Machine Vision: Accurate Verification for 1D and 2D Barcodes

Barcodes play a critical role in the modern industrial world, aiding in inventory management, product tracking, and process automation. Thus, accurately and efficiently verifying barcodes is of utmost importance. Machine vision systems serve that purpose adequately. This guide dives into the world of 1D and 2D barcodes, machine vision verification, and the value it brings to industrial workflows.

A] Overview of 1D and 2D Barcodes

1. What are 1D Barcodes?

One-dimensional (1D) barcodes, also known as linear barcodes, are visual codes used to identify products, track inventory, and manage assets. They are placed vertically with multiple straight lines containing numeric and letter data. Depending on the size of the data to be encoded, the width of the vertically placed lines may vary. Each 1D code contains up to 85 alphanumeric characters, however, the bigger the size of the barcode, the more data it contains. Laser scanners or linear scanners are required to scan, read, and verify 1D barcodes. Perfect examples of 1D barcodes are UPC, EAN, ITF, Code 39, Code 128, and Code 93.

2. What are 2D Barcodes?

Two-dimensional (2D) barcodes, also known as stacked barcodes, are an advanced version of traditional barcodes, capable of storing way more data than 1D barcodes. The 2D barcode structure contains geometric patterns like dots, squares, rectangular, and hexagonal shapes. These geometric patterns offer extensive space (up to 7089 characters) to encode data in both dimensions (i.e., horizontal and vertical). These barcodes encrypt data like web addresses, text, numerals, images, and codes. They are widely used for various industrial and individual purposes, including healthcare, manufacturing, and retail. Perfect examples of 2D barcodes are QR codes, PDF417, Data matrix, Codebar, Databar, MS Plessar, and Aztec.

3. Key Differences Between 1D and 2D Barcodes

1D vs 2D barcodes, both barcodes serve their fundamental purpose of storing and encrypting data in linear and geometrical patterns. Although, when it comes to data storage capacity, 2D barcodes offer way more storage than a 1D barcode. Additionally, 1D barcodes have lower error correction capabilities, whereas 2D barcodes offer advanced error correction features to identify and fix errors during transmission. When comparing scanning speeds, 2D barcodes take slightly longer to scan. However, advanced barcode inspection systems, like machine vision systems, are designed to scan and display data swiftly and efficiently.

B] What is Machine Vision Verification?

Machine vision systems have revolutionised barcode verification by providing automated, precise, and real-time results. These systems capture barcode images, decode the data, and verify compliance with barcode grading standards.

How It Works

1. Image Capture: High-resolution cameras capture barcode images on production lines or in warehouses.
2. Decoding: Whether it is a 1D or 2D format, advanced algorithms decode the data within the barcode.
3. Analysis: The system compares the decoded data against preset parameters, ensuring compliance with ISO/IEC standards.
4. Feedback: Results are displayed instantly with pass or fail outcomes, allowing operators to take required action.

C] Components of Machine Vision Systems for Barcode Verification

1. Cameras and Lenses

High-resolution cameras are critical for capturing detailed images of barcodes, ensuring that even minor defects are detected. Proper lenses enhance image clarity, making decoding more reliable.

2. Lighting Systems

Lighting plays a crucial role in barcode verification. It reduces shadows, highlights contrasts and ensures uniform illumination. This uniformity is particularly important for scanning reflective or damaged barcodes.

3. Barcode Readers and Software

Advanced software paired with 2D barcode verifier devices decodes barcodes and evaluates their quality. These systems also ensure adherence to barcode grading standards, identifying flaws in data encoding or printing.

4. Processors and Controllers

Processors execute real-time analysis, enabling swift decision-making. Controllers integrate with production lines, ensuring seamless operation and minimal downtime.

D] Benefits of Machine Vision in Barcode Verification

1. Improved Accuracy

Machine vision systems eliminate human errors by providing precise barcode verification. This accuracy ensures that only readable and compliant barcodes proceed through the supply chain.

2. Enhanced Speed and Efficiency

Real-time processing allows high-speed production lines to maintain efficiency without compromising on quality. A bar code verifier can scan and validate thousands of barcodes per hour with consistent accuracy.

3. Cost-Effectiveness

By minimising errors and downtime, machine vision systems reduce operational costs. Their ability to identify defective barcodes early prevents costly reworks and delays. These systems effectively pay for themselves over their lifetime.

4. Compliance Assurance

Machine vision verification ensures adherence to regulatory standards and customer requirements, fostering trust and reliability in industrial processes.

Conclusion

Machine vision systems offer a cutting-edge solution for barcode verification, ensuring accuracy, speed, and compliance across industries. As barcodes play an integral role in modern supply chains, adopting modern systems like machine vision verification becomes essential. If you are planning to leverage this advanced technology and boost your supply chain efficiency, don’t look further than Pixelwise Technology Pvt. Ltd. We are the pinnacle of  1D and 2D Code Verification Systems, helping thousands of businesses to automate their supply chain and gain their true business potential. Next could be you. Get in touch today to explore state-of-the-art barcode verification solutions tailored to your business needs.

Devashish Patwardhan

Devashish Patwardhan is a dedicated and highly skilled manager at Pixelwise Technology LLP, where he excels in providing cutting-edge inspection and automation solutions for the printing, packaging, and pharmaceutical sectors. With over seven years of hands-on experience in industrial automation and vision inspection, Devashish continuously develops innovative, cost-effective systems that meet his clients' diverse needs. A graduate of the esteemed Pune Institute of Computer Technology & Electronic Research, he holds a degree in Electronics Engineering (2017) and is known for his strong engineering background. Devashish's passion for utilising his technical expertise and creative problem-solving skills drives him to become a top technocrat entrepreneur.