Optical scanner apparatus

Abstract: The invention provides for optical scanner apparatus (21) having a dynamic laser diode aperture (37) for collimating light from a laser diode (34) so as to increase the power of the beam to a predetermined maximum. The optical scanner (21) includes a motor (24) for driving a hollow cylindrical shaft (28) through which the output laser light passes. A lens member (35) focuses the light, and the aperture (37), located within a cap member (31) within an end of the motor shaft (28) closest to the laser diode (34), collimates the focused light. The aperture (37) approximates to the cross-sectional shape of the unfocused light pattern from the laser diode (34) and in a preferred embodiment, the aperture (37) is generally elliptical in shape.

Description: The present invention relates to an optical scanner apparatus. Optical scanners are commonly used in retail check-out and inventory control apparatus. Optical scanners generally employ a laser diode, the light from which is focused and collimated to produce a scanning beam. An optical transceiver directs the beam against a plurality of stationary mirrors, and collects the beam after it is reflected by a bar code label. A motor rotates the optical transceiver, and a detector receives the returning beam. The pattern produced by such a scanner is characterized by lines oriented at various angles to one another. An example of an optical scanner is disclosed in U.S. Patent No. 4,971,410. The laser diodes used in optical scanners exhibit both desirable and undesirable characteristics. Output laser light from a laser diode produces a scanning ellipse, which is suitable for use in optical scanners which generate scan lines in one direction only, and which is suitable for scanning bar code only if the minor axis of the ellipse is oriented perpendicular to the lines and spaces of the bar code label. Furthermore, laser output power has two propagation axes, one axis diverging around thirty-five degrees and the other axis diverging around ten degrees. Thus, the asymmetry of the scanning ellipse makes light collection techniques in optical scanners difficult. However, light from the scanning ellipse has advantageous characteristics in that it generates more optical power than a focused and collimated substantially circular narrow light beam, and reduces print defects by averaging them to yield a modulated signal with less print-generated noise. Known focusing techniques for optical scanners, employ a single focusing lens followed by a circular aperture. The circular aperture determines the size of the laser beam projected at a reference plane. Since the dimensions of the aperture remain constant relative to the propogation axes, it can be referred to as a "static" aperture. However, the circular static aperture attenuates as much as eighty-five percent of the light power available from the laser diode because the diameter of the circular aperture must be limited to maintain the optimum "F" number for a proper beam profile about the primary focus. It is an object of the present invention to provide an optical scanner apparatus having a rotatably driven transceiver and which has improved power and noise characteristics. In accordance with the present invention there is provided optical scanner apparatus comprising a laser diode, a lens for collimating light output from said laser diode along an optical axis of said apparatus, a hollow shaft which in operation is rotatably driven about said optical axis by a motor and through which said focussed light output from said laser diode travels to transceiver apparatus mounted on said shaft for rotation therewith and at its end remote from said laser diode, characterized by cap means having an aperture the length of which in a first direction passing through said optical axis which is greater than the width in a second direction passing through said optical axis and substantially perpendicular to said first direction, the cap means being mounted for rotation with said shaft. Advantageously the present invention provides a dynamic laser diode aperture which produces a collimated light beam having more power than light beams from scanners employing static circular apertures and whose shape approximates the shape of the unfocused light pattern from the laser diode. According to another advantage, the present invention provides an apparatus forming the aperture which apparatus can be readily installed into existing scanners. The invention is described further hereinafter, by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a representation of a bar code label containing print defects; Fig. 2 is a scanning ellipse generated by a laser diode; Fig. 3 is an optical scanner employing a dynamic laser diode aperture according to one embodiment of the present invention; Fig. 4 is a rear view of an end cap member for forming a dynamic laser diode aperture; Fig. 5 is a side view of the end cap member of Fig. 4; and Fig. 6 is a rear view of another end cap member for forming a dynamic laser diode aperture. Turning now to Fig. 1, a bar code label 10 having lines and spaces is shown. Typically, bar code labels suffer from printing defects. Lines 11 and 12 are characterized by irregularities on the surfaces 13 and 14 between them, which cause the shortest distance between bars 11 and 12 to vary along these surfaces. Since scanners read the distance between the bars, this variation in distance can cause erroneous readings. Referring now to Fig. 2, there is shown a scanning ellipse 15 from a laser diode 16. The laser diode 16 has propagation axes 17, 18, and 19. Axis 17 coincides with the centre of beam 20. Axes 18 and 19 are useful in measuring the divergence of the beam 20 from the axis 17. Axis 18 measures vertical divergence along the major axis of the scanning ellipse 15, while axis 19 measures horizontal divergence along the minor axis of the scanning ellipse 15. Both vertical and horizontal divergence are symmetric about the centre axis 17, the vertical divergence approximating seventeen and a half degrees either side of the centre axis 17 for a total of thirty-five degrees and the horizontal divergence approximating five degrees either side of the centre axis 17 for a total of ten degrees. Referring now to Fig. 3, there is shown an optical scanner 21 employing the dynamic laser diode aperture of the present invention. The optical scanner 21 includes a molded frame support member 22 having a plurality of latching portions 23. The frame support member 22 may be molded of any type of shock resistant plastic material such as polycarbonate. Mounted within the support member 22 is a motor 24. Journaled within the motor 24 by bearings 26 is a hollow drive shaft 28 extending through the motor 24. Mounted within a rear extension portion 30 of the frame support member 22 is a brass laser diode 34 and a collimating and focusing lens member 35 both of which are in alignment with the spin axis 60 of the drive shaft 28. The diode 34 outputs a diverging light beam which is collimated and focused on a reference plane (not shown) in front of the optical scanner 20 by the lens member 35 and the dynamic aperture 37. Dynamic aperture 37 is contained within end cap member 31, which is inserted into the bore 62 of the end of the motor shaft 28 closest to the laser diode 34. Circular aperture 36 is large enough to allow a beam from the laser diode 34 to pass through virtually unobstructed and unattenuated. Slidably mounted within the frame support member 22 is a molded mirror support member 38 constructed of any type of polycarbonate plastic which includes a plurality of acrylic turning or pattern mirrors 40, each of which extends outwardly from the support member 38 at an angle of approximately thirty-three degrees and in which each mirror is offset to each of the other mirrors 40 by approximately three degrees. The number of mirrors employed is controlled by the number of scan lines required for the scan pattern. In the optical scanner 21, there are eight turning mirrors. The mirrors have their reflecting surfaces coated with gold. The support member 38 includes a rearwardly extending key rib portion 39 which is positioned within a key slot 41 located in the frame support member 22 for snap fitting the support member 38 within the support member 22. Secured to the front end of the drive shaft 28 is one embodiment of an optical transceiver 42 comprising a flat deflecting mirror portion 44 which extends obliquely across the spin axis 60 of the drive shaft 28 and a collection mirror portion 46 which comprises a sloping aspheric concave surface 47 for collecting the scanning light beams reflected from a scanned bar code label. The optical transceiver 42 may be fitted over the shaft 28 using a snap fitting member 29 and may be molded of any type of transparent material such as a polycarbonate plastic material. The reflecting surfaces of the transceiver 42 are coated with gold which reflects the red light band while allowing all other bands of light to pass through the surface of the transceiver 42. In order to reduce the noise generated by the stray light passing through the transceiver 42, the rear surfaces of the transceiver 42 may be coated with silicon oxide which absorbs the light. The deflecting mirror portion 44 extends through a slot 64 in the collecting surface 47 of the collection portion 46. The mirror portion is oriented at an oblique angle to the surface 47. The transceiver includes a rear portion 49 which includes a plurality of depending rib portions 45 which provide a balance to the transceiver when rotated about the spin axis. Mounted to the front portion of the mirror support member 38 is a transparent acrylic photodetector support member 50, having a plurality of flexible finger members 52 which snap over the latching portions 23 of the frame support member 22 for holding the photodetector support means 50 to the mirror support member 38. Coating the reflecting surfaces of the mirrors 40 and the transceiver 42 with gold, together with the use of the acrylic support member 50, provides high reflectivity and transmission of light. Mounted within a protruding housing portion 54 of the support member 50 is a detector assembly 51 comprising a support member 53 having a limiting aperture 55 and a photodetector 56 secured to the member 53 and mounted within a holder 58 secured to the inside end portion of the housing portion 54. Referring now to Figs. 3, 4, and 5, the present invention includes an end cap member 31 which is easily inserted into the bore 62 of the end of the motor shaft 28 closest to the laser diode 34. In the preferred embodiment, the end cap member 31 is generally cylindrical in shape and is made of opaque polycarbonate plastic by known methods. A plug portion 66 fits snugly within the bore 62 and a lip portion 68 fits snugly against the end of the motor shaft 28. Dynamic aperture 37 approximates the shape of the unfocused light pattern from the laser diode, i.e., the scanning ellipse. In the preferred embodiment, it is generally rectangular in shape for ease of manufacture, having two long sides 70 and 72, and two short sides 74 and 76. In the preferred embodiment, the long sides 70 and 72 are straight and measure 3.0 millimeters, and the short sides 74 and 76 are curved, following the bore 62; the width of the dynamic aperture 37 is 1.2 millimeters. The axis 18 of the scanning ellipse 15 is orientated vertically and in line with the deflecting mirror 44 at the other end of the motor shaft 28. Referring now to Fig. 6, an alternative embodiment of the present invention is shown. The end cap member 31 employs a dynamic aperture 37 having an elliptical shape. In operation, dynamic aperture 37 allows more light energy to be emitted than a circular aperture. As the motor shaft 28 rotates, the dynamic aperture 37 and deflecting mirror 44 rotate. Laser diode 34 remains stationary with its major axis orientated vertically. Advantageously, the generated scan pattern includes horizontal lines which possess the desirable characteristics of the static scanning ellipse 15. The effects of print defects are reduced because the horizontal scan lines are those of the scanning ellipse 15. The vertical scan lines look like those generated by a circular aperture since the width of the dynamic aperture 37 limits the major axis 18 of the scanning ellipse 15 when the dynamic aperture 37 is oriented ninety degrees to the scanning ellipse 15. Use of the dynamic aperture 37 also allows more power for scanning. Maximum power output occurs in the horizontal lines when the dynamic aperture 37 is aligned with the scanning ellipse 15, while minimum power output occurs in the vertical lines when the dynamic aperture 37 is oriented ninety degrees to the scanning ellipse 15. Scan lines which are neither vertical nor horizontal have characteristics between those extremes. For all scan lines, the beam power is controlled by the width of the dynamic aperture 37. In addition, all scan lines satisfy the criterion that the minor axis 19 of the ellipse is perpendicular to the scan lines of the bar code label.

Claims: Optical scanner apparatus (21) comprising a laser diode (34), a lens (35) for collimating light output from said laser diode (34) along an optical axis of said apparatus (21), a hollow shaft (28) which in operation is rotatably driven about said optical axis by a motor (24) and through which said focussed light output from said laser diode (34) travels to transceiver apparatus (42) mounted on said shaft (28) for rotation therewith and at its end remote from said laser diode (34), characterized by cap means (31) having an aperture (37) the length of which in a first direction passing through said optical axis is greater than the width in a second direction passing through said optical axis and substantially perpendicular to said first direction, said cap means (31) being mounted for rotation with said shaft (28). Apparatus according to claim 1, characterized in that the shape of said aperture (37) approximates to the cross-sectional shape of the light output from said laser diode (34). Apparatus according to claim 2, characterized in that said aperture (37) is defined by two straight and parallel edges (70,72) and two curvilinear edges (74,76) connecting the ends of said straight edges (70,72), the distance between said straight edges (70,72) being less than the length of said straight edges. Apparatus according to claim 2, characterized in that said aperture (37) is elliptical in shape. Apparatus according to any one of the preceding claims, characterized in that said cap means (31) is mounted in the end of said shaft (28) adjacent said laser diode (34). Apparatus according to claim 5, characterized in that said cap means (31) comprises a flanged plug member. Apparatus according to any one of the preceding claims, characterized in that said cap means is made of opaque plastic.

Inventors: AMES STEPHEN JOHN, WIKE CHARLES KENNETH JR, AMES, STEPHEN JOHN, WIKE, CHARLES KENNETH, JR.
Applicants: AT & T GLOBAL INF SOLUTION, AT&T GLOBAL INFORMATION SOLUTIONS INTERNATIONAL INC.
Application year: 1992
Main classification: G02B26
IPC codes: G06K7, G02B26, G02B27, H04N1