Bar code reader head

Abstract: A bar code reader head having an optical block with cavities (26) formed therein into which various optical elements may be placed without the need for any adjustment thereof. A first illumination source (16), producing any desired spectrum of light, illuminates at least a portion of the bar code (48). A second illumination source (18) may be provided to produce a second spectrum of light. Reflected light passes through a lens (24) in front of which is an aperture slit (46) parallel to the bar code bars. A channel (20) is formed between the lens and a photodetector (28) perpendicular to the light path. If both visible and infrared illumination sources (16/18) are used, visible light is focused at the side of the channel toward the lens and infrared light is focused at the other side of the channel. In the channel is a template (34) having at least one discriminator (54, 56) slit parallel with the slit in front of the lens.

Description: The present invention relates to bar code readers generally and more particularly to a novel reading head for such devices and one which may be used with illuminating light of different wavelengths and for reading different bar codes having substantially different widths of bars. Bar codes have found application in a wide variety of applications as an information source, typically for digital processors. Such bar codes are used at point-of-sale in merchandising for pricing and inventory count, in controlled personnel access systems, and in manufacturing for work-in-process and inventory control, to name only a few applications. The bar codes themselves comprise a series of parallel lines, typically in the range of about 1/8" to 1" in height and from about 1 to 50 mils in thickness, arrayed on a contrasting background, The lines may variously have unequal spacings and/or unequal thicknesses, with the variations in spacing and/or thickness determined by the information "stored" in the bar code. A bar code is "read" by serially illuminating the bars, with the bars absorbing the light and the background reflecting the light. The resulting pattern of reflection and nonreflection is sensed by a light detecting device which provides input to the digital processor. The reader head may be of the type that is passed over the bar code or of the type with which the bar code is moved passed the reading head, such as might be used with a personal identification card. While the present invention is directed generally toward the latter type, it will be understood that it may be modified and applied to the former type, as well, or even where there is no relative motion, by one having ordinary skill in the art. One class of conventional bar code reader heads comprises those that are point detectors; that is, the detecting device is focused at a single, relatively small point. Such a reader head is described, for example, in U.S. Patent No. 4,143,809, to Uebbing et al. These readers have two major disadvantages. First, since the detector is focused at a point on the bar code, the reader has a very short depth of field, possibly on the order of 5 mils at a distance of 300 mils from the focusing lens. This means that the substrate carrying the bar code must be accurately placed in distance from the lens in order to provide good resolution. Second, if a bar on the bar code is unintentionally broken or otherwise defective at the point of focus, it will be detected as being absent, thus providing misinformation to the data processor. A further limitation of conventional devices is that no known bar code reader heads have the desirable ability to employ either visible or infrared illuminating light in the same device, although such would be advantageous in some applications. Typically, visible red light generated by a light emitting diode (LED) is used for reading visible bar codes or bar codes that cannot be read with infrared radiation such as thermally printed bar codes with low carbon content. These bar codes are useful where it is convenient to be able to visually read the bar codes or to identify them as such. However, in some applications, it is necessary to read "masked" bar codes, such as those described in U.S. Patent No. 4,359,633 to Bianco, titled "Specially-Limited Bar-Code Label and Identification Card". In the latter applications, infrared illumination is used to read bar codes that cannot be read visually. U.S. Patent No. 4,408,120 discloses a bar code scanner having an array of light responsive elements upon which light reflected from a bar code is focussed by a lens. An aperture arranged orthogonally to the major axis of the bar code is located between the lens and the array at some distance from the focal plane of the lens. Additionally, no known bar code reader heads have the desirable ability to be adjusted for use with different bar codes having bars of substantially different widths. A further limitation of known bar code reader heads is that they are of relatively complicated manufacture and require relatively precise adjustment during or after manufacture. The present invention provides an improved bar code reader head comprising: (a) a body; (b) a first illuminating source, producing a first spectrum of light wavelengths disposed within the body so as to illuminate at least a portion of a bar code; (c) a first lens, disposed within the body to focus the first spectrum of light wavelengths reflected from the bar code, the reflected light being focussed at a first focussing plane within the body distant from the first lens; and (d) detector means, characterised by (e) discriminator means disposed within the body and placed at the first focussing plane, such as to limit the width of the bar code which can be seen by the detector means, further characterised in that the detector means is disposed within the body on the side of the first focussing plane opposite the first lens to detect light focussed by the first lens. The body may be an optical block, which may be simply and conveniently injection molded in thermoplastics material. The block may include cavities formed therein into which the various optical elements may be placed, without the need for any adjustment thereof. An unfocussed first illumination source in the optical block illuminates at least a portion of the bar code to be read as the bar code moves relative to the reader head. The illumination source may produce any desired spectrum of light, while a second illumination source may be provided in the block to increase the intensity of light in the same spectrum or to produce illumination in a second spectrum. The discriminator means preferably comprises a slit parallel to the bars of the bar code for providing increased depth of field. The detector means may have a second lens in front of it to improve collection of light to the detector, allowing for less exacting manufacturing tolerances. The discriminator means is preferably housed in a channel formed between the first and second lenses and perpendicular to the light path. If, say, both visible red and infrared illumination sources are being used, the channel is positioned and dimensioned such that visible red light will be focussed at the side of the channel towards the first lens and infrared light will be focussed at the side of the channel toward the second lens. In a preferred embodiment of the invention the discriminator means is removably disposed in the channel and comprises a template having, preferably, a resilient body with a clear backing on one surface thereof and a black film on the other surface thereof. The black film may have formed therein at least one discriminator slit parallel with the slit in front of the first lens. The width of the discriminator slit depends upon the widths of the bars to be read. When visible read light is used, the template is positioned with the slit side towards the first lens. When infrared light is used, the template is positioned with the slit side toward the second lens. The template may have additional slits for changing the resolution of the device by sliding the template to align a slit having a different width with the light path, thus allowing use of the device with different bar codes having substantially different bar widths. In one embodiment, the light path is folded through use of a mirror disposed between the first lens and the channel to provide for a reduced dimension perpendicular to the plane of the bar code. The preferred embodiments of the invention thereby provide a bar code reader head that may be used with more than one frequency range of illuminating light, as well as a reader head that can be adjusted for use with different bar codes having bars of substantially different widths. The preferred reader head has a relatively deep depth of field and reads a substantial height of each bar. It is also relatively simple to manufacture without requiring relatively precise adjustments either during or after manufacture. The invention will now be described by way of example with reference to the drawings in which: Figure 1 is an enlarged, exploded perspective view of one embodiment of the invention; Figure 2 is an enlarged, exploded perspective view of another embodiment of the invention; Figure 3 is an enlarged front elevation view of the template of the embodiment shown in Figure 1; Figure 4 is an enlarged cross-sectional view of the template of Figure 3; and Figure 5 is an enlarged top plan view of the template of the embodiment shown in Figure 2. Referring now to the drawings, Figure 1 shows an enlarged perspective view of one embodiment of the present invention which includes an optical block, generally indicated by the reference numeral 10, which defines: cavities 12 and 14 for the placement of illuminating sources 16 and 18, respectively; an elongated channel 20; cavity 22 for the placement of a first lens 24; a cavity 26 for the placement of a photodetector 28 which may have an integral second lens 30; channel 32 for the placement of template 34, said channel extending in width between a first opening 36 defined by the end of elongated channel 20 and a second opening 38 in front of second lens 30. Template 34 has defined therein a first discriminator slit 54 and may have defined therein a second discriminator slit 56. Cavity 26 has defined at the distal end thereof an opening 40 to accommodate the leads 42 of photodetector 28. The distal ends of cavities 12 and 14 are similarly open for connection of leads 44 of illuminating sources 12 and 14 to conventional external circuitry (not shown). Elongated channel 20 further defines a first slit 46 which serves as an aperture reduction in front of first lens 24 to provide for increased depth of focus for the first lens. Having a long slit 46 allows first lens 24 to "look" at a substantial height of bar, thus reducing the effect of edge irregularities and density variations over the bar. Lid means (not shown) may be placed over optical block 10 to hold the internal elements in position. Illuminating sources 16 and 18, first lens 24, and photodetector 28 may be of any conventional type known in the art. Photodetector 28 may be provided without second lens 30, but that lens is useful in gathering additional light so that less critical dimensional tolerances may be accommodated. In operation, illuminating sources 16 and/or 18, which may be visible and/or infrared LEDs, or other illuminating sources known in the art, illuminate a bar code 48 which is moving relative to optical block 10 in the direction indicated by "A" on Figure 1. First lens 24 is preferably disposed so that the optical axis thereof is substantially orthogonal to the plane of bar code 48. The light from illuminating sources 16 and/or 18 preferably strikes bar code 48 at an angle of approximately 45 degrees from the optical axis of first lens 24. Light is absorbed by the bars, as at 50, and reflected by the bar code substrate 52. The reflected light passes through first slit 46 in the front of elongated channel to first lens 24. The light exiting first lens 24 continues to pass through elongated channel 20 and depending on its wavelength, is focused either at a plane intersecting first opening 36 or at a plane intersecting second opening 38, both planes being perpendicular to elongated channel 20. If the illuminating source is visible red, the light will be focused at first opening 36. If the illumination is infrared, the light will be focused at second opening 38. Depending on the illuminating source, template 34 is positioned so that one of discriminator slits 54 or 56 is at the opening where the light is focused. The discriminator slit is preferably chosen so that its width is somewhat less than the narrowest bar 50 of bar code 48. Whichever type of illuminating light is used, second lens 30 gathers the available light through opening 38 and passes the same to photodetector 28. The present invention may also use a first lens, known in the art, designed to focus both infrared and visible light at only one of first and second openings 36 and 38. Referring now to Figure 2, there is provided a "folded" embodiment of the present invention shown on Figure 1, with like elements having primed reference numerals. The embodiment shown on Figure 2 is advantageous when it is important to minimize the length of the bar code reader head in the dimension perpendicular to the plane of bar code 48′. In this embodiment is included mirror 60 which bends focused light from first lens 24′ in elongated channel 20′ about 90 degrees to template 58. Cavity 62 is provided to position mirror 60 in optical block 10′. Also in this embodiment is a clear window member 64 which is provided to seal the front of optical block 10′. A lid (not shown) may be provided to hold the internal elements in place. In the embodiment shown, template 58 has a single discriminator slit 66, as channel 32′ is not designed to allow back-and-forth movement of the template between two or more positions. When it is desired to employ a different discriminator slit, template 58 is "moved" by removing it and replacing it with a template having a different width slit. Also, in this embodiment, the single illuminating source 16′ may be chosen to produce any of two different spectra of light wavelengths. The operation of the embodiment of the present invention shown on Figure 2 is similar to the operation of the embodiment shown on Figure 1. Referring now to Figure 3, a front elevation of template 34 of Figure 1, and Figure 4, a cross-sectional view of template 34, template 34 includes a resilient substrate 70, preferably formed of a cellular plastic material having a first clear, resilient backing 72 on one face thereof for structural rigidity. On the other face of template 34 is a second clear resilient material 74 having a "black" inside surface 76 which does not transmit the wavelengths of light to be used and which may be photographic emulsion. When photographic film is used, the photoemulsion 76 is preferably placed on the inside surface of clear material 74, as shown, to avoid scratching. Formed in black surface 76 are first and second discriminator slits 54 and 56, which are preferably exposed areas of the photoemulsion of the black surface, and which have different widths as shown. Of course, additional discriminator slits may be provided, as well. Template 34 defines an open passage 78 extending between first and second resilient backings 72 and 74 to permit the transmission of light through the template. Figure 5 is a top plan view of template 58 of Figure 2, with primed reference numerals indicating like elements in template 34 of Figures 1, 3 and 4 and shows a construction similar to that of template 34 in Figures 1, 3 and 4 except that, in the case of template 58, open passage 78' is not punched from substrate 70', but rather is formed between two separate strips of the substrate, as is further described below. Substrate 70 has a slight resiliency and has a natural thickness dimension somewhat greater than channel 32 so as to removably hold template 34 in the channel in the desired position when slightly compressed, although any means known in the art may be used to hold the substrate in position. As noted above with reference to Figure 1, one of slits 54 or 56 is placed adjacent first opening 36 at the end of channel 20 when light in the visible range is being used, as first lens 24 focuses visible light at that distance from the lens. When light in the infrared range is being used, one of slits 54 or 56 is placed at second opening 38 adjacent second lens 30, as first lens 24 focuses infrared light at that distance from the first lens. The choice of which of slits 54 and 56 is to be used depends upon the narrowest bar 50 on the bar code 52 to be read. Since the slit determines the amount of the bar code "read" by the photodetector, it is necessary to limit that amount so that the photodetector can discriminate between bars. It has been found that providing a discriminator slit that is about 75% of the width of the narrowest bar on the bar code gives good resolution. One could use a very narrow slit to read all bar codes; however, because of less critical dimensional tolerances used with bar codes having wider bars, there would be poor resolution, the focused image would not be clear, and the signal from the reader would be noisy. Template 34 may be conveniently constructed in quantity by providing a sheet of resilient substrate 70 of urethane foam and punching columns of open passages therethrough. Then a heavy clear plastic first sheet of backing material 72 is adhesively attached to one side of substrate 70. A second heavy clear plastic sheet of material 74 furnished with a photoemulsion on one side is exposed and processed to produce a series of parallel clear lines on a black background, with the width of the lines being equal to the desired width of slits 54 and 56. The second sheet is adhesively attached to the other side of substrate 70 so that slits 54 and 56 are in line with open passages 78 and the assembly cut to produce templates 34. Template 58 may be conveniently constructed in quantity by exposing and processing a heavy clear plastic second sheet 74′ with photoemulsion on one side to produce a series of parallel clear lines on a black background, with the width of the lines being equal to the desired width of slit 66. Then, strips of urethane foam substrate 70′ are placed between the lines. The foam strips may be as manufactured by The 3M Company, having an adhesive on two opposite sides covered with a release paper. First, the release paper on one side is stripped off and the foam strips are placed on the photoemulsion side of the first sheet. Then, the release paper on the other side of the strips is removed and the first clear plastic sheet 72′ is placed on the strips. The resulting sandwich may then be cut into templates 58. The clear plastic sheets 72, 72′, 74, and 74′ may be of any material known in the art, provided that it does not substantially color with age. Thus, uniquely, a single element of optical blocks 10 and 10′ ,respectively, templates 34 and 58, permit use of the optical blocks with illuminating sources of different wave lengths, and with different bar codes having substantially different widths of bars, with no changes or adjustments to the optical block other than changing the placement of the templates in their respective channels 32 and 32. Although not critical to the practising of the present invention, optical block 10 is preferably constructed by the injection molding of an engineering thermoplastic such as Noryl manufactured by The General Electric Company, although any material having desirable characteristics, such as dimensional stability, known in the art may be used as well. Additionally, in the embodiment shown, the optical block is preferably configured as shown so that it may be simply molded as a side-pull-out casting. Following the molding step, the internal components are easily placed in their respective cavities manually or robotically. Since the casting provides for proper placement dimensionally, there is no need to make any final adjustments during or after insertion of the internal components. All internal components are conventional components which are readily available, with the exception of the template which is simply constructed. Thus, what has been described is a novel bar code reader head that is compact and easily manufactured, that can be used with different wavelength ranges of illuminating light, and that may be used to read different bar codes having substantially different width bars. It will thus be seen that the objects set forth above, among those made apparent from the preceding description are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown on the accompanying Drawing shall be interpreted as illustrative and not in a limiting sense. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Claims: A bar code reader head, comprising:- (a) a body (10); (b) a first illuminating source (16), producing a first spectrum of light wavelengths disposed within the body (10) so as to illuminate at least a portion of a bar code (48); (c) a first lens (24), disposed within the body to focus the first spectrum of light wavelengths reflected from the bar code (48), the reflected light being focussed at a first focussing plane within the body distant from the first lens (24); and (d) detector means, (28); characterised by (e) discriminator means (34, 58) disposed within the body (10) and placed at the first focussing plane, such as to limit the width of the bar code (48) which can be seen by the detector means (28), further characterised in that the detector means is disposed within the body (10) on the side of the first focussing plane opposite the first lens (24) to detect light focussed by the first lens (24). A reader head according to claim 1, characterised by a second illuminating source (18), producing a second spectrum of light wavelengths disposed within the body (10), so as to illuminate at least a portion of the bar code (48), the first lens (24) focussing the second spectrum of light wavelengths reflected from the bar code (48), at a second focussing plane distant from the first lens (24). A reader head, according to claim 2, characterised by a channel (32) formed in the body (10) between and perpendicular to the path of light from the first lens (24) to the detector means (28), with one wall of the channel (32) lying in the first focussing plane and the opposite wall of the channel lying in the second focussing plane, wherein the discriminator means (34; 58) is releasably held in the channel (32). A reader head according to claim 2 or claim 3, characterised in that the discriminator means (34; 58) is moveable between the first and second focussing planes. A reader head according to any preceding claim, characterised in that the discriminator means (34; 58) comprises a first discriminator slit (54) arranged to be parallel to the bars of the bar code (48), and disposed in the path of light from the first lens (24) to the detector means (28). A reader head according to claim 5, characterised in that the discriminator means (34; 58) is movable to place the first discriminator slit (54) at either of the first focussing plane or at a second focussing plane. A reader head according to claim 5, characterised in that the discriminator means (34; 58) comprises at least a second discriminator slit(56) arranged to be parallel to the bars of the bar code (48) and in that the discriminator means (34; 58) is movable to place either of the first (54) and second (56) discriminator slits in the path of light from the first lens (24) to the detector means (28), and is movable to place either of the first (54) and second (56) discriminator slits at either of the first focussing plane and a second focussing plane. A reader head according to any of claims 5 to 7, characterised in that the first discriminator slit (54) is defined as a clear line on a black photoemulsion (76) disposed and developed on a first clear film (74). A reader head according to claim 8, characterised in that the discriminator means comprises: (a) the said first clear film (74); (b) flexible means (70) disposed on one side of the first clear film (74); (c) a second clear film (72) disposed upon the flexible means (70); and (d) an open passage (78) defined within the flexible means (70) such that light may pass therethrough from the second clear film (72) to the first discriminator slit (54); whereby slight compression of the flexible means (70) will hold the discriminator means (34; 58) releasably within the channel (32). A reader head according to any preceding claim, characterised by a second lens (30) between the discriminator means (34; 58) and the detector means (28). A reader head according to any of claims 2 to 4, characterised in that the first spectrum of light wavelengths is in the range of visible light and the second spectrum of light wavelengths is in the range of infrared light. A reader head according to any of claims 2 to 4 and 11, characterised in that the first lens (24) focusses both the first and second spectra of light wavelengths at one of the first and second focussing planes. A reader head according to any of claim 2 to 4, 11 and 12, characterised in that both the first (16) and second (18) illuminating sources are disposed within the body (10) at the same time. A reader head according to any preceding claim, characterised in that the body (10) is formed as a side-pull-out injection molded part. A reader head according to claim 14, characterised in that the body (10) is formed of a moldable thermoplastic. A reader head according to any preceding claim, characterised in that the first lens (24), the discriminator means (34; 58), and the detector means (28) are disposed along a common axis which, in use of the head, also contains the bar code (48). A reader head according to claim 16, characterised by a mirror (60) disposed between the first lens (24), and the discriminator means (58) thereby to bend, by about 90 degrees, the light path therebetween. A reader head according to any preceding claim, characterised in that the body (10) is provided with a clear window (64) disposed thereon for location between the bar code (48) and the first lens (24). A reader head according to claim 1, characterised in that the elements (b), (c), (d), and (e) disposed within the body (10), may be placed within cavities (12, 14, 26), or channels (32), accessible from one side of said body, the cavities (12, 14, 26) or channels (32) so fitting the parts that no adjustment thereof is required when or after the elements are so placed. A reader head according to claim 19, further characterised by a cover fitting over the said side of the body (10), thereby to retain the elements therein. A reader head according to claim 1, characterised by an aperture-reducing slit (46) disposed in the body (10) between the first lens (26) and the bar code (48) and parallel to the bars on the bar code. A reader head according to claim 1, characterised in that the optical axis of the first lens (26) is substantially orthogonal to the plane of the bar code (48). A reader head according to claim 1, characterised in that the light from the illuminating source or sources (16, 18) strikes the bar code (48) at an angle of approximately 45 degrees from the optical axis of the first lens (24).

Inventors: BIANCO JAMES SALVATORE, DARCY EMILE, DRUMMOND BERNARD, BIANCO, JAMES SALVATORE, DARCY, EMILE, DRUMMOND, BERNARD
Applicants: CONTROL MODULE INC, CONTROL MODULE, INC.
Application year: 1988
Main classification: G06K7
IPC codes: G06K7