Optical scanner having enhanced item side coverage

Abstract: A dual aperture optical scanner which produces horizontal, vertical, and diagonal scan patterns. The optical scanner includes a housing having a substantially vertical surface containing a first aperture (30) and a substantially horizontal surface containing a second aperture (28). A laser diode (12) produces a laser beam. A spinner (16) produces first (I), second (II), and third (III) groups of scanning beams. A plurality of pattern mirrors (18) reflects the first group of scanning beams in a substantially horizontal direction through the first aperture, the second group of scanning beams in a substantially downward diagonal direction through the first aperture, and the third group of scanning beams in a substantially vertical direction through the second aperture.

Description: The present invention relates to optical scanners and more specifically to an optical scanner having enhanced item side coverage. U.S. Patent No. 5,229,588 to Detwiler et al. discloses a dual aperture optical scanner which includes horizontal and vertical apertures. The scanning light beams from a single laser diode pass through these apertures to provide coverage for up to four sides of a scanned item: the side facing the vertical aperture (front), the side facing the horizontal aperture (bottom), and the left and right sides. While this scanner requires much less item orientation than a single aperture scanner, it is not capable of scanning the top and rear sides of scanning items. It is an object of the invention to provide an optical scanner which is capable of scanning as many as five sides of a typical merchandise item. United Kingdom Patent Application GB 2284086 describes a multiple plane scanning system ( Figure 20) which permits scanning of five sides of a typical merchandise item, but this is a complex arrangement having three separate apertures at different angles to one another. It is a further object of the present invention to provide a simplified scanner which is capable of scanning as many as five sides of a typical merchandise item. In accordance with the invention there is provided a bar code scanning system comprising a housing having first and second windows arranged generally orthogonally to one another, a laser source, a rotatable mirror polygon, and first, second and third sets of plane pattern mirrors arranged to provide scanning beams which illuminate an object to be scanned with a plurality of intersecting lines, the three sets of pattern mirrors being arranged to provide two groups of scanning beams (I,II) which pass through the first window and a further group of scanning beams (III) which passes through the second window, characterized in that the three groups of scanning beams together illuminate the object from angles corresponding to five of the six sides of a cube. Preferably the three groups of scanning beams together illuminate the object from angles corresponding to five of the six codes of a cube. The invention will now be described by way of example only with reference to the accompanying drawings, in which: Fig. 1 is a block diagram of the optical scanner having enhanced item side coverage of the present invention; Fig. 2 is an exterior perspective view of the scanner of the present invention, including a reference coordinate system for the group of pattern mirrors within the scanner of the present invention; Fig. 3 is an interior perspective view of the scanner of the present invention; Fig. 4 is a sectional view of the scanner of the present invention along lines 4-4 of Fig. 3; Fig. 5 is a reference coordinate system for determining one-suitable orientation for the group of pattern mirrors within the scanner of the present invention; Fig. 6 is a plan view of the scan pattern emanating upwardly from a horizontal aperture; Fig. 7 is a plan view of a first scan pattern emanating outwardly from a vertical aperture; Fig. 8 is a plan view of a second scan pattern emanating outwardly from the vertical aperture; Fig. 9 is a plan view of the combined first and second scan patterns of Figs. 7 and 8; and Fig. 10 is a perspective view of a laser assembly showing two lasers. Referring now to Fig. 1, a point-of-service (POS) system 10 includes optical scanner 11 and POS terminal 13. POS terminal 13 receives transaction data, for example, in the form of SKU numbers from scanner 11 and completes a transaction by finding price data for the SKU numbers in a price-lookup data file. Scanner 11 of the present invention includes laser 12, optical transceiver 14, mirrored spinner 16, pattern mirrors 18, deflector mirror 19, photodetector 20, and control circuit 21. Laser 12 includes a laser diode or other suitable laser source. A focusing lens or lenses and a collimating aperture are also preferably used to produce a focused and collimated laser beam 22. In the preferred embodiment, the laser diode emits visible light within a wavelength range of 670-690nm and the collimating aperture and focusing lens produce a beam 22 having a beam waist of 220 microns in the center of the read zone. Other wavelengths and beam waists may be suitably employed. Beam 22 passes through optical transceiver 14, which includes a mirrored collecting surface and an aperture for passing beam 22. The mirrored collecting surface preferably has an ellipsoidal or other curved surface. Beam 22 contacts mirrored spinner 16, which preferably has four planoreflective mirrored facets 108-114 for producing scanning beams 24 (Fig. 3). Four facets were chosen as an optimal compromise between the increased line length created by using three facets and the increased rastering provided by spinners having more than four facets. Scanning beams 24 impact pattern mirrors 18, which produce a plurality of scan lines 26. In the preferred embodiment, pattern mirrors 18 are preferably flat and produce forty scan lines 26 for each complete revolution of mirrored spinner 16. Advantageously, all forty scan lines 26 are preferably produced by only one laser 12 and motor 17. Use of a greater or lesser number of scan lines and pattern mirrors will be apparent to those skilled in the art. Some scan lines 26 pass through a substantially horizontal aperture 28 and some pass through a substantially vertical aperture 30 in scanner housing 32 on their way to bar code label 34 on merchandise item 36. Substantially vertical aperture 30 is preferably oriented at 5¾ degrees from a vertical plane. The choice of angle is chosen to optimize the scan volume and line length of the scan lines. It is desirable to achieve a ratio of the minimum length of the longest scan line to the maximum length of the shortest scan line as close as possible to one. At about ten degrees, scanning is adversely impacted for the configuration of pattern mirrors 18 illustrated herein. According to the present invention, scan lines 26 are divided into three groups. Scan lines within a first group (Group I) emanate outwardly and downwardly from vertical aperture 30 to illuminate the top and customer sides of an item. Scan lines within a second group (Group II) emanate outwardly from aperture 30 as three sub-groups to illuminate the customer side (Sub-group IIa), the customer and leading sides (Sub-group IIb), and customer and trailing sides (Sub-group IIc). Scan lines from the third group (Group III) emanate upwardly from horizontal aperture 28 as three sub-groups to illuminate the bottom (Sub-group IIIa), leading side (Sub-group IIIb), and trailing side (Sub-group IIIc). Reflected light 37 is redirected by pattern mirrors 18 towards spinner 16, which further directs it towards optical transceiver 14. Optical transceiver 14 directs and focuses reflected light 37 at deflector mirror 19, which further directs reflected light 37 towards photodetector 20. Photodetector 20 generates electrical signals representing the intensity of reflected light 37. Control circuitry 21 decodes bar code label 34 and controls power to laser 12 and motor 17. Control circuitry 21 may remove power from laser 12 and motor 17 to increase the longevity of laser 12 and motor 17. When scanner 11 is equipped with two lasers (Fig. 10), control circuitry 21 alternates power removal from lasers 140 and 142. For example, control circuitry 21 may remove power from laser 140 during one complete revolution of spinner 16, and remove power from laser 142 during the following revolution. Turning now to Fig. 2, scanner 11 is shown in perspective. Horizontal aperture 28 is located within substantially horizontal surface 38 of housing 32. Vertical aperture 30 is located within substantially vertical surface 40. Preferably, scanner 11 may be easily adapted to fit in a typical checkout counter 42. Standard dimensions for apertures in checkout counters like checkout counter 42 are about eleven inches in length (i.e., in the direction of item flow), twenty inches in width (i.e., in the direction across the direction of item flow), and five inches deep. Thus, despite its improved scan coverage, scanner 11 easily fits within standard apertures. This is due to the optimal size and arrangement of components within scanner 11. It is envisioned that top surface 38 be made substantially flush with the top surface 44 of counter 42, and also include a scale 43. Scanner 11 is installed within checkout counter 42 so that substantially vertical aperture 30 faces a store employee. Referring now to Figs. 3 and 4, the presently preferred arrangement of scanner components is shown in more detail. Laser 12 is preferably oriented at thirtyfive degrees from the horizontal or X-axis as shown in Fig. 2. Laser 12 is mounted within a bracket 15 which attaches to the lower wall of scanner 11. Beam 22 contacts planoreflective surfaces 108-114 of mirrored spinner 16 (Fig. 4). Spinner axis 116 is preferably oriented at twenty-two and a half degrees from a vertical or Z-axis. Facets 108-114 are preferably oriented at two and half degrees, four degrees, seven degrees, and eight and a half degrees, respectively, from spinner axis 116. These angles cause spinner 16 to generate four different sets of scan lines (Table III below) and are chosen to balance spinner 16 as much as possible consistent with the goal of generating four different sets of scan lines. Pattern mirrors 18 are all preferably flat mirrors. Scanning beams 24 from spinner 16 impact a first set of mirrors 50-72 and reflect therefrom to a second set of mirrors 74-98. Mirrors 80-98 within the second set further direct beams 24 to a third set of mirrors 100-106. The reference coordinate system for mirrors 50106 is shown in Figs. 2 and 5, and includes X, Y, and Z axes, with the Z-axis being out of the page. Coordinates Xm, Ym, and Zm are measured in inches, and angles Xr and Yr, are measured in degrees, with positive angles being measured in a counter-clockwise direction. Pattern mirrors 18 are positioned or located with respect to this coordinate system as described below. Each mirror is first oriented parallel to the X-Y plane through a point (Xm, Ym, Zm). Each mirror is rotated through an angle Xr about a line X' parallel to the X-axis and containing the point (Xm, Ym, Zm). Each mirror is rotated through an angle Yr about a line Y' parallel to the Y-axis and containing the point (Xm, Ym, Zm). Thus, these five variables uniquely define planes for mirrors 50-106 and are shown in Table I. Presently preferred values are shown. Origin O is defined such that: X=0 is on the centerline of the scanner; Z=0 is on the centerline of the scanner; and Y=0 is on the substantially horizontal surface 38. Mirror Xm Ym Zm Xr Yr 50 +3.375 -0.825 +3.200 +19.50 -108.50 52 +4.200 -0.825 +0.010 +24.00 -100.00 54 +4.200 -0.825 -0.010 +24.00 -80.00 56 +3.375 -0.825 -3.200 +19.50 -71.50 58 -3.400 -2.010 +4.345 +14.00 -168.25 60 -3.400 -2.010 -4.345 +14.00 -11.75 62 -3.905 -1.635 +3.850 -11.00 -125.00 64 -2.950 -3.410 +1.030 +21.50 -85.00 66 -2.950 -3.410 -1.030 +21.50 -95.00 68 -3.905 -1.635 -3.850 -11.00 -55.00 70 -5.430 -0.050 +4.720 +30.00 -132.50 72 -5.430 -0.050 -4.720 +30.00 -47.50 74 -1.315 -2.300 +4.585 -30.00 -167.25 76 +4.900 -4.725 +0.000 -77.50 +90.00 78 -1.315 -2.300 -4.585 -30.00 -12.75 80 -5.185 -3.095 +3.795 -60.00 +77.50 82 -4.880 -2.910 +3.685 -66.00 +102.50 84 -4.600 -3.155 +4.040 -52.25 +136.25 86 -4.600 -3.165 +4.040 -58.75 +149.00 88 -4.600 -3.165 -4.040 -58.75 +31.00 90 -4.600 -3.155 -4.040 -52.25 +43.75 92 -5.185 -3.095 -3.795 -60.00 +102.50 94 -4.880 -2.910 -3.685 -66.00 +77.50 96 -7.515 +0.485 +0.060 -37.00 +67.50 98 -7.515 +0.485 -0.060 -37.00 +112.50 100 -3.745 +6.250 +2.610 +50.00 +137.50 102 -6.420 +4.900 +0.000 +38.25 +90.00 104 -3.165 +6.275 +0.000 +69.25 +90.00 106 -3.745 +6.250 -2.610 +50.00 +42.50 Table II shows orientation and location data for the laser, spinner, and photodetector: Component Xm Ym Zm Laser -4.050 -3.940 +0.000 Spinner -6.875 -2.175 +0.000 Photodetector -4.645 -4.580 +0.000 In operation, laser beam 22 strikes each facet of mirrored spinner 16 in sequence. Table III summarizes the facet and mirrors involved in generating the forty scan lines (Figs. 6-9) during one revolution of spinner 16. The forty scan lines are arranged in the sequence in which they are generated as spinner 16 rotates in a counter-clockwise direction as viewed from above. Scan Line Facet Primary Mirror Secondary Mirror Tertiary Mirror Group Sub-group H1 108 70 82 104 I O1 108 62 96 102 II IIa L1 108 64 86 104 I E1 108 50 76 III IIIa D1 108 52 76 III IIIa B1 108 54 76 III IIIa C1 108 56 76 III IIIa N1 108 66 88 104 I P1 108 68 98 102 II IIa I1 108 72 94 104 I G1 112 70 80 100 II IIb F2 112 58 78 III IIIc K1 112 64 84 104 I E3 112 50 76 III IIIa D3 112 52 76 III IIIa B3 112 54 76 III IIIa C3 112 56 76 III IIIa M1 112 66 90 104 I A2 112 60 74 III IIIb J1 112 72 92 106 II IIc H2 110 70 82 104 I 02 110 62 96 102 II IIa L2 110 64 86 104 I E2 110 50 76 III IIIa D2 110 52 76 III IIIa B2 110 54 76 III IIIa C2 110 56 76 III IIIa N2 110 66 88 104 I P2 110 68 98 102 II IIa I2 110 72 94 104 I G2 114 70 80 100 II IIb F1 114 58 78 III IIIc K2 114 64 84 104 I E4 114 50 76 III IIIa D4 114 52 76 III IIIa B4 114 54 76 III IIIa C4 114 56 76 III IIIa M2 114 66 90 104 I A1 114 60 74 III IIIb J2 114 72 92 106 II IIc Referring now to Figs. 6-9, horizontal scan pattern 120, vertical scan pattern 122, and top-down scan pattern 124 are shown. Some of scan lines 26 appear to be curved. This is because scan beams 24 from spinner 16 do not lie in a flat plane; they lie on the surface of a shallow cone. The curvature of scan lines 26 represents the intersection of that cone and a particular intersecting plane (e.g., an aperture). The amount of curvature depends on the relative angle between the projected cone and this plane. Since the cone of light projects at different angles for the various scan lines 26, scan lines 26 may appear to have different curvatures. Horizontal scan pattern produces Group III scan lines which emanate from horizontal aperture 28. Scan lines within Sub-group IIIa include B1-B4, C1-C4, D1-D4, and E1-E4. Scan lines within Sub-group IIIb include A1-A2. Scan lines within Sub-group IIIc include F1-F2. Side 130 of aperture 28 is the operator side. Vertical scan pattern 122 (Fig. 7) produces Group II scan lines which emanate from vertical aperture 30. Scan lines within Sub-group IIa include O1-O2 and P1-P2. Scan lines within Sub-group IIb include G1-G2. Scan lines within Sub-group IIc include J1-J2. Side 132 of aperture 30 is the top side. Top-down scan pattern 124 (Fig. 8) produces Group I scan lines which emanate from vertical aperture 30 and include scan lines H1-H2, I1-I2, K1-K2, L1-L2, M1M2, and N1-N2. Fig. 9 illustrates the combined scan lines emanating from vertical aperture 30. Turning now to Fig. 10, bracket 15 may contain two lasers 140 and 142. Lasers 140 and 142 are preferably combined such that their laser beams are co-linear. This is accomplished by using a transparent window 144 with one partially reflective side 146. Window 144 is mounted on a support member and placed in front of laser 140 so that its beam strikes window 144 at a forty-five degree incidence angle. Laser 142 is oriented so that its beam is orthogonal to the beam of laser 140 and has a forty-five degree incidence angle with window 146. The resulting co-linear beams of both lasers 140 and 142 are parallel to and substantially co-linear with the path of the beam of laser 12 in the single-laser embodiment. Additional lasers may be easily incorporated by adding additional windows. Bracket 15 may be easily modified to accommodate three or more lasers. Preferably, lasers 140 and 142 are substantially identical and have substantially identical foci. The foci are preferably offset to increase the effective depth of field of scanner 11. Alternatively, the foci of lasers 140 and 142 may be different to enable scanner 11 to read bar codes of various spatial frequencies.

Claims: A bar code scanning system comprising a housing having first and second windows (30, 28) arranged generally orthogonally to one another, a laser source, (12), a rotatable mirror polygon (16), and first, second and third sets of plane pattern mirrors (50-72; 74-98; 100-106) arranged to provide scanning beans which illuminate an object to be scanned (36) with a plurality of intersecting lines, the three sets of scanning mirrors being arranged to provide two groups of scanning beams (I, II) which pass through the first window (30) and a further group of scanning beams (III) which passes through the second window (28), characterized in that the three groups of scanning beams together illuminate the object (36) from angles corresponding to five of the six sides of a cube. A scanning system according to claim 1 characterized in that the first window is substantially vertical and the second window is substantially horizontal. a scanning system according go claim 1 or claim 2, characterized in that the first set of scanning beams (I) is directed obliquely downwards on the object (36) to illuminate its upper side and the side adjacent the first window (30); the second set of scanning beams (II) is directed on the object (36) to illuminate its side adjacent the first window and the leading and trailing sides in the direction of scan; and the third set of scanning beams (III) is directed upwards on the object to illuminate its lower side and the leading and trailing sides in the direction of scan. A scanning system according to any preceding claim, characterized in that the first set of mirrors (50-72) receives light reflected from the rotatable polygon (16); the second set of mirrors (74-98) receives light reflected from the first set; and the third set of mirrors (100-106) receives light reflected from the second set. A scanning system according to any proceeding claim, characterized in that the rotatable mirror polygon (16) has four plane reflecting surfaces (108-114) each arranged at a different angle to the axis of rotation (116) of the polygon. A scanning system according to claim 5, characterized in that the axis of rotation (116) of the spinner (16) is orientated at an angle to the vertical. A scanning system according to any preceding claim, characterized by further comprising an optical transceiver (14) arranged to receive light reflected by the scanned object (36), and light sensitive means (20) arranged to generate signals representing the intensity of light reflected from a bar code (34) on the object. A scanning system according to any preceding claim, characterized by first and second laser sources (140,142) arranged to provide coincident beams, and to have offset foci whereby the effective depth of field of the scanning system is increased. A scanning system according to any one of claims 1 to 7, characterized by first and second laser sources (140,142) arranged to provide coincident beams, and to have different foci, whereby bar codes of different spatial frequencies can be read.

Inventors: DETWILER PAUL OLIVER, MERGENTHALER BARRY MYRON, TANG HONG, DETWILER, PAUL OLIVER, MERGENTHALER, BARRY MYRON, TANG, HONG
Applicants: NCR INT INC, NCR INTERNATIONAL INC.
Application year: 1996
Main classification: G06K7
IPC codes: G06K7