U.S. patent application number 16/731863 was filed with the patent office on 2021-07-01 for methods, apparatuses, and systems for batch print voiding.
The applicant listed for this patent is Datamax-O'Neil Corporation. Invention is credited to Thomas Axel Jonas CELINDER, Sze Ping CHING, Harry Nicholas Makabali LANSANGAN, Cheng Khoon NG.
Application Number | 20210197601 16/731863 |
Document ID | / |
Family ID | 1000004593820 |
Filed Date | 2021-07-01 |
United States Patent
Application |
20210197601 |
Kind Code |
A1 |
CELINDER; Thomas Axel Jonas ;
et al. |
July 1, 2021 |
METHODS, APPARATUSES, AND SYSTEMS FOR BATCH PRINT VOIDING
Abstract
Various methods and systems for a printer having verifiers are
disclosed herein. Such methods provide for voiding a printed media
in a batch printing run. The methods further correspond to
identifying the printed media that is printed as part of the batch
printing run as a failed media in an instance an assigned grade
fails to satisfy a predetermined threshold, marking the printed
media as a failed printed media, determining one or more
subsequently printed media that were printed after the failed
printed media, and reprinting the printed failed media in a next
available media after the one or more subsequently printed
media.
Inventors: |
CELINDER; Thomas Axel Jonas;
(Singapore, SG) ; NG; Cheng Khoon; (Singapore,
SG) ; CHING; Sze Ping; (Singapore, SG) ;
LANSANGAN; Harry Nicholas Makabali; (Singapore, SG) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Datamax-O'Neil Corporation |
Altamonte Springs |
FL |
US |
|
|
Family ID: |
1000004593820 |
Appl. No.: |
16/731863 |
Filed: |
December 31, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B41J 29/393
20130101 |
International
Class: |
B41J 29/393 20060101
B41J029/393 |
Claims
1. A method for voiding a printed media in a batch printing run,
the method comprising: identifying the printed media that is
printed as part of the batch printing run as a failed printed media
in an instance in which an assigned grade fails to satisfy a
predetermined threshold; marking the printed media as the failed
printed media; determining one or more subsequently printed media
that were printed after the failed printed media; and reprinting
the failed printed media in a next available media after the one or
more subsequently printed media.
2. The method according to claim 1 further comprising: scanning,
with an inspection device, the printed media to generate at least a
portion of a printed image; and determining the assigned grade for
the at least the portion of the printed image.
3. The method according to claim 1, further comprising: marking the
one or more subsequently printed media as additional failed printed
media; and reprinting the additional failed printed media in
sequence after the failed printed media before continuing the batch
printing run.
4. The method according to claim 1, further comprising scanning,
with an inspection device, the printed media to generate at least a
portion of a printed image, wherein the at least the portion of the
printed image comprises a barcode.
5. The method according to claim 4, wherein determining the
assigned grade for the at least the portion of the printed image
comprises: detecting barcode symbols of the at least the portion of
the printed image to obtain a scan reflectance profile; and
calculating, using the scan reflectance profile, a grade against a
plurality of quality parameters comprising a decode parameter,
symbol contrast, minimum reflectance, edge contrast, modulation,
defects, and decodability.
6. The method according to claim 1, further comprising: determining
a count of the printed media that is printed; and identifying the
one or more subsequently printed media based on the count of the
printed media that is printed.
7. The method according to claim 1, further comprising: determining
a distance between a print head and an inspection device;
determining a media size; and identifying the one or more
subsequently printed media based on the distance between the print
head and the inspection device and the media size.
8. The method according to claim 2, wherein marking the printed
media as the failed printed media comprises printing a voiding
pattern over or adjacent to the at least the portion of the printed
image, wherein the voiding pattern is configured to render the at
least the portion of the printed image unreadable by an automated
reading device while only minimally obscuring the at least the
portion of the printed image for visual inspection.
9. An apparatus, comprising: a processor; and a non-transitory
memory including computer program instructions, the non-transitory
memory and the computer program instructions configured to, when
executed by the processor, cause the apparatus to at least:
identify a printed media that is printed as part of a batch
printing run as a failed printed media in an instance in which an
assigned grade fails to satisfy a predetermined threshold; mark the
printed media as the failed printed media; determine one or more
subsequently printed media that were printed after the failed
printed media; and reprint the failed printed media in a next
available media after the one or more subsequently printed
media.
10. The apparatus according to claim 9, wherein the non-transitory
memory including the computer program instructions is further
configured to, when executed by the processor, cause the apparatus
to select a decoding algorithm from a plurality of decoding
algorithms each configured to: scan, with an inspection device, the
printed media to generate at least a portion of a printed image;
and determine the assigned grade for the at least the portion of
the printed image.
11. The apparatus according to claim 9, wherein the non-transitory
memory including the computer program instructions is further
configured to, when executed by the processor, cause the apparatus
to: mark the one or more subsequently printed media as additional
failed printed media; and reprint the additional failed printed
media in sequence after the failed printed media.
12. The apparatus according to claim 9, wherein the non-transitory
memory including the computer program instructions is further
configured to, when executed by the processor, cause the apparatus
to scan, with an inspection device, the printed media to generate
at least a portion of a printed image, wherein the at least the
portion of the printed image comprises a bar code.
13. The apparatus according to claim 10, wherein the non-transitory
memory including the computer program instructions is further
configured to, when executed by the processor, cause the apparatus
to: detect barcode symbols of the at least the portion of the
printed image to obtain a scan reflectance profile; and calculate,
using the scan reflectance profile, a grade against a plurality of
quality parameters comprising a decode parameter, symbol contrast,
minimum reflectance, edge contrast, modulation, defects, and
decodability.
13. (canceled)
14. The apparatus according to claim 9, wherein the non-transitory
memory including the computer program instructions is further
configured to, when executed by the processor, cause the apparatus
to: determine a distance between a print head and an inspection
device; determine a media size; and identify the one or more
subsequently printed media based on the distance between the print
head and the inspection device and the media size.
15. The apparatus according to claim 10, wherein the non-transitory
memory including the computer program instructions is further
configured to, when executed by the processor, cause the apparatus
to print a voiding pattern over or adjacent to the at least the
portion of the printed image, wherein the voiding pattern is
configured to render the at least the portion of the printed image
unreadable by an automated reading device while only minimally
obscuring the at least the portion of the printed image for visual
inspection.
16. A printer comprising: a print verification device configured to
monitor print quality of images printed onto a print media, wherein
the print verification device is configured to identify a printed
media that is printed as part of a batch printing run as a failed
printed media in an instance in which an assigned grade fails to
satisfy a predetermined threshold; a printing mechanism configured
to print the images onto the print media, wherein the printing
mechanism is configured to mark the printed media as the failed
printed media and reprint the failed printed media in a next
available media after one or more subsequently printed media; and a
processor configured to determine the one or more subsequently
printed media that were printed after the failed printed media.
17. The printer according to claim 16, wherein the print
verification device is further configured to: scan the printed
media to generate at least a portion of a printed image; and
determine the assigned grade for the at least the portion of the
printed image.
18. The printer according to claim 16, wherein the printing
mechanism is further configured to: mark the one or more
subsequently printed media as additional failed printed media; and
reprint the additional failed printed media in sequence after the
failed printed media.
19. The printer according to claim 16, wherein the print
verification device is further configured to scan the printed media
to generate at least a portion of a printed image, wherein the at
least the portion of the printed image comprises a bar code.
20. The printer according to claim 17, wherein the print
verification device is further configured to: detect barcode
symbols of the at least the portion of the printed image to obtain
a scan reflectance profile; and calculate, using the scan
reflectance profile, a grade against a plurality of quality
parameters comprising a decode parameter, symbol contrast, minimum
reflectance, edge contrast, modulation, defects, and
decodability.
21. The apparatus according to claim 9, wherein the non-transitory
memory including the computer program instructions is further
configured to, when executed by the processor, cause the apparatus
to: determine a count of the printed media that is printed; and
identify the one or more subsequently printed media based on the
count of the printed media that is printed.
Description
FIELD OF THE INVENTION
[0001] Example embodiments relate to printers, printing, printed
image verification, and voiding. More particularly, the present
method and apparatus provides robust printed image verification and
void printing in a batch printing run.
BACKGROUND
[0002] Notwithstanding the revolution in digital communications and
digital transmission/viewing of documents, hardcopy printed
media--printing onto tangible sheets of paper or labels--remains
essential for many purposes. Hardcopy printing may be accomplished
via multiple types of devices, including thermal printers, inkjet
printing, and laser printers. For all hardcopy media and printing
methods, an important objective is a high level of visual clarity
of the final printed output. When a document is intended for
conventional, narrative text or images to be read/viewed by a
person, visual clarity ensures the document is both readable and
aesthetically appealing. Applicant has identified many deficiencies
and problems associated with existing printers.
BRIEF SUMMARY
[0003] In some examples, the systems and methods disclosed herein
solves one or more problem via computer software which controls a
hardware processor of the printer. Under software control, the
hardware processor is configured to identify a printed media that
is printed as part of a batch printing run as a failed media in an
instance an assigned grade fails to satisfy a predetermined
threshold. The hardware processor is further configured to mark the
printed media as a failed printed media and determine one or more
subsequently printed media that were printed after the failed
printed media. The hardware processor is then configured to reprint
the failed printed media in a next available media after the one or
more subsequently printed media.
[0004] The method, in some examples, also employs the hardware
processor to scan, with an inspection device, the printed media to
generate at least a portion of a printed image and determine the
assigned grade for the at least a portion of the printed image. The
method then marks the one or more subsequently printed media as
additional failed printed media and reprints the additional failed
printed media in sequence after the failed printed media. In an
embodiment, the at least a portion of the printed image comprises a
bar code.
[0005] The method is further configured to detect barcode symbols
of the at least a portion of the printed image to obtain a scan
reflectance profile and calculate, using the scan reflectance
profile, a grade against a plurality of quality parameters
comprising a decode parameter, symbol contrast, minimum
reflectance, edge contrast, modulation, defects, and
decodability.
[0006] In some embodiments, the method is further configured to
determine a count of the printed media that is printed and identify
the one or more subsequently printed media based on the count of
the printed media that is printed.
[0007] In accordance with various embodiments, a method for
determining a distance between a print head and the inspection
device is provided. The method further determines a media size and
identifies the one or more subsequently printed media based on the
distance between the print head and the inspection device and the
media size.
[0008] In some embodiments, marking the printed media as a failed
printed media comprises printing a voiding pattern over or adjacent
to the at least a portion of the printed image, wherein the voiding
pattern is configured to render the at least a portion of the
printed image unreadable by an automated reading device while only
minimally obscuring the at least a portion of the printed image for
visual inspection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The description of the illustrative embodiments may be read
in conjunction with the accompanying figures. It will be
appreciated that for simplicity and clarity of illustration,
elements illustrated in the figures have not necessarily been drawn
to scale. For example, the dimensions of some of the elements are
exaggerated relative to other elements. Embodiments incorporating
teachings of the present disclosure are shown and described with
respect to the figures presented herein, in which:
[0010] FIG. 1A depicts a plurality of exemplary printed barcodes on
print media;
[0011] FIG. 1B depicts an exemplary printed barcode;
[0012] FIG. 2A graphically illustrates a portion of an exemplary
printer-verifier (a cover of the printer-verifier removed) to
illustrate an interior thereof, according to various example
embodiments;
[0013] FIG. 2B schematically depicts a block diagram of the
printer-verifier of FIG. 2A, according to various example
embodiments;
[0014] FIG. 3 schematically depicts an exemplary printer
communicatively coupled to a verifier in a system for printing an
image and verifying a print quality of the image, according to
various example embodiments;
[0015] FIGS. 4A, 4B, and 4C are flowcharts of exemplary methods for
robust voiding and reprinting in a batch printing run, according to
various example embodiments; and
[0016] FIGS. 5A and 5B depict schematic views of some internal
operating elements of an exemplary printer, including a print head,
verifier, and tear bar, according to various example
embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Some embodiments of the present disclosure will now be
described more fully hereinafter with reference to the accompanying
drawings, in which some, but not all embodiments of the disclosure
are shown. Indeed, these disclosures may be embodied in many
different forms and should not be construed as limited to the
embodiments set forth herein; rather, these embodiments are
provided so that this disclosure will satisfy applicable legal
requirements. Like numbers refer to like elements throughout.
[0018] Unless the context requires otherwise, throughout the
specification and claims which follow, the word "comprise" and
variations thereof, such as, "comprises" and "comprising" are to be
construed in an open sense, that is as "including, but not limited
to."
[0019] Reference throughout this specification to "one embodiment"
or "an embodiment" means that a particular feature, structure or
characteristic described in connection with the embodiment is
included in at least one embodiment. Thus, the appearances of the
phrases "in one embodiment" or "in an embodiment" in various places
throughout this specification are not necessarily all referring to
the same embodiment. Furthermore, the particular features,
structures, or characteristics may be combined in any suitable
manner in one or more embodiments.
[0020] The word "example" or "exemplary" is used herein to mean
"serving as an example, instance, or illustration." Any
implementation described herein as "exemplary" is not necessarily
to be construed as preferred or advantageous over other
implementations.
[0021] If the specification states a component or feature "may,"
"can," "could," "should," "would," "preferably," "possibly,"
"typically," "optionally," "for example," "often," or "might" (or
other such language) be included or have a characteristic, that a
specific component or feature is not required to be included or to
have the characteristic. Such component or feature may be
optionally included in some embodiments, or it may be excluded.
[0022] Various example embodiments will be described in relation to
a thermal transfer printer. However, the examples herein may be
equally applicable to other types and styles of printers (inclusive
of printer-verifiers) (e.g., a thermal direct printer, a laser
toner printer, an ink drop printer, etc.).
[0023] The headings provided herein are for convenience only and do
not limit the scope or meaning of the claimed invention.
I. Definitions and Overview
[0024] Quality of printed document may be assessed to identify
printing problems. For example, example embodiments may scan a
printed document or printed media after the printing process is
complete, and identify errors in the final output. In some
examples, the so-called errors may be related to verification of
decodable indicia (e.g., barcodes) whereas in other examples
so-called errors may relate to overlap of printed subject matter,
printing errors, illegible text, and/or the like.
[0025] Various example embodiments provide systems and methods for
a printer to mark a printed media as a failed printed media,
determine one or more subsequently printed media after the failed
print media, and reprint the failed printed media in sequence after
the one or more subsequently printed print media, such as on the
next available print media. In some examples, by allowing for the
failed printed media, and in some examples a series of failed
printed media, to be reprinted provides maximum throughput when
batch printing.
[0026] In some examples, by voiding a printed media and any
subsequently printed media, the printer may reprint the failed
printed media and the subsequently printed media in the proper
sequence so as to enable ease of application, increased throughout,
and/or reduce errors. For example, in operations where print media
is to be applied to packages in order or in a sequence, the overall
throughput of the packages may, in some examples, be increased
based on the sequential batch printing disclosed herein.
[0027] The terms "print media," "physical print media," "paper,"
and "labels" refer to tangible, substantially durable physical
material onto which text, graphics or images may be imprinted and
persistently retained over time.
[0028] The term "printed media" refers to when a paper or label has
been imprinted by the printer. In other words, the print media is
labeled (e.g., imprinted with an image).
[0029] Physical print media are used for personal communications,
business communications, to convey prose expression (including
news, editorials, product data, academic writings, memos, and many
other kinds of communications), data, advertising, fiction,
entertainment content, and illustrations and pictures.
[0030] Physical print media are generally derivatives of wood pulp
or polymers, and includes conventional office paper, clear or
tinted acetate media, news print, envelopes, mailing labels,
product labels, and other kinds of labels. Thicker materials, such
as cardstock or cardboard may be included as well. More generally,
print media is used to receive ink, dye, or toner, or is a media
whose color or shading can be selectively varied (for example,
through selective application of heat, light, or chemicals) to
create a persistent visual contrast (in black and white, shades of
gray, and/or colors) that can be perceived by the human eye as
text, images, shapes, symbols, or graphics.
[0031] In exemplary embodiments discussed throughout this document,
reference may be made specifically to "paper" or "labels;" however,
the operations, system elements, and methods of such exemplary
applications may be applicable to media other than or in addition
to the specifically mentioned "paper" or "labels."
[0032] A "printer" is a device which imprints text, images, shapes,
symbols, or graphics onto print media to create a persistent,
human-readable representation of the text, images, shapes, symbols,
or graphics. Printers may include, for example, laser printers,
light-emitting diode (LED) printers, inkjet printers, thermal
printers, dot matrix printers, impact printers, and line
printers.
[0033] Generally, printers are designed so that one or more sheets
of paper, one or more labels, or other print media can be inserted
or "fed" into the printer. For example, multiple sheets or other
media can be inserted into a holding tray or other container
element of the printer for temporary storage. In alternative or
additional embodiments, individual sheets of print media may be
hand-fed into a printer one at a time. Command and content
instructions are then sent to the printer electronically, for
example, from an external computer that is communicatively linked
to the printer. The printer feeds a sheet of paper, or a label, or
other print media into itself and towards a printhead within the
printer. The printhead of the printer then imprint the appropriate
contents onto the print media.
[0034] Further, the term "printer" refers to both a
printer-verifier (in which a printer and verifier are integrated in
a single device) such as exemplified in FIGS. 2A-2B and a separate
printer as exemplified in FIG. 3. As depicted in FIG. 3, and
hereinafter described, the separate printer 328 may be
communicatively coupled to a verifier 302 in a system 300 for
printing an image and verifying a print quality of the image. The
verifier 302 may be attached to the printer 328 or may be a
standalone device to where the user brings the printed image from
the printer for verifying the print quality of the image printed on
the print medium. The terms "verifier" and "inspection device"
refer to the same device.
[0035] As depicted in FIGS. 2A-2B, printer-verifier 200 is
configured for both printing the image and verifying a print
quality of the image printed on print medium, as hereinafter
described. Printer-verifier 200 is configured for printing the
image and a verifier within the printer-verifier 200 is configured
for verifying the print quality of the image printed on print
medium. As used herein, the "image" may be text, a line, a box, a
symbol, a barcode, optical character recognition (OCR) text,
etc.
[0036] In an example, printers may comprise verifiers or
communicably coupled with standalone verifiers that determine, in a
verification process, whether the machine-readable symbol meets
print quality standards. However, in some examples, if an issue
with print media is detected by the verifier, the printer is
stopped until a solution can be found. Not only can this process be
time consuming, but also a user must get involved to resolve the
issues. For example, the user may need to remove defective labels
and separate them from properly printed labels. Also, the user may
need to reboot the printer and/or manually change printer settings.
In another example, verifiers may support printing in batch mode,
but do not have the ability to void defective media or print media
that is assigned a grade that does not satisfy a threshold. In this
case, the printing throughput is high but requires the user to
manually interact with the printer to remove defective or failed
print media. Indeed, in some examples, a user may be required to
process the labels out of sequence.
[0037] In addition and in some examples, printers may fail to
provide maximum printing throughput when a defective label is
detected. For example, each label is printed, verified, and
potentially voided before the next (e.g., subsequent) label starts
to print. In these situations, overall printing throughput is low.
None of existing printers have been successful in reliably and
consistently batch printing images and voiding images at the same
time.
II. Example Apparatus for Implementing Example Embodiments
[0038] Example embodiments may be implemented as apparatus and
systems for verifying printed image and improving print
quality.
[0039] The present system and method is applicable to different
kinds of printers, including but not limited to laser printers, LED
printers, inkjet printers, thermal printers, dot matrix printers,
and others. For convenience, an exemplary laser printer is
illustrated and discussed in some exemplary embodiments below, and
these embodiments can be employed on other kinds of printers as
well.
A. Print Media and Machine-Readable Indicia
[0040] Referring to FIGS. 1A and 1B, an exemplary print media 102
is shown according to various example embodiments. On the exemplary
print media 102, machine-readable indicia (e.g. barcodes 104a and
104b) may be printed to create a printed media 106.
[0041] In some examples and in FIG. 1A, a printed media may
comprise one or more one-dimensional bar codes. As illustrated in
FIG. 1A, a printed barcode 104a may comprise a one-dimensional
barcode having bars parallel to the direction of the print media
through the printer and a printed bar code 104b may comprise a
one-dimensional barcode having bars perpendicular to the direction
of the print media through the printer. In some examples and in
FIG. 1B, a two-dimensional printed barcode 104c (a QR Code) is
shown. The two-dimensional printed barcode 104c, in some examples,
incorporates both vertical and horizontal dimensions.
[0042] As is described herein, an example printer-verifier is
configured to monitor the quality of the printed media 102,
comprising one or more one-dimensional barcodes, two-dimensional
barcodes and/or other decodable indicia, as it is printed onto
print media. As described herein, an example printer-verifier is
configured to analyze the print quality to determine if the print
quality meets predetermined quality standards. In some examples and
when the example printer-verifier determines that the print quality
does not meet the predetermined quality standards, example
printer-verifier may instruct the printing mechanism to mark a
printed media as a failed printed media and to reprint the failed
printed media in accordance with the batch sequential or
non-sequential example methods described herein.
B. Printer and Printer with Verifier/Scanner
[0043] Referring now to FIGS. 2A-2B, an exemplary printer-verifier
200 capable of printing on print media 212 is partially shown. The
depicted printer-verifier 200 of FIG. 2A has a body 218 for
enclosing an interior thereof. The printer-verifier 200 further
comprises a power source and a moveable cover for accessing the
interior and any components therein.
[0044] In various embodiments, the printer-verifier 200 is a
thermal transfer printer-verifier that includes a ribbon supply
spindle 230 contained within the body 218. A ribbon supply roll 208
is configured to be disposed on the ribbon supply spindle 230. The
ribbon supply roll 208 comprises ink ribbon 202 wound on a ribbon
supply spool 204. The ink ribbon supplies the media (e.g., ink)
that transfers onto the print media. The printer-verifier 200 may
further comprise a thermal printhead 216 utilized to thermally
transfer a portion of ink from the ink ribbon 202 to the print
media 212 as the ink ribbon is unwound from the ribbon supply spool
204 along a ribbon path (arrow B in FIG. 2A), and the print media
212 is unwound from a media supply spool 214 along a media path
(arrow C in FIG. 2A).
[0045] A media supply roll 210 comprises the print media 212 wound
on the media supply spool 214. A media supply spindle 232 on which
the media supply roll 210 is configured to be disposed is contained
within the body 218. A ribbon rewind spindle 234 on which unwound
ribbon is wound up may also be contained within the body 218. A
ribbon take-up 206 may be disposed on the ribbon rewind spindle
234, although the ribbon take-up 206 on the ribbon rewind spindle
234 may not be necessary.
[0046] The printer-verifier 200 may further comprise one or more
motors for rotating the ribbon supply spindle 230 and the ribbon
supply roll 208 disposed thereon (if present) in a forward (arrow A
in FIG. 2A) or a backward rotational direction (dependent on the
ink surface), for rotating the media supply roll 210 disposed on
the media supply spindle 232 in a forward rotational direction, and
for rotating the ribbon rewind spindle 234. In a thermal direct
printer-verifier, the ribbon supply spool, the ribbon rewind spool,
and the ribbon may be eliminated and a thermally sensitive paper
replaces the print media. These components are also included in a
printer-verifier 200 as hereinafter described.
[0047] The printer-verifier 200 may include a GUI 222 for
communication between a user and the printer-verifier 200. The GUI
222 may be communicatively coupled to the other components of the
printer-verifier for displaying visual and/or auditory information
and receiving information from the user (e.g., typed, touched,
spoken, etc.). As depicted in FIG. 2A, the body 218 of the
printer-verifier 200 may include the GUI 222 with, for example, a
display 224 and a keypad 226 with function buttons 228 that may be
configured to perform various typical printing functions (e.g.,
cancel print job, advance print media, and the like) or be
programmable for the execution of macros containing preset printing
parameters for a particular type of print media. The graphical user
interface (GUI) 222 may be supplemented or replaced by other forms
of data entry or printer control, such as a separate data entry and
control module linked wirelessly or by a data cable operationally
coupled to a computer, a router, or the like. The GUI 222 may be
operationally/communicatively coupled to a processor (CPU) 220 for
controlling the operation of the printer-verifier 200, in addition
to other functions. In some embodiments, the user interface may be
different from the one depicted in FIG. 2A. In some embodiments,
there may not be a user interface.
[0048] Referring now to FIG. 2B, an example block diagram of the
printer-verifier 200 is shown. The printer-verifier 200 may
comprise the processor 220, a memory 240 communicatively coupled to
the processor 220, and a power source. The printer may further
comprise a communications module 242 communicatively coupled to one
or more of the other printer components.
[0049] The central processing unit (CPU) (i.e., the processor 220)
is the electronic circuitry within a computer that carries out the
instructions of a computer program by performing the basic
arithmetic, logical, control and input/output (I/O) operations
specified by the instructions as hereinafter described. The
printer-verifier 200 may be communicatively connected using the
communications module 242 to a computer or a network 244 via a
wired or wireless data link. In a wireless configuration, the
communications module 242 may communicate with a host device over
the network 244 via a variety of communication protocols (e.g.,
WI-FI.RTM.), BLUETOOTH.RTM.), CDMA, TDMA, or GSM). In accordance
with Various example embodiments, the memory 240 is configured to
store a print quality verification program 246, a reference image
248, an offset value 250, and a drifting offset value 252 as
hereinafter described.
[0050] Still referring to FIGS. 2A and 2B, an imaging module 236 is
disposed in the printer-verifier 200 and is configured to capture a
representation of the printed image (e.g., printed barcode 254 on
print medium 212 within a field of view 256), using an image sensor
258 (i.e., the imaging module 236 comprises the image sensor 258)
to obtain a captured image. The image sensor 258 comprises a light
source 260 for illuminating the field of view. The image sensor 258
uses an imaging lens (or lenses) to form a real image of the field
of view 256 on an array of photo sensors (e.g., a linear or 2D
array CCD, CMOS sensor, CIS, etc.). Electronic signals from the
photo sensors are used to create gray level or color images, which
would result in a digital image similar to that which may be
obtained by a digital camera.
[0051] The processor 220 is further configured to determine a
failed printed media and cause the failed printed media to be
reprinted in a next available media (e.g., a blank or unused print
media) and, based on an the printer operating in a sequential or
non-sequential batch printing mode, will cause additional printed
media to be voided and reprinted in sequence after the failed
printed media.
[0052] Referring now to FIG. 3, an example printer 328
communicatively coupled to verifier 302 (also known as "inspection
device") in system 300 for printing an image and verifying a print
quality of the image is shown. Printer 328 may be similar to the
printer-verifier 200 depicted in FIGS. 2A-2B, except that the
imaging module of the verifier is separated from the printer in
system 300. In this regard, printer 328 has a body for enclosing an
interior thereof. The printer 328 further comprises a power source
and a moveable cover for accessing the interior. Similar to the
printer-verifier 200 described above in connection with FIGS.
2A-2B, the printer 328 may comprise a ribbon supply spindle
contained within the body. A ribbon supply roll is configured to be
disposed on the ribbon supply spindle. The ribbon supply roll ink
ribbon wound on a ribbon supply spool. The ink ribbon supplies the
media (e.g., ink) that transfers onto the print media.
[0053] Similar to the printer-verifier 200 described above in
connection with FIGS. 2A-2B, the printer 328 may further comprise a
thermal printhead utilized to thermally transfer a portion of ink
from the ink ribbon to the print media, as the ink ribbon unwinding
from the ribbon supply spool along a ribbon path and the print
media unwinding from a media supply spool along a media path. A
media supply roll comprises the print media wound on the media
supply spool. A media supply spindle (on which the media supply
roll is configured to be disposed) is contained within the body. A
ribbon rewind spindle on which unwound ribbon is wound up may also
be contained within the body. A ribbon take-up may be disposed on
the ribbon rewind spindle, although the ribbon take-up on the
ribbon rewind spindle may not be necessary.
[0054] The printer 328 may further comprise one or more motors for
rotating the ribbon supply spindle and the ribbon supply roll
disposed thereon (if present) in a forward or a backward rotational
direction (dependent on the ink surface), for rotating the media
supply roll disposed on the media supply spindle in a forward
rotational direction, and for rotating the ribbon rewind spindle.
In a direct transfer printer-verifier, the ribbon supply spool, the
ribbon rewind spool, and the ribbon may be eliminated and a
thermally sensitive paper substituted for the print media.
[0055] Similar to the printer-verifier 200 described above in
connection with FIGS. 2A-2B, the printer 328 may further comprise a
processor, a memory communicatively coupled to the processor, and a
power source. The printer may further comprise a communications
module communicatively coupled to one or more of the other printer
components. The printer 328 may have a fewer or greater number of
components as hereinafter described.
[0056] The verifier 302 comprises imaging module 336, a memory (a
verifier memory 314) communicatively coupled to the imaging module
336 and a central processing unit (CPU) (herein a "verifier
processor" 310 or "inspection device processor") communicatively
coupled to the verifier memory 314 and imaging module 336. The
verifier 302 may further comprise an I/O module 322 and a verifier
communication module 316.
[0057] The subsystems in the verifier 302 of FIG. 3 are
electrically connected via a coupler (e.g., wires, traces, etc.) to
form an interconnection subsystem. The interconnection system may
include power buses or lines, data buses, instruction buses,
address buses, etc., that allow operation of the modules/subsystems
and the interaction there between. The I/O module 322 may include a
verifier graphical user interface. In various embodiments, the
verifier 302 may be communicatively connected using the verifier
communication module 316 to the computer or the network 318 via a
wired or wireless data link. In a wireless configuration for the
wireless data link, the verifier communication module 316 may
communicate with a host device, such as the computer, or the
network 318, via a variety of communication protocols (e.g.,
WI-FI.RTM., BLUETOOTH.RTM., NFC.RTM., RFID.RTM.), CDMA, TDMA, or
GSM). The verifier memory 314 may store a print quality
verification program 320, the reference image 323, the offset 324,
and the drifting offset 326.
[0058] While FIG. 3 depicts a verifier memory 314 and a verifier
processor 310 in the verifier 302, it is to be understood that only
the printer 328 or only the verifier 302, or both the printer 328
and verifier 302 communicatively coupled thereto may comprise the
memory and the processor for executing the steps as hereinafter
described (i.e., at least one of the verifier and the printer
comprises a memory communicatively coupled to the imaging module
and a processor communicatively coupled to the imaging module and
memory). The verifier 302 that is attached to the printer may rely
on the memory and the processor of printer for executing the steps
as hereinafter described while the verifier 302 that is a
standalone device has its own verifier memory 314 and verifier
processor 310 for executing the steps as hereinafter described.
Additionally, or alternatively, the printer may rely on the
verifier memory 314 and the verifier processor 310 of verifier 302
attached to the printer for executing the steps as hereinafter
described.
[0059] The imaging module 336 disposed in verifier 302 is
configured to capture the representation of the printed image (e.g.
the printed barcode 301 on the print media 312 in FIG. 3) within a
field of view 303, using the image sensor 304 (i.e., the imaging
module 336 comprises the image sensor 304). The image sensor 304
comprises the light source 306 for illuminating the field of view.
The image sensor 304 uses an imaging lens (or lenses) to form a
real image of the field of view 303 on an array of photo sensors
(e.g., a linear or 2D array CCD, CMOS sensor, CIS device, etc.).
Electronic signals from the photo sensors are used to create gray
level or color images, e.g., which would result in a digital image
that may be obtained by a digital camera.
[0060] While a thermal transfer printer-verifier and printer are
described, it is to be understood that Various example embodiments
may be used in other types of printers (e.g., ink-drop printer,
laser-toner printer, etc.). It is also to be understood that the
print media can be supplied from other than a media supply spindle
(e.g., in a "fan-fold" configuration).
III. Example Method for Implementing Example Embodiments
[0061] FIGS. 4A, 4B, and 4C are flowcharts of exemplary methods for
robust voiding and reprinting in a batch printing run, using
printer-verifier 200. The methods and flowcharts highlight the
steps of an exemplary embodiment. Indeed, exemplary methods 400A,
400B, and 400C illustrates printing of print media in a batch mode
(e.g., two or more print media in a print job or print run).
[0062] It will be understood that exemplary methods 400A, 400B, and
400C are performed by a hardware processor (such as by processor
220 or verifier processor 310) of an exemplary printer, in
conjunction with or controlled by suitable computer code which
implements the method. The code may be encoded directly into either
of the logic of processor 220 or 310, or may be stored as firmware
in a static memory (such as static memory 240), or may be part of
device driver code stored (for example, volatile printer raster
memory). In an alternative embodiment, the methods 400A, 400B, and
400C may be performed in whole or in part by a hardware processor
of an external computer which is linked to a printer by a suitable
wired or wireless communications means.
[0063] Method 400A begins with step 401, where the printer-verifier
200 (such as by processor 220 or verifier processor 310) identifies
the printed media that is printed as part of the batch printing run
as a failed printed media in an instance an assigned grade fails to
satisfy a predetermined threshold. In an example embodiment, to
determine printed media as a failed printed media, the
printer-verifier 200 scans, with a verifier, printed media after it
is output from a printhead to generate at least a portion of a
printed image. Based on the printed image, the printer then
determines an assigned grade for the at least a portion of the
printed image.
[0064] In some examples, the printer-verifier 200 determines the
assigned grade for the at least a portion of the printed image by
detecting barcode symbols of the at least a portion of the printed
image to obtain a scan reflectance profile and thereafter,
calculating, using the scan reflectance profile, a grade against a
plurality of quality parameters comprising a decode parameter,
symbol contrast, minimum reflectance, edge contrast, modulation,
defects, and decodability. In some examples, the step of
calculating the grade alternatively or additionally comprises
analyzing one or more barcode quality parameters of a printed
barcode from the scanned image and comparing the results against a
barcode print quality standard such as a barcode print quality
standard set forth in the ISO/IEC 15415, 29158, or 15416 barcode
print quality test specifications.
[0065] The parameters of barcode quality affect the quality of the
printed barcode and are based on the optics of bar code scanning
systems. Barcode print quality parameters may include, among other
parameters, a modulation parameter and a defects parameter. Each
quality parameter will either Pass, Fail, or be graded. Both the
modulation parameter and the defects parameter may be graded.
[0066] In addition to evaluating barcode print quality for meeting
a print quality standard based on, for example, ANSI/CEN/ISO
guidelines, the evaluation of barcode quality includes matching a
printing application requirement such as a customer specification.
Dependent on the printing application requirement, higher or lower
modulation grades and/or defects grades may be required.
[0067] Returning to method 400A, in step 402, the printer-verifier
200 (such as by processor 220 or verifier processor 310) is
configured to cause the printer to mark the printed media as the
failed printed media. For example, in some embodiments, the
printer-verifier 200 may cause one or more void marks to be printed
over portions of the printed media. In an embodiment, marking the
printed media as a failed printed media comprises printing a
voiding pattern over or adjacent to the at least a portion of the
printed image, wherein the voiding pattern is configured to render
the at least a portion of the printed image unreadable by an
automated reading device while only minimally obscuring the at
least a portion of the printed image for visual inspection. In
embodiments, the failed printed media may be retracted back into
the printer and branded with the one or more void marks, after
which a next print media is printed by the printer.
[0068] In step 403 of method 400A, the printer-verifier 200 (such
as by processor 220 or verifier processor 310) determines one or
more subsequently printed media that were printed after the failed
printed media. The one or more subsequently printed media are
determined based on one or more pre-determined distances. For
example, a distance between a printhead and a verifier and/or a
tear bar. In some examples, the one or more subsequently printed
media are determined based on the print media size (e.g., label
size or paper size).
[0069] In an example embodiment, the printer-verifier 200
determines a distance between a print head and the verifier,
determines the media size, and identifies the one or more
subsequently printed media based on the distance between the print
head and the verifier and the media size. In other words, the
printer-verifier 200 is configured to deduce the number of
subsequently printed media based on the distance between the print
head and the verifier. Alternatively or additionally, the one or
more subsequently printed media may be determined based on a count
of printed media, a current print media in the sequence (e.g. a
difference between the printed media number in sequence that failed
and the print media number in sequence that is currently being
printed or recently was printed). Alternatively or additionally, a
next available media may be identified by the printer-verifier 200
and any preceding print media may be identified as the one or more
subsequently print media.
[0070] In step 404A, the printer-verifier 200 (such as by processor
220 or verifier processor 310) determines whether the batch print
run is in sequential mode or non-sequential mode. In some example
embodiments, the printer-verifier 200 determines whether the batch
print run is in sequential mode or non-sequential mode whereas in
alternative or additional embodiments, the mode is set by a user,
is set as part of a print job or print run, and/or is predetermined
based on a number of print media.
[0071] FIG. 4B illustrates the subsequent operations in response to
determining that the printer-verifier is in sequential mode, the
operations proceeding to follow FIG. 4A in reference to connector
4A. In step 405B, the printer-verifier 200 (such as by processor
220 or verifier processor 310) additionally marks the one or more
subsequently printed media as additional failed printed media. The
printer-verifier 200 may then cause the failed printed media to be
printed in sequence after the one or more subsequently printed
media and on the next available media as shown in step 406B. The
printer-verifier 200 is further configured to reprint the
additional failed printed media in sequence after the failed
printed media as shown in step 407B. That is, in sequential mode,
the failed printed media is voided and any subsequent printed media
are voided so that the sequence of the print job can be maintained
starting with the failed printed media in the next available
media.
[0072] FIG. 4C illustrates the subsequent operations in response to
determining that the printer-verifier is in non-sequential mode,
the operations proceeding to follow FIG. 4A in reference to
connector 4A. In step 405C, the printer-verifier 200 verifies the
one or more subsequently printed media. In embodiments, verifying
the one or more subsequently printed media is needed because the
one or more subsequently printed media may have changed or may not
yet have been verified. In an example embodiment, the
printer-verifier 200 verifies the print quality of the printed
image on the print media and determines the assigned grade for the
printed image. In step 406C, the printer-verifier 200 reprints the
failed printed media in a next available media after verifying the
one or more subsequently printed media. That is, the failed printed
media is printed at the next available print media, such as is
shown in FIG. 5B.
[0073] Referring now to FIGS. 5A and 5B, which illustrate some
elements of an exemplary printer-verifier 200 (referred to
generally herein as printer-verifier 200) in a schematic view,
according to the present system and method. For example, the
printer-verifier 200 may comprise a print head, a verifier (also
known as "inspection device"), and a tear bar. The print head is
configured to print a plurality of sequential dots onto each of a
corresponding plurality of sequential segments of a media. For
example, the print head prints new text/new graphics on a print
media (e.g., label), based on a rasterized image, resulting in a
printed label (e.g., printed media). The verifier, as described
herein, is configured by the print quality verification program to
execute processes to control the print quality of the printed
barcode. The tear bar is used to tear a paper strip into multiple
pieces, such as in the form of labels, each label having a barcode
image.
[0074] Returning to FIG. 5A, FIG. 5A illustrates an example
embodiment illustrating the printer operating in a sequential mode.
As is illustrated, "Label #1" (502A) is identified as failed
meaning that Label #1 (502A) was assigned a grade by the
printer-verifier that failed to satisfy a predetermined threshold.
The printer-verifier 200 will then mark Label #1 (502A) as a failed
printed media. As can be seen in before 501A, a plurality of
subsequently printed labels 503A have been printed before "Label
#1" (502A) was identified as failed. Label 504A is the next
available label as it has not yet reached the printhead.
[0075] According to example embodiments described in this
disclosure and as shown in after 511A, the printer-verifier 200 is
configured to determine or otherwise identify the one or more
subsequently printed labels 513A (e.g., three labels) after the
failed print media 512A and marks those labels as voided or failed.
As disclosed herein, the one or more subsequently printed media
labels 513A are determined based on one or more pre-determined
distances. For example, a distance between a printhead and a
verifier and/or a tear bar. In some examples, the one or more
subsequently printed labels 513A may be determined based on a count
of printed media. After the print head prints text/graphics on the
label, the printer-verifier 200 then increments the printed media
count and stores the printed media count data in a memory, for
example, memory 240.
[0076] The printer-verifier 200 is then configured to cause the
failed print media 512A to be reprinted in sequence at the next
available label 514A. The one or more subsequently printed labels
513A may be reprinted in sequence after next available label
514A.
[0077] FIG. 5B illustrates an example embodiment illustrating the
printer operating in a non-sequential mode. As is illustrated,
"Label #1" (502B) is identified as failed meaning that Label #1
(502B) was assigned a grade by the printer-verifier that failed to
satisfy a predetermined threshold. The printer-verifier 200 will
then mark Label #1 (502B) as a failed printed media. As can be seen
in before 501B, a plurality of subsequently printed labels 503B
have been printed before "Label #1" (502B) was identified as
failed. Label 504B is the next available label as it has not yet
reached the printhead.
[0078] According to example embodiments described in this
disclosure and as shown in after 511B, the printer-verifier 200 is
configured to determine or otherwise identify the one or more
subsequently printed labels 513B (e.g., three labels) after the
failed print media 512B. However, in non-sequential mode, the one
or more subsequently printed labels 513B are not marked as voided
or failed. Instead, under non-sequential mode operations the
printer-verifier 200 is configured to verify the one or more
subsequently printed labels. The printer-verifier 200 is then
configured to cause the failed print media 512B to be reprinted in
sequence at the next available label 514B.
IV. Additional Implementation Details
[0079] In the specification and figures, typical embodiments of the
invention have been disclosed. The present invention is not limited
to such exemplary embodiments. The use of the term "and/or"
includes any and all combinations of one or more of the associated
listed items. The figures are schematic representations and so are
not necessarily drawn to scale. Unless otherwise noted, specific
terms have been used in a generic and descriptive sense and not for
purposes of limitation.
[0080] The foregoing detailed description has set forth various
embodiments of the devices and/or processes via the use of block
diagrams, flow charts, schematics, exemplary data structures, and
examples. Insofar as such block diagrams, flow charts, schematics,
exemplary data structures, and examples contain one or more
functions and/or operations, each function and/or operation within
such block diagrams, flowcharts, schematics, exemplary data
structures, or examples can be implemented, individually and/or
collectively, by a wide range of hardware, software, firmware, or
virtually any combination thereof.
[0081] In one embodiment, the present subject matter may be
implemented via Application Specific Integrated Circuits (ASICs).
However, the embodiments disclosed herein, in whole or in part, can
be equivalently implemented in standard integrated circuits, as one
or more computer programs running on one or more computers (e.g.,
as one or more programs running on one or more computer systems),
as one or more programs running on one or more controllers (e.g.,
microcontrollers), as one or more programs running on one or more
processors (e.g., microprocessors), as firmware, or as virtually
any combination thereof.
[0082] In addition, those skilled in the art will appreciate that
the control mechanisms taught herein are capable of being
distributed as a program product in a variety of tangible forms,
and that an illustrative embodiment applies equally regardless of
the particular type of tangible instruction bearing media used to
actually carry out the distribution. Examples of tangible
instruction bearing media include, but are not limited to, the
following: recordable type media such as floppy disks, hard disk
drives, CD ROMs, digital tape, flash drives, and computer
memory.
[0083] The various embodiments described above can be combined to
provide further embodiments. These and other changes can be made to
the present systems and methods in light of the above-detailed
description. Accordingly, the invention is not limited by the
disclosure, but instead its scope is to be determined by the
following claims.
* * * * *