Patent Description:
Radio frequency identification (RFID) tags are electronic devices that may be affixed to items whose presence is to be detected and/or monitored. The presence of an RFID tag, and therefore the presence of the item to which the RFID tag is affixed, may be checked and monitored by devices known as "readers" or "reader panels. " Readers typically transmit radio frequency signals to which the RFID tags respond. Each RFID tag can store a unique identification number. The RFID tags respond to reader-transmitted signals by providing their identification number and additional information stored on the RFID tag based on a reader command to enable the reader to determine an identification and characteristics of an item.

Current RFID tags and labels are produced through the construction of an inlay which includes a chip connected to an antenna applied to a substrate. The inlay is then inserted into a single tag or label. These labels or tags are then printed by either conventional printing processes, such as flexographic processes, and then variable information may be printed either with the static information or singularly. The chips are then encoded in a printer which has a read/encoding device or separately by a reader/encoding device. This method is slow and costly due to multiple steps that are involved in the manufacture of the product. In addition, such a method can only be accomplished typically one tag or label at a time per lane of manufacturing capability. This can result in higher cost, limited output, and limited product variation in terms of size, color, and complexity.

Furthermore, typically RFID output power is set to what is necessary to encode the transponder that is electrically singulated in the RF field. There is no other singulation for the transponders therefore it is expected that there is only one transponder present in the RF field at a time. However, the transponder positioned over the antenna may be defective or less sensitive to the set power level such that an adjacent transponder is acquired by the antenna and therefore encoded creating misreads and other errors.

Thus, there exists a need for an RFID printer that is capable of both printing on record members, such as labels, tags, etc., and capable of encoding, or writing to and/or reading from an RFID transponder contained on the record member, as well as verifying the data encoded to the RFID tags. Further, there exists a need for preventing misreads or other errors such as duplicate tags with the same encoded data.

<CIT> describes a system, methods and a computer program product for an adaptive control for adjusting the electromagnetic interrogation signal of an RFID transceiver where said signal is used to read and/or write to an RFID transponder, or to adjust the gain of the RFID transceiver, or adjust both the gain and the signal strength. The system includes a RFID transceiver having at least a transmitter portion and a receiver portion and capable of generating electromagnetic signals, a signal-to-noise ratio module, and an adaptive control module that adjusts the power of the electromagnetic signal of the transmitter portion or the gain of the receiver portion according to the signal-to-noise ratio of a first electromagnetic signal. In one embodiment the system may be employed in printer-encoder devices for reading or encoding RFID transponders during a printing process.

<CIT> describes a calibration apparatus for determining a location of a transponder supported by a printer media. The calibration apparatus uses a transceiver to attempt to read, write or otherwise communicate with the transponder. Controller logic of the calibration apparatus uses successful and unsuccessful attempts to communicate to determine the location of the transponder.

<CIT> describes a method of RFID power ramping for tag singulation that includes activating the trigger control of an RFID reader for engaging power to begin reading RFID tags. A user may take a first reading at a low power level of a volume around the RFID reader establishing a first read volume. If the user does not detect a particular RFID tag, the user may then increase the transmitting power from the RFID reader to a second higher power level obtaining a second reading of RFID tags in a second read volume.

<CIT> describes a media processing apparatus including a self-calibrating encoding assembly that sends read/write inquires to determine appropriate power levels for encoding encodable objects. The apparatus includes a control subsystem that tracks the power levels of the encoding assembly and the corresponding positions of media carrying the encodable objects.

The claimed invention is defined by the independent claim. Specific embodiments are defined in the dependent claims.

The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.

A high speed tabletop and industrial printer with integrated high speed RFID encoding and verification at the same time is disclosed. The industrial printer is capable of both printing on record members, such as labels, tags, etc., and capable of encoding from an RFID transponder contained on the record member, as well as verifying the data encoded to the RFID tags. The industrial printer may comprise two RFID reader/writers that may be individually controlled, such that the industrial printer can encode and verify at the same time. Specifically, one of the RFID reader/writers may encode RFID tags while the web is moving; and the second RFID reader/writer may verify the data encoded to the RFID tags. Further, the printer may utilize adaptive RFID power settings to prevent misreads and other errors when encoding tags.

Referring initially to the drawings, <FIG> illustrates a thermal tabletop and/or industrial printer device <NUM> with integrated high speed RFID encoding and verification. The thermal tabletop and/or industrial printer <NUM>, comprises a reader and/or encoding device, as well as a verification device. The reader and/or encoding device can read and program an RFID device, such as a RFID chip, that is contained in an inlay which may or may not be incorporated into a label, tag, or any other desired product, and which can also print onto the product without damaging or otherwise undesirably affecting the RFID device. The inlay may also be affixed directly to the product without necessarily being incorporated into a label or tag, such as through use of an adhesive to affix the inlay to the product.

In some exemplary embodiments, the products can be arranged into sheets or rolls, and multiple products can be printed, encoded, or verified at one time, in a sequential manner, simultaneously or substantially simultaneously. In some exemplary embodiments, reader and chip/antenna configurations can allow the encoding and verification to occur in line, so that printing, encoding, variable data imaging, verifying, and finishing can all be completed in one continuous process. As used herein a continuous process includes both a roll to roll configuration, and a sheet fed process in which there is no stopping of the process. Continuous may also include a slight incremental stopping, indexing, advancing or the like which does not last longer than a couple of seconds.

Furthermore, a cutter (not shown) can also be included in the printer <NUM>. The cutter would be used to cut the web being printed on and the RFID tags disposed thereon. Typically, the cutter would be powered from the printer <NUM>, or can be powered by any suitable means as is known in the art.

Printing as provided herein may be accomplished by using any number of processes, including impact and non-impact printers, flexographic, gravure, ink jet, electrostatic and the like just to provide some representative examples. Static printing may include company logos, manufacturers' information, size, color and other product attributes. Variable printing may include identification numbers, bar codes, pricings, store location and such other information as a retailer may decide is required.

Exemplary RFID devices, e.g. inlays, tags, labels and the like are available from Avery Dennison RFID Company and Avery Dennison Retail Information Services of Clinton, SC and Framingham, MA, respectively. Such devices may be provided in any number of antenna and size configurations depending on the needs or end-use applications for which the product is intended.

<FIG> disclose multiple views of the industrial printer <NUM>, and are described below. The printer <NUM> can be any suitable size, shape, and configuration as is known in the art without affecting the overall concept of the invention. One of ordinary skill in the art will appreciate that the interior and/or exterior shape of the printer <NUM> as shown in <FIG> is for illustrative purposes only and many other shapes of the printer <NUM> are well within the, scope of the present disclosure. Although dimensions of the printer <NUM> (i.e., length, width, and height) are important design parameters for good performance, the printer <NUM> may be any shape that ensures optimal high speed encoding and verification.

Generally referring to <FIG>, the thermal tabletop and industrial printer <NUM> has a generally rectangular shape with a printer cover <NUM>. However, tabletop printer covers can be cumbersome to remove when standard screws are used to fasten the cover down. Thus, in a preferred embodiment, the standard screws are replaced with thumb screws <NUM> (as shown in <FIG>). The thumb screws <NUM> can be any suitable thumb screw <NUM> as is known in the art, and allow a user to easily remove the printer cover <NUM> whenever necessary without need of a screwdriver or other such tool. Further, the printer <NUM> comprises an access door <NUM> and handle <NUM>. The access door <NUM> can be actuated via the handle <NUM> to provide access to the front of the printer <NUM> and to load supplies. Once the access door <NUM> is opened, the user installs the supply roll <NUM> on the supply roll holder <NUM>. The supply roll <NUM> contains supplies for the printer <NUM> to print on. Then, the liner table up <NUM> acts as a rewind holder for spent liner for adhesive backed labels.

Furthermore, the printer <NUM> comprises a supply damper <NUM> that helps to remove vibration from the supply roll <NUM> to improve print quality. And, an out of stock switch <NUM> provides an on/off indication if supplies are loaded in the printer <NUM>, or if the printer <NUM> is in need of supplies. A supply guide or frame <NUM> holds and centers supplies. Further, an array sensor (shown in <FIG> as <NUM>) is attached to the supply guide to detect and accommodate minor variations in aperture location. An upper guide <NUM> guides supplies within the printer <NUM>, and a loading label <NUM> is a label indicating the supply path for users to load supplies into the printer <NUM>. In one embodiment, the upper guide <NUM> includes a lighted paper path to Illuminate the supplies for the user. The printer further comprises a print head <NUM>. The print head <NUM> is a thermal print head such that the printer <NUM> automatically detects dot density and the location of failed heating elements. Additionally, the printer comprises a print head holder <NUM> which is a cast aluminum piece that the print head <NUM> is installed on to secure the print head <NUM> in place. Further, a release handle <NUM> releases the print head <NUM> from the holder <NUM> when needed.

The printer <NUM> also comprises a ribbon spindle <NUM> and a ribbon take-up <NUM>. The ribbon spindle <NUM> is a DC motor-controlled supply for ribbon, and the ribbon take-up <NUM> is a DC motor-controlled takeup for ribbon. Further, a wireless antenna <NUM> is also included within the printer <NUM>. The wireless antenna <NUM> is an <NUM> b/g/n dual band antenna for communicating with a router or other device. Additionally, the printer comprises two other antennas. An RFID antenna <NUM> to allow for the RFID encoding of supplies, and an RFID verifier <NUM>, which is an external antenna for reading RFID supplies. It is noted that the power used to on the second RFID module controlling the verify antenna can be either the writer adjust power from the first RFID module, the write power from the RFID encode module or another suitable power setting.

Generally referring to <FIG>, the printer <NUM> comprises an overhead LED (light emitting diode) door <NUM> which covers the overhead LED board <NUM> which is a reflective supply sensor LED. Further, the printer includes an LED cap <NUM> which is a reflective supply sensor reflector, and an index sensor <NUM> which is a unique array sensor that automatically detects aperture sense marks. Specifically, the lighted sensor array <NUM> automatically senses the position of holes disposed through the web which are used for sense marking, and correctly indexes the printing to the RFID tags. By using the sensor array <NUM>, the printer <NUM> can determine which of the individual sensors within the array should be used for the indexing to account for manufacturing variations in the placement of the aperture.

Generally referring to <FIG>, the back of the printer <NUM> comprises a back cover <NUM> that covers the electronics panel (shown in <FIG>). A display panel <NUM> displays a user interface, and the wireless antenna <NUM> (as shown in <FIG>) can also be seen on the back of the printer <NUM>. Generally referring to <FIG>, the back of the printer <NUM> is shown without the cover <NUM>. The CPU board <NUM> or main PC board is shown, as well as the RFID I/O board <NUM> which is a module that contains both the encoding and verification modules. The power supply <NUM> which is the main supply for power in the printer <NUM> is also shown at the back of the printer <NUM>. Furthermore, the display panel <NUM> (as shown in <FIG>), and the wireless antenna <NUM> (as shown in <FIG>) can both be seen in <FIG> as well.

Generally referring to <FIG>, the right side of the printer <NUM> is shown. The right side of the printer <NUM> shows the front cover <NUM>, as well as the wireless antenna <NUM> (as shown in <FIG>). Further, the CPU board <NUM> (as shown in <FIG>) is shown, as well as an I/O switch <NUM> and I/O outlet <NUM>. Generally referring to <FIG>, the left side of the printer <NUM> is shown. The left side of the printer <NUM> shows the wireless antenna <NUM> (as shown in <FIG>), as well as a supply door <NUM> that secures and allows access to the supply roll <NUM>. Further, a NFC I2C chip <NUM> is also disclosed which provides unique capability to the printer <NUM> and allows the printer <NUM> to communicate directly with the main processor through a bridge. Finally, the printer <NUM> comprises a display panel <NUM> which includes a keypad <NUM>. The present invention contemplates that communication to the printer's main processor can use Near Field Communication (HF RFID) for both forward and reverse data.

In a preferred embodiment, the printer <NUM> includes a plurality of keys including the keypad <NUM> and a trigger key. The keypad <NUM> may be utilized to enter alpha-numeric data to the printer <NUM>. Alternatively, the keypad <NUM> may have only a limited number of keys that are actuable in accordance with information depicted on a display <NUM> for selecting a number of operations of the printer, for example, feeding a web of record members through the printer <NUM>, displaying status information, etc. The trigger key may be actuable by a user in various modes of the printer <NUM> to actuate the printing system and/or the RFID read/write module <NUM>. Alternatively, one or more of these devices can be actuated automatically by a controller of the printer <NUM> in accordance with a stored application program. In addition to displaying status information or data entered via the keypad <NUM>, the display <NUM> may also be controlled to provide prompts to the user to actuate the trigger key and/or other keys so as to control various operations of the printer <NUM>.

Generally referring to <FIG>, the top, perspective view of the printer <NUM> discloses the RFID verifier <NUM> and the RFID encoder <NUM> (as shown in <FIG> as antennas <NUM> and <NUM> respectively). Specifically, the RFID encoder <NUM> encodes RFID tags while the web is moving, and the RFID verifier <NUM> verifies the data encoded to the RFID tags.

Specifically, the industrial printer <NUM> may comprise two RFID reader/writers (<NUM> and <NUM>) that may be individually controlled, allowing the industrial printer <NUM> to encode and verify at the same time. Thus, the industrial printer <NUM> may comprise both an RFID writer or encoder <NUM> module and an RFID verifier <NUM> module that operate independently encoding and verifying RFID transponders within the label, tag, or other construction media. The two RFID modules may cooperate with each other and with the processor of the industrial printer <NUM>. The RFID encoder module <NUM> may encode the desired information to the RFID transponder when the transponder reaches the encoding location. The RFID verifier module <NUM> may read the transponders and may compare it with information provided by the printer controller. Then, any stock that contains a failed RFID may optionally be marked by the print mechanism, so as to designate it as defective with a visual indication for the user, and the failed verification will be sent to a host for data logging purposes.

Furthermore, typically RFID output power may be set to what is necessary to encode the transponder that is electrically singulated in the RF field. There may be no other singulation for the transponders therefore it is expected that there is only one transponder present in the RF field at a time. However, the transponder positioned over the antenna may be defective or less sensitive to the set power level such that an adjacent transponder is acquired by the antenna and therefore encoded. Thus, to prevent misreads or other errors such as duplicate tags with the same encoded data, the printer <NUM> may utilize adaptive RFID power settings.

Generally referring to <FIG>, the industrial printer <NUM> may comprise two RFID reader/writers (<NUM> and <NUM>) that may be individually controlled, allowing the industrial printer <NUM> to encode and verify at the same time. Thus, the industrial printer <NUM> may comprise both an RFID writer or encoder <NUM> module and an RFID verifier <NUM> module that may operate independently encoding and verifying RFID transponders within the label, tag, or other construction media. The two RFID modules may cooperate with each other and with the processor of the industrial printer <NUM>. At <NUM>, a label may be fed into position, and then at <NUM> the RFID encoder module <NUM> may encode the desired information to the RFID transponder when the transponder reaches the encoding location. At <NUM>, the RFID verifier module <NUM> may read the transponders and at <NUM> may compare it with information provided by the printer controller. Thus, the two RFID reader/writers (<NUM> and <NUM>) may be operated independently (see <NUM>), allowing the industrial printer <NUM> to simultaneously encode and verify the RFID transponders within the RFID labels (see <NUM>). At <NUM>, it may be determined whether the RFID tag contains a failed RFID. Then, at <NUM> any stock that contains a failed RFID may optionally be marked by the print mechanism, so as to designate it as defective with a visual indication for the user, and the failed verification will be sent to a host for data logging purposes (see <NUM>).

Furthermore, typically RFID output power is set to what is necessary to encode the transponder that is electrically singulated in the RF field. There is no other singulation for the transponders therefore it is expected that there is only one transponder present in the RF field at a time. However, the transponder positioned over the antenna may be defective or less sensitive to the set power level such that an adjacent transponder is acquired by the antenna and therefore encoded. Thus, to prevent misreads or other errors such as duplicate tags with the same encoded data, the printer <NUM> utilizes adaptive RFID power settings.

Specifically, two power levels are employed to assist in the electrical singulation by software. As reading the contents of a transponder requires less power than encoding it, a sufficiently low power level is used to create an RF field small enough in strength so that the only transponder acted upon is the one positioned immediately over the antenna. At this write adjust power level, the serialized tag identification (TID) field of the RFID transponder would be read and saved. Next, the power level would be increased to the level necessary to write the tag. The TID serial number would be included in the encode command to singulate on the particular tag containing the serial number and ignore any adjacent tags that may accidently be in the RF field. Finally, the RF power level is reduced back down to the selected write adjust level, such that the RFID verifier can read and compare the encoded data of the tag with the data originally sent in the write command to confirm the tag is accurately encoded.

Furthermore, it is known that there is variation within a supply roll from RFID transponder to RFID transponder. The disclosed printer utilizes an adaptive algorithm that will allow for a variation in transponders without generation of an error. This algorithm will start at a write adjust low enough not to detect a transponder and then will increment up in steps until a transponder is seen. For the next transponder, the previous detection point will be used as a starting point and then will increment up if needed. If more than one transponder is detected the write adjust owner will be reduced, if no transponders are detected then the write adjust power will be increased until a transponder is detected. The selected power will then be used as a starting point for the next transponder and so forth. If this is not sufficient to uniquely identify the transponder the singulation process will be enhanced as follows.

It may be advantageous to place a shield between Reader <NUM> and <NUM> as shown in <NUM> <FIG> to minimize the cross talk between Reader <NUM> and <NUM>.

Generally referring to <FIG>, two power levels are employed to assist in the electrical singulation by software. As reading the contents of a transponder requires less power than encoding it, a sufficiently low power level is used to create an RF field small enough in strength so that the only transponder acted upon is the one positioned immediately over the antenna (see <FIG>,<NUM>). At this writer adjust power level, the serialized tag identification (TID) field of the RFID transponder would be read and saved (see <NUM>). At <NUM>, the power level is increased to the level necessary to write the tag. At <NUM>, the TID serial number would be included in the encode command (see <NUM>) to singulate on the particular tag containing the serial number and ignore any adjacent tags that may accidently be in the RF field. At <NUM>, the RF power level is reduced back down to the selected read level, and at <NUM> the RFID verifier can read and compare the encoded data of the tag with the data originally sent in the write command to confirm the tag is accurately encoded.

Furthermore, it is known that there is variation within a supply roll from RFID transponder to RFID transponder. The disclosed printer utilizes an adaptive algorithm that will allow for a variation in transponders without generation of an error. At <NUM>, this algorithm will start at a writer adjust power low enough not to detect a transponder and then at <NUM> will increment up in steps until a transponder is seen. For the next transponder, the previous detection point will be used as a starting point and then will increment up if needed (see <NUM>). If more than one transponder is detected the writer adjust power will be reduced. If no transponders are detected then the writer adjust power will be increased until a transponder is detected. The selected power will then be used as a starting point for the next transponder and so forth.

Generally referring to <FIG>, the microprocessor controls the printer <NUM> of the embodiments of the present invention to encode, write to and/or read an RFID transponder in a label and to print on that same label. At block <NUM>, the processor controls the printer motor to feed a label into position at which point the movement of the label web is stopped. Once the label is in position, the RFID transponder will be generally aligned with the antenna. At block <NUM>, the microprocessor retrieves data from the memory that has been sent from the host for writing to the RFID transponder. This data may be for example electronic product code (EPC) information or other data. Thereafter, at block <NUM>, the microprocessor generates a program command. The program command is a packet of control information to be sent to the RFID interrogator or module. From block <NUM>, the microprocessor proceeds to block <NUM> to send the generated packet to the RFID module i.e. interrogator.

it is noted that in a preferred embodiment, the RFID module or interrogator includes its own microprocessor. The RFID module performs a number of functions. For example, the module determines whether an RFID transponder is within its field by reading the RFID transponder's identification code. The RFID module as instructed by the controller erases the data stored in the RFID transponder, verifies the erasure and then programs the RFID data received from the microprocessor into the RFID transponder. The RFID module also verifies that the data has been programmed Into the RFID transponder by reading the data stored in the transponder after a programming operation to verify that the data was correctly written into the RFID transponder. Upon completing the verification process, the RFID module generates a response packet that is transmitted back to the microprocessor.

The microprocessor, at block <NUM>, receives the response packet from the RFID module and at block <NUM>, the microprocessor extracts data from the response packet. The data in the response packet may include a code representing the successful programming of the RFID transponder or the data may include a code representing a particular error. For example, the response data may include an error code indicating that the RFID module could not read an RFID tag, or a code indicating that the tag could not be erased or a code indicating that the tag was not accurately programmed. At block <NUM>, the microprocessor decodes the data in the response packet to determine at block <NUM> whether the programming of the RFID transponder was successful or whether the response packet from the RFID module included an error code. If the programming of the RFID transponder was determined to be successful, that is, without error, at block <NUM>, the microprocessor proceeds to block <NUM> to control the feeding or movement of the web and the printing of data on the label via the print head. It is noted, that while the RFID transponder is being read from or programmed, the web is stationary. However, during the printing of information on a record member at block <NUM>, the microprocessor moves the web past the print head during the printing operation. If the microprocessor determines at block <NUM> that the response packet received from the RFID module indicated an error condition, the microprocessor proceeds to block <NUM> to display an error message on a liquid crystal display of the printer. From block <NUM>, the microprocessor proceeds to block <NUM> to feed the label with the defective RFID transponder past the print head and controls the print head to print an overstrike image, such as evenly spaced longitudinally extending bars, on the record member RM. This indicates that the RFID transponder is defective. From blocks <NUM> or <NUM>, the microprocessor proceeds to block <NUM> to feed the next label into position as discussed above.

Furthermore, in a preferred embodiment, the thermal printer <NUM> also provides for optimized RFID encoding by reducing the time required to complete a user defined function. A user sequence may include the following command sequence that will select a tag, write the words (<NUM>-<NUM>) of the EPC memory, write the access password in the reserved memory and set the lock memory to password lock and then read the the EPC memory. In a RFID printer with a RIFD writer (interrogator) there are two opportunities for optimization. The RFID printer communicates across a communication channel for example serial, USB or other method to a RFID writer that contains an independent processor. This communication involves a handshake and necessary error processing. If it is already known that a sequence of commands will be sent to the RFID writer, the implementation of a command stack sent in one sequence will eliminate unnecessary overhead between the RFID printer and the RFID writer. If this is not sufficient to uniquely identify the transponder the singulation process will be enhanced as follows.

RSSI singulation process begins with <NUM> in <FIG>. Printer <NUM> either backfeeds or forward feeds in order to center the metal of the first candidate inlay over the centerline of the coupler depending on the value of tag save as indicated by <NUM>. The amount of distance to overfeed, <NUM>, or backfeed, <NUM>, as determined by the user in identifying the ideal couple point which will be referred to as first tid position.

in step <NUM> the power is set to a write adjust power and (in <NUM>) attempt to read a <NUM>-bit TID. In <NUM> we determine if we successfully read a <NUM> bit tag. If we have we continue on to <NUM>. If we fail to read a <NUM> bit transponder we will go to step <NUM>. On step <NUM> we will try to read a <NUM> bit transponder in <NUM>. If we fail we will record the error as <NUM> and go to <NUM> else we go to step <NUM>. in <NUM> we determine if we are encoding while the web is moving. If this is a stop to encode case we go to <NUM>.

In the case of encoding while the web is moving we will do a tag inventory with the tag population set to <NUM>. If from the tag inventory we receive <NUM> tags will record <NUM> and go to error processing <NUM>. If we find <NUM> or more transponders will record error <NUM> and go to error processing <NUM>. If there is only one transponder we will determine if we are going to move forward or reverse in step <NUM>. If there are <NUM> or <NUM> tags the RSSI values will be compared in step <NUM>. If there is not a transponder with a count return signal strength indicator of <NUM> or more we will record error <NUM> and processed to error processing <NUM>. If there is a candidate transponder indicated by the RSSI we will processed to step <NUM> to determine motion direction.

In step <NUM> depending on the user selection of the Tag Saver value we determine the motion. If the value is yes we processed to the tag saver function in <NUM> if the value is no we processed to encoding the transponder in <NUM>.

For encoding the transponder in <NUM> we will proceed to <NUM> to determine the number of transponders located. If there was one one transponder located we encode it in <NUM> and proceed to the finish encode in <NUM>. If the number of transponders in <NUM> is greater than <NUM> we go to <NUM> to advance the encode zone into the RFID encode antenna. If <NUM> we perform another Inventory with a transponder population set to <NUM>. In <NUM> we determine the number of transponders that responded. If the number is less than <NUM> or greater than <NUM> we record the error as <NUM> and proceed to error process <NUM>. If there was one tag responding in <NUM> we determine if we have already seen this transponder. If we have we record the error as <NUM> and proceed to error process <NUM>. is this the first time we have seen this transponder we proceed to encoding in <NUM>. Backing up to step <NUM> if two tags responded we processed to <NUM> where we decide if one of the tags has been seen before. If not we record the error as <NUM> and proceed to error process <NUM>. If we have seen on of the transponders before we proceed to select new transponder in <NUM> and proceed to <NUM> to encode transponder.

In <NUM> we encode the transponder with the new data setting S3 and proceed to finish encoding in <NUM>.

If after <NUM> it was determined that the tag saver was desired by the user in <NUM> we proceed to 2220to reverse motion the transponder over the RFID encoding antenna show in Fig <NUM>. The tag inventory with the transponder population set to <NUM> in <NUM> is performed. If only <NUM> transponder responds we proceed to <NUM> to encode the required data into the transponder. If there is any other response error <NUM> is recorded and we proceed to error processing <NUM>.

After <NUM>, the method proceeds to finish encode in <NUM>. A decision point is reached if we have more inlays to process as required by the user in <NUM>. If there is no decision point, then in step <NUM> a done state is reached. If there are more inlays to process we increment the step count for the RFID process and then look to see if the step count is equal to the next inlay position in <NUM>. If no, return to increment the step count. If yes we do an inventory with a transponder population set to <NUM> setting S2. If there do a check in <NUM> if we located <NUM> transponder. If we did in <NUM> we encode the transponder with the required data and proceed to <NUM> decision. If there is any other response we set the error code to <NUM> or <NUM> and proceed to error processing <NUM>.

If at decision <NUM> we took the stop to encode path this is the process. In <NUM> we proceed to determining if the motion is stopped in <NUM>. If no we return wait. If yes we proceed to <NUM> and do a tag inventory with the population set to <NUM>. If we received <NUM> or more than <NUM> tags responding in <NUM> we mark the error code and proceed to error process <NUM>. if there was <NUM> tag we proceed to <NUM>. If we received <NUM> or <NUM> tags we compare the RSSI value at <NUM>. In <NUM> we check to see if we have an RSSI value of on tag that is at <NUM> count greater than the other tags. If no we mark the error code <NUM> and proceed to error process <NUM>. If yes we proceed to <NUM> and encode with the required data.

In <NUM> we determine if there are more transponders to encode if yes we return to decision point <NUM>. If no we proceed to done state <NUM>.

The error process is brief - at <NUM> we enter the error process. On <NUM> we stop motion of printer <NUM> and inform the user there is an error then proceed to the done state <NUM>.

Generally referring to <FIG>, traditional communication operation <NUM> would involve the RFID printer <NUM> issuing individual commands for Write EPC <NUM>, Write Access <NUM>, Password Lock <NUM>, and Read EPC <NUM>, then the RFID interrogator <NUM> would process each command (<NUM>, <NUM>, <NUM>, and <NUM>) and respond <NUM> after each command creating unnecessary overhead between the RFID printer <NUM> and the RFID interrogator <NUM>. Generally referring to <FIG>, the RFID printer <NUM> creates a high level command optimization operation <NUM>, wherein the RFID printer <NUM> issues the individual commands of Write EPC, Write Access, Password Lock, and Read EPC as one command <NUM>, allowing the RFID interrogator <NUM> to process all the commands <NUM> at once and then respond <NUM>, saving time and eliminating the unnecessary overhead between the RFID printer <NUM> and the RFID interrogator <NUM>.

in addition between the RFID writer and the RFID tag there is a handshake that can be optimized if there is pre-knowledge that a set of high level commands will be sent. The handshake process can be optimized if there is no reason to power down the RFID tag. However, one reason the RFID tag may need to be powered down is to change the power level to a different power. For instance if the RFID tag EPC memory was written at one power and the RFID tag EPC memory was read at a different power, then a power down is necessary.

Furthermore, EPC RFID access commands must follow an inventory to obtain the tag handle REQ_RN. For each access (Read, Write, Kill, Lock) command that is done this sequence must be followed. For a thermal barcode printer with an RFID writer this sequence contains redundant steps if more than one access command is executed after the tag has been acquired since the REQ_RN handle must be reacquired for the same tag for each access command. The EPC Gen <NUM> protocol specifies that as long as the tag is powered on it must retain the REQ_RN handle. Thus, in order to optimize the command sequence the select and inventory commands issued for each access command have been optimized out as long as the tag is powered on.

Generally referring to <FIG>, the traditional communication process of a high level command sequence, for illustrative purposes the following commands: Write EPC, Write Access Code, Lock Tag, ReadEPC; without foreknowledge of communication requires the RFID Interrogator <NUM> for to issue the command sequence for encoding the <NUM> bit EPC, a query command <NUM> and the RFID tag <NUM> will respond RN_16 ,<NUM>, then the RFID interrogator <NUM> issues Ack (RN16) <NUM> and the RFID tag <NUM> responds with PC, EPC & CRC-<NUM><NUM> to identify the command stream. Then the RFID interrogator <NUM> issues REQ_RN <NUM> and the RFID tag <NUM> issues the handle (New RN16) <NUM>, then the RFID Interrogator <NUM> issues the Write Command <NUM> and the RFID tag <NUM> responds with the Status - Success, Error Failure <NUM>. At this point the RFID Interrogator <NUM> issues Read PC bits and ReqRN <NUM> to which tag <NUM> responds with the EPC. Since the RFID Interrogator had not preprocessed the command sequence in Encode Access Password the chip must be powered on and transitioned to the Open state. RFID Interrogator <NUM> reissues the Query, ACK, ReqRN, ReqRN before writing the Access Password in <NUM>. The tag <NUM> will respond appropriately in <NUM> to these commands. Next the RFID interrogator <NUM> will issue the command sequence required to lock the tag <NUM>. Since the tag <NUM> was not kept in the open state the RFID Interrogator <NUM> will need to reissue Query, ACK, ReqRN, ReqRN before locking tag <NUM>. Tag <NUM> will respond appropriately <NUM>. A final read is shown in <NUM> that could be used for validation purposes to ensure accuracy. The tag <NUM> is starting from power on the Query, ACK and Query Rep need to be issued from RFID Interrogator <NUM> to which tag <NUM> responds in <NUM>. However, if the RFID Interrogator <NUM> already has knowledge of a command stream as illustrated in <FIG> then the select and query commands become redundant, and the interrogator <NUM> and the chip (or tag <NUM>) only need to issue the Req-RN <NUM> before receiving the next access command <NUM>. Thus, as illustrated in <FIG>, the communication process with foreknowledge of the communication sequence discloses the RFID Interrogator <NUM> issuing the next access command <NUM> to encode the Access Password the Query and ACK are eliminated to increase the encoding throughput. Req_RN command at1022 followed by the <NUM> bit write to the access password. RFID tag <NUM> at <NUM> issuing the handle (New RN <NUM>) <NUM> and the RFID Interrogator <NUM> responding with the Access Command <NUM> and the RFID tag <NUM> responding with the Status - Success, Error Failure <NUM>. This process is continued to be followed in <NUM> for the lock command. In <NUM> the tag <NUM> responds appropriately. If it is desired to do a final read to ensure encoding accuracy if the read is at the same power the process between <NUM> and <NUM> is shown streamlined in <NUM> and <NUM>. Thus, with knowledge of a command stream, the communication sequence between the interrogator <NUM> and the chip (or tag <NUM>) can be optimized via removal of the query and Ack commands between the access commands. This optimization reduces the overall cycle time.

Further, a composite RFID Interrogator Host Write memory command which provides for successive writes to various memory blocks in a RFID Gen <NUM> Tag device before returning the results of the command to the host can be utilized to optimize system throughput. This command accepts memory block identification for each memory block to be written and data to be written into each memory block. The RFID Interrogator executes the necessary Gen <NUM> RFID tag device commands to place the tag into the Open State and then proceeds to execute to Gen <NUM> the successive Write commands to the various memory blocks, defined in the host command.

When all memory blocks have been written, the RFID Interrogator returns the tag device to the ready state and returns the status of the results to the host.

Furthermore, optimization of the thermal printer occurs with successive write and verify commands. Specifically, a composite RFID interrogator host write/verify command which provides for multiple writes to various memory areas in an RFID Gen <NUM> tag device where the tag device is left in the Open state for the duration of the entire set of command write/verification operations is utilized. The command is executed in two stages. In the first stage, the command is defined as a record with a unique ID, followed by a flag that specifies whether an optional tag identification (TID) is to be used for identifying the tag to be written to. This is followed by one or more write directives, where each directive is comprised of the memory bank to write to, the word offset into the memory bank to begin writing, the number of words to write, and a flag that indicates whether the write is to be verified.

In the second stage, the data to be encoded for each tag is sent as a record beginning with a unique ID that matches the ID defined in the first stage, followed by an optional TID used to identify the tag in the RF field, followed by one or more write directives that match the write directives defined in stage <NUM>. In this record each write directive contains the actual data to be written to the memory areas specified in stage <NUM>. After writing, the specified memory banks optional verification read could occur in the same state. If the chip architectures requires a new session for the verification read, this will be done immediately after the write phase. Upon completion of the write and verification phases the Interrogator returns the tag device to the Ready state and returns the results of the command to the host.

Thus, this composite RFID interrogator Host Write memory command would be used in the RFID enabled thermal barcode printer <NUM> reducing the amount of time required to complete a user defined command sequence increasing the overall throughput of the RFID encode sequence which would allow a user to increase the throughput and encode at higher web speeds. As a result, more RFID tags per minute can be produced thus increasing printer productivity. This higher productivity would increase printing capacity to meet demand.

Generally referring to <FIG>, an exemplary embodiment of a system which may include at least a printer <NUM> and encoder/verifier is shown. Printer <NUM> can print through flexographic, offset, gravure, digital offset or xerographic digital processes, or any other desired print process. Printer <NUM> can accept input information in any format, for example Portable Document Format (PDF), Personalized Print Markup Language (PPML), Java Script Object Notation (JSON) or any other desired format. The information is typically provided from a computer which may either be collocated with the printer <NUM> or may be provided in a remote location. The printer <NUM> may be connected to the computer via an intranet or over the Internet, depending on the requirements of the manufacturing operation. Printer <NUM> can also include one or more RFID readers and RFID encoders <NUM> (as shown in <FIG>, such as for example <FIG>) which can be arranged in any configuration, for example in a configuration that allows RFID encoding to occur in line, either before or after printing.

in exemplary embodiments, printer <NUM> can contain multiple RFID readers and RFID encoders <NUM>, arranged in such a way that allows multiple products, for example in sheet or roll form, to be printed and encoded as part of a continuous process. It should be understood that the reader and encoder can be combined in a single unit or provided in a two separate components. Printer <NUM> can also comprise an RFID verifier <NUM> that verifies the data encoded by the RFID encoder <NUM>. The RFID encoder <NUM> and RFID verifier <NUM> are individually controlled such that encoding and verifying can occur at the same time. Printer <NUM> can also isolate adjacent products from radio-frequency cross-coupling and interference using physical screening, for example with a moving shutter, electrical screening, for example using infrared light or an interfering carrier signal, or by any other desired method for providing electrical shielding.

Still referring to <FIG>, printer <NUM> can also have a quality control system (not shown), such as a vision inspection system, RFID test system or other device to ensure adequate quality in the unit. Quality control system can be located in line with the printer <NUM>, or it can be located off line, such as with a remote RFID test station. Quality control system can include one or more RFID readers and RFID encoders <NUM>, which can allow quality control system to check products for errors in RFID encoding. Quality control system can also include optical readers or scanners in any desired configuration, which can allow quality control system to check products for errors in printing. Quality control system can further include a die cutter, which can allow the system to separate improper or defective products so that they can be discarded or reprocessed. RFID products that are detected as being defective can be marked or otherwise identified so that they can be removed from the web or sheet during manufacturing or inspection or can be easily recognized by the customer so that the end user does not use the defective tag as part of RFID tag or label.

Referring generally to the figures, printer/encoder <NUM> can encode RFID devices using full encoding or it can encode RFID devices or products using partial encoding with the remainder of the coding to be completed by the end user such as a retail or brand owner. When using full encoding, printer/encoder <NUM> may fully program each RFID device or product individually. This programming can occur all at once (e.g. substantially simultaneously) or in stages, in an incremental fashion or as desired. When using partial encoding, printer/encoder <NUM> can program each RFID device or product with only a portion of the information that is to be stored on the products. This programming can occur all at once or in stages, as desired. For example, when using EPCs and partial encoding, printer/encoder <NUM> can receive a sheet of RFID products that have already been programmed with the portion of the EPCs that are common to all RFID products in the sheet, batch of sheets or roll. This can allow printer/encoder <NUM> to save time by only encoding each RFID device or product with variable information that is different for each product In the sheet or roll. In some embodiments, fixed data fields can be encoded and the unique chip identification number can be used as the serialization.

In another embodiment, the printer <NUM> includes a microprocessor and a memory (not shown). The memory includes non-volatile memory such as flash memory and/or a ROM such as the EEPROM. The memory also includes a RAM for storing and manipulating data. In accordance with a preferred embodiment of the present invention, the microprocessor controls the operations of the printer <NUM> in accordance with an application program that is stored in the flash memory. The microprocessor may operate directly in accordance with the application program. Alternatively, the microprocessor can operate indirectly in accordance with the application program as interpreted by an interpreter program stored in the memory or another area of the flash memory.

The microprocessor is operable to select an input device to receive data therefrom and to manipulate the receive data and/or combine it with data received from a different input source in accordance with a stored application program. The microprocessor couples the selected, combined and/or manipulated data to the printing system for printing on a record member. The microprocessor may select the same or different data to be written to an external RFID chip. The microprocessor couples the data selected for writing to the RFID read/write module wherein the data is written in encoded form to the external RFID chip. Similarly, the microprocessor can select the same or different data for storage in a transaction record in the RAM and for uploading via the communication interface to a host. The processor is operable to select data to be coupled to the printing system independently of the data that the processor selects to be coupled to the RFID read/write module to provide greater flexibility than has heretofore been possible.

In <FIG>, <NUM>, shows a representation of a web of tag supply with aperture holes. Reference numeral <NUM> (see <FIG>) indicates one embodiment of the aperture on the tag located on roll <NUM> that be pushed past sensor <NUM> retained in supply guide <NUM>. In one embodiment the aperture hole enables light to pass from the emitter to the detector as it moves by the sensor array indicated by <NUM> on <FIG> which obtains the reference voltage by using the controller logic retained on CPU board <NUM>. The aperture or break in the supply <NUM> will normally exceed the focal point of one of the sensors contained in <NUM>. The aperture or break in supply <NUM> can be aligned anywhere along sensor <NUM>.

Prior to running supplies <NUM> through printer <NUM> it would be expected that the calibration processes initiated in process <NUM> depicted on would be completed. The flow of calibration is to prompt the user if they would like to calibrate aperture supply, <NUM>, if not the process exits in <NUM>. If the user wishes to continue he is prompted to align the aperture in sensor <NUM> installed in printer <NUM> for the calibration process. The diameter of the aperture shown by reference numeral <NUM> in <FIG> must be placed in sensor <NUM> prior to moving to decision point <NUM>. The user is prompted verify that the supplies are properly aligned in <NUM> prior to moving the <NUM> to acquire the actual voltage. The read voltage is compared to the desired reference voltage if the read voltage in <NUM> meets or exceeds the reference voltage the process is completes and exits in <NUM>. If the read voltage is less than the reference voltage the power is increased to the sensor in <NUM> and the read voltage is acquired again.

When printer <NUM> prepares to move web <NUM> showing the feed direction in <NUM> the selected media sensor is enters the process of checking which sensor is being used, <NUM> on <FIG>. Prior to testing the sensors there is a test to determine if the web is moving in <NUM>. If there is no movement the process exits in <NUM>. If the aperture sensor is selected <NUM> the process continues to <NUM> else the process exits in <NUM>. In <NUM> the voltage determined in <NUM> is applied to sensor <NUM>. The voltage is acquired from sensor <NUM> in <NUM>. A test is completed in <NUM> to determine if the reference voltage matches or exceeds the reference voltage. If not the process returns to <NUM> if the reference voltage does exceed reference voltage in <NUM> it is recorded that a mark is seen and the process terminates in <NUM>. This process represents one example of control logic for sensor <NUM>. In other examples is presumed that hysteresis would be added to the control logic depicted in <FIG> to prevent false readings of a mark.

In <FIG>, <NUM> shows checking the status of the printer in order to set the backlight for the display shown in <NUM> on printer <NUM>. When the status of the printer is determined one of four paths are followed: <NUM> is if the status of the printer is idle the backlight will be set to white. In <NUM> if the status of the printer is offline the backlight is set to white. In <NUM> if the status of the printer is active the backlight is set to green. In <NUM> if the status of the printer is an operator intervention required the backlight is set to read. Finally the process enters the subprocess <NUM> to count down the system flag status check. If <NUM> when the count reaches zero we reenter <NUM> to reset the interval counter and then check the current status of the industrial printer in <NUM>.

Claim 1:
A thermal printer (<NUM>) configured for adapting RFID power settings, the thermal printer (<NUM>) comprising:
a processor;
at least one RFID reader/writer (<NUM>, <NUM>) having an adjustable power setting,
characterized in that
the processor is configured for
utilizing a selected read RF power level sufficiently low to create an RF field small enough in strength so that a single RFID transponder is acted upon;
reading and saving a serialized tag identification, TID, field for the single RFID transponder;
increasing the RF power level;
encoding data on the single RFID transponder;
reducing the RF power level back down to the selected read RF power level; and
reading and comparing the encoded data with data originally sent in a write command to confirm if the encoded data is accurately encoded.