tags have data written to them during manufacturing to allow for a data sensitivity measurement to be taken. The testing entails several steps of external power attenuation for measuring tag performance. A variable linear attenuator (VLA) may be used to excite the tag with a specific power level. The resolution of the station is preferably about 0.5 dB or better and most preferably is about 0.1 dB. If the tag passes the battery of tests at the sensitivity test station  54 , it is pre-configured to customer specifications to prepare it for the final programming, step  1024  of  FIG. 3 , of tag specific information. 
     Once the RF sensitivity testing is complete, the tag  20  then moves to the phase-locked loop (PLL) testing station  56 , step  1022  of  FIG. 3 . As the resonant cavity  68  for the PLL testing station  56  is tuned to a different frequency than the resonant cavity at the RF sensitivity station  54 , another stepped attenuation sensitivity test may be performed. PLL testing  1022  may be performed by first reading the tag at 3 db above the ATA sensitivity, measuring the Interrupt Frequency and converting this reading to the Oscillator Frequency. The proper correction factor for this value will be calculated and the Oscillator Control Byte will be written to a pre-determined byte on the tag  20 . 
     The PLL may then be read and tested to see if it passes or fails the necessary requirements. For example, the tag will be read at ATA wakeup and ATA wakeup +15 db. The calculated frequency difference between the two reads will be calculated and compared to a predetermined level to assign the tag a pass or fail rating. The tag might be assigned a pass rating if the difference between the ATA wakeup and the ATA wakeup +15 db frequencies is less than about 4-5 KHz. It is contemplated that the PLL may also be tested at other values, such as by comparing the frequency difference between readings at ATA wakeup +4 db and ATA wakeup +15 db. It is also contemplated that other PLL tests may be used at the PLL testing station, comparing other frequency differences. 
     The tag  20  then indexes to the programming and locking station  58 , step  1024  of  FIG. 3 . As the resonant cavity  68  at this station is tuned to a different frequency than the previous resonant cavities, a stepped attenuation sensitivity test may be performed at this station without interference from the resonant cavities  68  at the other stations. All of the tag specific data to be stored in the ASIC is transferred to the tag  20  from the database  1008  via the master controller  1012  and verified at the programming station  58 . An RF reader is used at this station to confirm that the data written to the tag matches that in the database  1008 . The RF reader is then used to set data locks according to customer specifications. Once the data locks have been set, the tag data may only be unlocked using an specific RF key provided to the customer. 
     The tag  20  then indexes to the labeling station  60 , step  1026  of  FIG. 3 . An applicator is used at this station to meet the requirements for quality, reliability, flexibility and durability of the tag labels. A preferred embodiment of the applicator mechanism  76  is shown in  FIGS. 10A and 10B . The applicator mechanism  76  has an applicator arm  78 , an applicator head  80  and a soft applicator pad  82 . The main table  14  indexes so the tag  20  in the nest  50  is positioned directly below the applicator pad  82 , as shown in  FIG. 10A . There may also be an optional sensor (not visible) underneath the nest  50  at the labeling station  60  to determine whether there is a tag  20  in the nest  50  before labeling begins. 
     The printed label  84  is drawn out onto the applicator pad  82  with the adhesion side down using a vacuum mechanism, as shown in  FIG. 10B . A vacuum sensor detects whether or not a label has been drawn out onto the pad. The applicator arm  78  then moves downward until the applicator pad  82  makes contact with the tag  20  in the nest  50  causing the label to be applied to the tag  20 , as shown in  FIG. 10C . The applicator  76  then returns to the starting position shown in  FIG. 10A , allowing the table to index and the process to be repeated for the next tag  20 . 
     Although it is contemplated that the labeling station  60  is an applicator  76  for applying pre-printed labels, a printer applicator (PA) can also be used that allows for the printing of information specific to the tag  20  to be labeled. The printer of the PA can print labels with a resolution of at least 300 dots per inch (dpi), or it can print labels with a higher or lower resolution, such as 100 dpi, 600 dpi, or 1200 dpi. Information specified by the customer can also be printed on the labels. A variety of label printing techniques may be used to print the labels, as long as the technique satisfies requirements for producing a clean, readable and durable label. 
     Tags that have failed testing are also labeled as appropriate to clearly distinguish them from good tags. If practical, failed tags will also be labeled with debugging information describing the failed test parameters to assist with troubleshooting and possible repair of the tag. 
     As the PA will require the most frequent maintenance of all of the stations, the PA is ideally designed so that label stock and the printing ribbon may be replaced and the print head may be cleaned in 15 minutes or less. As frequent maintenance is required, it is also ideal that the PA is situated in the enclosure  9  in a way that makes it easily accessible to the operator. As shown in  FIG. 1 , the labeling station  60  is located near doors in the enclosure  9  for easy access. In full production, the PA may need cleaning up to 3 or more times in a 24 hour period. To facilitate this, the PA may be mounted on a track or other mechanism that allows for it to easily be moved out of the enclosure  9  for better accessibility. The PA may also have a light tower to indicate its status. 
     If one label is printed every three seconds, the print head of the PA will preferably have a mean time between failures (MTBF) of greater than about 2000 hours of continuous operation. At the same rate the print engine will preferably have a MTBF of 5000 hours. If the PA requires prolonged repairs, a backup PA can be available at the production facility to use as a spare. It should take no longer than 30 minutes to remove the PA and replace it with a new one. Along with being located within the system for convenient operator access, the PA may also be mounted on special fixtures that allow it to be easily removed and installed from the system. 
     It is also contemplated that other PA may be used within the scope of the present invention, including those with different printing and or applicator systems. Any PA that can be modified to be used with the system of the invention and that is capable of printing labels as desired could be substituted for the PA described herein. 
     Once labeled, the tag  20  then moves to the machine vision testing station  62 , step  1028 , of  FIG. 3 . A diagram of the machine vision station  62  is shown in  FIG. 11 . The tag  20  is inspected by an automated machine vision camera  86  to verify label presence, correct label placement and to confirm the information printed on the label is correct and readable. The tag  20  may be illuminated by a light source  88  to make the printing on the label more visible. The machine vision device is linked to optical character recognition software which will compare the text and graphics printed on the tag with the customer&#39;s specifications. Any tags that are missing labels, or that have labels that are incorrectly placed or misprinted will be rejected. 
     The tag  20  then indexes to the RF verification station  64 , step  1030  of  FIG. 3 . As the resonant cavity  68  at this station is tuned to a different frequency than all of the previous resonant cavities, a stepped attenuation sensitivity test may be performed. The stepped attenuation sensitivity tests performed at each RF station (i.e., stations  54 ,  56 ,  58  and  64 ) measure the RF performance of the tag  20  over the frequency range at which the tag  20  will operate. After this last stepped attenuation sensitivity test is performed, the RF performance of the tag  20  in everyday use will have been sufficiently verified. The testing performed at this station also verifies that the dynamic range of the tag  20  is within the specified parameters. The RF verification step  1030  is used as a final check to make sure that the tag data and tag ID match that in the database  1008 . 
     For the tag  20  to be verified, the information on the tag  20  is read and compared with the information for that specific tag  20  stored in the database. If the tag data matches the database, the tag has passed all tests. If the tag data does not match the database, it is failed and will be discarded. 
     The tag  20  then indexes to the output station  66 . From the output station  66 , the tag is transferred to the output table  16  ( FIG. 1 ). This transfer takes place through a transfer mechanism  127  which is shown in  FIG. 12 . The transfer mechanism  127  operates in the same manner as the transfer mechanism  41  diagrammed in  FIG. 5A , and components with like functions are labeled with like numbers. Tags  20  are picked up the carriage  41  as described in  FIG. 5C . The master controller  1012  identifies the tag at the output station  16  and the output transfer mechanism  43  whether the tag has passed or failed. If the tag has failed, it is transported and dropped in a fail bin  48  for later testing. If the tag has passed, it is transferred to the output table  16  for packaging. A sensor  139 , located beneath the output station  66 , detects whether a tag has actually been picked up. 
     A small number of tags that have passed all tests are collected for sample testing  1036 . These tags are transferred from the output station to a sample collection bin  131 . When the tag  20  is released into the bin  131 , it will fall onto a slide  135  where it will come to rest on a stop  137  in an opening the base  5 , as shown in  FIG. 1 . The sample tags will then be gathered and subjected to additional sample testing  1036 . This type of testing is highly accurate but is too slow to take place in-line with the tag processing system. Further, the testing  1036  involves the use of large anechoic chambers. 
     Preferably, samples will be collected from about 0.5% of the tags to be produced in the run. However, it is also contemplated that from about 0.1% to about 30% of the tags produced in the run may be collected. A certain number of sample tags will be subjected to intensive testing and will not be shipped to the customer. As tests are performed, quality data collected on the sample tags is relayed to the database  1008 , allowing for real time adjustment of the testing procedures. 
     Packaging, step  1032  of  FIG. 3 , of the tags takes place at the output table  16  as shown in  FIG. 13 . Barcoded shipping boxes  18  are placed in nests  90  in the top surface  92  of the output table as shown. The top surface  92  of the output table  16  is removable and is held in place with one or more thumbscrews  94 . In this way, the nests on the output table  16  can be changed to accommodate differently sized boxes  18  for differently sized tags without the use of tools. 
     The shipping boxes  18  are placed in the nests  90  so that the barcodes  96  face the inside of the output table  16 . A barcode reader on the output table  16  reads the barcode of the box  18  to be filled. The database records which specific tags  20  are packaged in which specific box  18 . The database  1008  records the number of tags  20  being packaged into the box  18  until the appropriate number of tags  20  are packaged. After one box  18  is completed, the output table  16  indexes to the next box  18  to repeat the process. The filled boxes then index back to the operator to be sealed for shipping, step  1034  of  FIG. 3 . 
     The input table  12  and output table  16  are provided to enable the system to process a large number of tags without operator assistance. However, a single bin (i.e., without a rotatable table  12 ,  16 ) can be used to process fewer tags, or where that bin or box  18  is able to accommodate a large number of tags. 
     As outlined in  FIG. 3 , the entire system is controlled by the master controller  1012 , which communicates with and commands the automation controller  1038 . The automation controller  1038  controls the movements of the various components of the processing system, such as the indexing of the table, while returning status reports to the master controller  1012 . The master controller  1012  then relays information from the database regarding the tags being processed at each station. 
     The master controller  1012  may be run by any type of appropriate software. Preferably, the master controller  1012  is run by software specifically designed for the system. Ideally, the software will be allow for easy operator interface and one that shows a clear indication of the tags being processed and their parameters as they compare to the database  1008 . 
     Returning to  FIG. 1 , a bench  5  with a working top surface  7  and an enclosure  9  surrounding the system  10  may be used to contain the system  10  in a tag production apparatus  3 . The RF testing stations  54 ,  56 ,  58 ,  62  are secured to the top surface  7  of the bench  5  by brackets  74 , while the machine vision station  62  is secured to the top surface  7  by bracket  65 . The brackets  74  are configured to extend over, and align with, the nest in the main table  14  so that the testing or labeling apparatus can directly interface with the tag. The transfer mechanisms  41  and  42  are secured to the top surface  7  by brackets  47  and  49 , respectively. The labeling station  60  may be mounted directly to the top surface  7 . The stations can be moved with respect to each other to be in a different order than that shown in the preferred embodiment. For instance, the programming station  58  can be located before the PLL station  56 . 
     The enclosure  9  is preferably made of glass or plexiglass to protect the system  10  and prevent people from being able to access the machine while it is operating. If the doors of enclosure are opened, the apparatus will immediately stop running. As shown, one end of the enclosure  9  has a side panel which permits a portion of the input table  12  and output table  18  to extend to the outside the enclosure  9 . Accordingly, an operator can quickly and easily remove empty bins from the input table  12  and replace them with loaded bins, without interfering with the operation of the system and minimizing entry of dust into the interior of the enclosure. Likewise, an operator can remove processed boxes from the output table  18  and replace them with empty boxes. Access panels are also positioned near the transfer devices to clear any jams, and to allow the failed tags from the reject bins. 
     The apparatus  3  is equipped with emergency stop buttons  11 , which cause the system to pause when pressed. Control buttons  13 , are used to re-home the machine to a neutral starting point if it is stopped for any reason. The apparatus  3  may also have sensors on any doors and light curtains which cause the system  10  to pause if someone attempts to reach inside the enclosure  9 . The apparatus  3  may also have a light tower  15 , which can give colored signals as to the status of the system  10 . For example, the light tower  15  may signal green if the system is running and red if the system has stopped for any reason. Other colors may be used to signal specific messages. Preferably, the system  10  of the invention can process about 800 tags/hour. 
     It should be apparent that there are other embodiments of the invention that fall within the scope and spirit of the claims as set forth below. Non-limiting examples of such embodiments include systems with differently shaped tables, or systems with transfer mechanisms alternate to the pick and place mechanism described. In addition, although the system, apparatus and method of the preferred embodiment is used with label-based RFID tags, other products can also be processed such as hard case tags. In addition, the present invention is easily adaptable to produce tags of various shapes and sizes.