Software Algorithm Reads Damaged Barcodes

Bad barcodes almost always cost a manufacturer money, in some cases even leading to a shutdown of an assembly line.

A new software algorithm for Cognex Corp., however, could change that. Known as PowerGrid, the software is said to read virtually all barcodes, even those that have been badly damaged. "If a barcode is printed too close to the edge of a label, or printed on a curved surface, or is extremely damaged in almost any way, we can still read it," noted David Lambert, a Cognex sales engineer who demonstrated the technology at the recent Design & Manufacturing Show in Minneapolis.

Cognex said PowerGrid is able to read two-dimensional matrix symbols that exhibit finder pattern damage, clocking pattern damage, missing "L" patterns, and quiet zone violations. It is believed to be the first such algorithm for an industrial barcode reader, and can be used on Cognex's DataMan 360 and Dataman 150/260 readers.

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Many manufacturers mark parts as a means of tracking them throughout manufacturing, shipping, and assembly processes. Medical device manufacturers use the marks on virtually all end products and sub-assemblies. Similarly, automakers use the markings on core components ranging from engine blocks and pistons to tires and brake assemblies, to name just a few. The markings are especially important in those industries during product recalls.

"In so many products, there's going to be a barcode somewhere," Lambert said. "The question is, when you get a 'no-read,' what's the cost? If you can't read the marking, there's almost always going to be a cost."

Senior technical editor Chuck Murray has been writing about technology for 31 years. He joined Design News in 1987, and has covered electronics, automation, fluid power, and autos.

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