Smart Cameras – Are they the future of Bar Code Scanners?

Smart cameras are the new look emerging for bar code scanners. As Data Matrix and other two-dimensional matrix codes become more prevalent in manufacturing applications, the new camera-based fixed-position scanners are rising to the occasion.

The smart camera is a fixed-position reader that combines the separate components of a vision system into one fully integrated unit. The first smart camera designed for bar code reading emerged on the scene at Scan-Tech in 1997 where Microscan introduced its Quadrusä, the first fully integrated reader to contain the light source, processing platform, and camera all in one compact unit. Simply put, smart cameras combine the advanced software features and functionality of a vision system with the ease of use and the price point of a laser scanner.

Smart Cameras Fill a NicHe

This combination is exactly what manufacturers have been waiting for. General Motors has already indicated that they would like to limit most of their future investments in bar code readers on their manufacturing lines to camera-based systems because of their capability to read both linear and 2D codes. "[Camera-based equipment] will definitely be on the upside over laser scanners, mostly because it takes care of today's needs as well as the new applications of tomorrow," commented Larry Graham, global manager of automatic identification for General Motors Corporation. "Once you capture an image, there's so much more you can do with it."

General Motors isn't the only one interested in smart cameras. David Krebs, industry analyst for Venture Development Corporation (VDC), commented that in the Americas, installments of CCD-based readers are growing by 20%, a rate much higher than the 7% growth rate of fixed-mount laser scanners. However, it must be noted that laser scanners have a much larger base of $150 million compared to the $34 million base for CCDs.

Growth of the smart camera can be largely attributed to the migration AIDC has made from the warehouses to the core process manufacturing and assembly lines. The applications on the manufacturing floor, however, often have much different specifications, requiring two-dimensional matrix codes and permanent marking. Until now, the only solution for these applications was high-end vision systems designed for much more complex tasks than simply decoding a symbol.

Since smart cameras are camera-based, they can read low contrast direct part marked codes and two dimensional codes, where as laser scanners cannot. As a result, the advantages of smart cameras are many. They allow for direct part marking, decode two-dimensional matrix codes, and perform part identification and validation. By forming a key link between part identification and part inspection, smart cameras play an instrumental role in enabling a company to achieve 100% quality control. Clinical labs are using smart cameras to meet strict FDA regulations, requiring them to count and verify each test tube. By installing a smart camera, the labs can count the test tubes, verify the cap is on each tube, and read the bar code all at the same time with the same unit.

Smart cameras also provide positive feedback when a customer receives a no read. "For the most part, a laser scanner is only capable of informing you that a no read occurred," commented Microscan product manager Matt Allen. "Since a camera-based system actually captures the image, it allows you to go back and determine exactly why that no read occurred. Maybe the symbol wasn't present, the quality of the code was poor, or the timing was off and the code wasn't in the field of view. By finding out why the no read occurred, you can take the appropriate measures to prevent the no read from occurring again."

More Work Still Ahead

While smart cameras have made great strides in technology development, manufacturers are still not quite satisfied. Manufacturers such as Pratt & Whitney indicate that additional development in camera-based readers in general would help make Data Matrix easier to use. Andy Kilguss, a manager for Pratt & Whitney and involved in the direct part marking program, commented, "Marking the symbol isn't the difficult part. What we need to focus technical developments on, is the ability to decode imperfect marks or marks with limited accessibility for illumination." Mike Woogerd, General Manager of ID Integration Inc. in Seattle, WA serves as a consultant for Boeing suppliers. He concurs, adding that he would like to see more consistency in performance from one reader to the next. He would also like to see some sort of uniform scale developed to help the verification process out.

Other systems integrators, such as John Griffen from Barcodes Inc in Chicago, IL, commented that he would like to see the same feature-set of a laser scanner incorporated into a smart camera, such as increased field of view and longer depth of field. Although recent product developments have increased the smart camera's depth of field, they are still no where near a laser scanner's read range and depth of field. Read ranges will have to improve significantly before smart cameras can truly replace laser scanners in automotive applications which, in some cases, require a 6-foot read range and depth of field of several inches.

Few products, if any, have reached the perfect combination of a laser scanner's ease of use and vision system's functionality. Most products are either light on performance or lack ease of use and come with a hefty price tag. VDC's Mr. Krebs commented that while camera-based readers have made a lot of improvements, they still have a ways to go. "Although they're easier to use, they are still not what you would consider plug-and-play yet."

Many manufacturers see the development cycle as a process to be expected. "I think the scanning technology can only improve over time," commented Nat Russhard of Rolls-Royce in the United Kingdom. Mr. Russhard manages the global direct part-marking program for their aerospace division. "When scanning was first introduced in the supermarkets, I am sure it was slower then than it is now. I'm sure it will be the same with the technology of today. Processing speed will improve, read range and field of view will improve. In 10 years, the smart camera equipment I have in my office today will look very ancient."

Even then it is debatable whether or not the smart camera will ever truly surpass the laser scanner as the product of choice for fixed-mount data capture applications. Although smart cameras provide a solution for a wide range of applications, perhaps their strongest asset is their ability to read 2D codes. However, 2D matrix codes have yet to reach critical mass and currently represent a very small part of the AIDC marketplace. Until the smart camera offers the same ease of use and feature-set as a laser scanner, the laser scanner will still be the product of choice for many applications.

This article was written and provided by Susan Snyder, responsible for research and public affairs for Microscan. In addition, Susan manages Microscan's global applications training program. Microscan is a world leader in the development of fixed-position bar code and 2D readers. First introduced at ScanTech in 1997, Microscan's 2D Data Matrix reader Quadrus was the first fully integrated Data Matrix reader to combine a light source, camera and decoder into one compact unit. For more information on Microscan or their products, please visit www.microscan.com.