Bar-code Recognition System Using Image Processing

Mikio Kuroki *,Takayuki Yoneoka *,Tetsuo Satou *,Yoichi Takagi *

Tadaaki Kitamura **,Noriaki Kayaniori ***
* HitRchi Process Computer Engineering, Inc.
** Hitachi Research Laboratory,Hitachi, Ltd.
*** Orriika Works, Hitichi, Ltd.

Divcrsc product sorting system by t h e barcode recognition system using image processing

Abstract-Information processing Is fast developing in
various sectors along with the spread of computer
tcchnology. The same goes for thc commodity
production and distribution Industries where the bar-
code system is increasingly utilized a s one of the most
useful tools for recognizing unique information related
to each commodity. While handy type bar-code readers
are normally used by retail shops where small amounts
o f diverse products are handled, a system to quickly
and automatically read out bar-code data pasted on a
continuous flow of products i s required for use in
production sites or distribution centers where large
volumes of products are handled. Demands at sitc for
the functionality and performance level of such systems
are quite challenging. For instance, it is impossible to
specify tha location to paste a bar-code on a round
container like a hat box. Cardboard cartons also come
In variable sizes in very large quantities.
In order to cope with such situations, the bar-code
recognition devices have been developed using the most
advanced image proce6sing technology in both soft-
and hardware.
The notable features are as follows:
1) Small bar-codes are read from a large sectional
area using a multi-camera.
2) Individual recognition Is achieved without
disturbing product flow by high speed parallel
processing,
3) The camera is capable of reading objects (bar-
codes) from a distance between one to two meters (to
allow the facility more flexibility in design),
4) The mainstream bar-codes in the distribution
industry such as Code 39 and t‘W are supported.
5) The high level of recognition efficiency and
safety.

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1 Introduction
There am a tremendous volume of goods being produced and
distributed around us daily. In order to effectively control the
production, storage and distribution of such goods, it will be
necessary to provided each individual item with proper information,
or data, to identify itself and encode and store such data in a
computer. The bar-code is widely used as a means to convert the
identity of each one of the goods into a datum.
The purpose of processing goods as data is to provide means to
carry out different processes including storage, sorting, sales
information control, and the preparation of various slips and
vouchers for FA,production control or distribution sectors.
While handy-type bar-code readers are normally used in the
sector where services are closely related to individual consumers
like retail shops, a system capable of automatically recognizing
each bar-code is required in production sites or large distribution
centers where large volumes of diverse products must be handled.
The requirements of the system for such sectors are as follows:
(1) The type of products that flow over the pi.oduction or
sorting h e cannot be limited to one but are quite variable. The
system, therefore, should be provided with a high degree of
freedom, or be less restricted, with respect to the size and shape of
2 General description of the Bar-code Recognition
System
2.1 Configuration
Fig. 2.1 shows the configuration of the Bar-code Recognition
System. The System which recognizes bar-codes from input images
To h e
linc
Fig. 2.1 Structural diagram of the Barcode Recognition System
569
products it can handle.
(2) The location of the small bar-code label on products is not
constant, therefore, the system should fist be able to detect the
location and direction of the label on each item and second to read
the content.
(3) The bar-code reading system can be physically located at a
distance from the production or sorting line and tolerable for
possible changes in the distance from one item to another because
of variable sizes.
(4) Because of the large volume of products it handles, the
system should be capable of high speed processing to read data
without intempting the flow.
( 5 ) Items with unrecognized data are normally sent to manual
sorting. The efficiency of the system, therefore, largely depends on
the recognition success rate. A high and stable success rate is the
key requirement for such a system.
The bar-code recognition system using the IP2000 serics image
processor (hereinafter called the Bar-code Recognition System) has
been developed as a system to satisfy the above requirements. A
general description and some of the advantages of the system are
given in the following section.
consists of an optoelectronic detector to catch the moving location
of each item, a camera to input images, lighting equipment to
ensure stable tight intensity, an image processor to recognize the.
bar-code from the input images, a conveyor and a controller to
effectivclycontrol the movement of the conveyor.
 As an item pasted with a bar-code label moving on a conveyor
comes into the visible range of the detector, information indicating
the movement of the item is sent from the detector to the image
processor via the conveyor controller. Receiving the information,
the image processor commands the lighting equipment to light up.
The camera takes in and inputs the image data upon lighting up to
initiate the bar-code recognition process.
The Bar-code Recognition System conducts the detection
process to determine the existence of the label and the location if it
exists. The bar-code recognition process then reads the content and
transmits the results to the conveyor. The conveyor controller
finally performs out control processes to sort and move the subject
item.

2.2 Specifications
The typical specifications of the Bar-code Recognition System
are as shown in Table 2.1. The differences between this System and
a laser type bar-code reader in specifications are as follows:
(1) The readable range is wider.
(2) The system can be installed l m to 2m away from the flow of
subject items by selecting a proper set of lenses.
(3) It is capable of reading not only bar-code but also characters
and symbols to provide greater extendibility.
(4) The recognition rate can be further improved by integrating
a number of rationalizing measures.
TableZ 1 Standard specifications of the
Barcode Recognition System
Basically speaking, the system can automatically detect the label
anywhere from within the field of view of the camera without
specifying a futed location to paste the label on provided, however,
that the field of view of one camera is determined by its resolution
since the s u e of the bar-code label is futed. Logically speaking, the
higher the resolution of the camera, the larger the field of view can
be, however, the system had to be based on a camera of the
standard resolution (512 x 480 pixels) in consideration of the price.
The coverage problem was overcome by using a number of
cameras installed in a line (see Fig. 2.2.)
The image recognition device IP2000 is suitable for multi-camera
processing as it can have up to 3 cameras connected to one image
board (ref. Paragraph 4.)

lYLT (the angle of tun with the line

P I M i (the angle of turn with he lie parallel 3Odeg Camera

to the width of the barcode as the axis.) I
SQEW (the angle of turn with the l i e pallel 45deg
to the height of the barcode as the axis.)

!
B
Depth of focus
Readablerange
Minimum width of barcode lines
t loo”
6” max
0.25” or larger
ITF, code 39. JAN
Applicable codes ando er
as b)
Trwsn-dssionmthod
Inage p ” s s 0 r - I1 \I c m r a
DistanoebehWell
quipmnt -
Image proccss0r Monitor within 50 m
h e e urocssor - Controller
0 to 40 dcg. #5 -’
Relative hunidity 40% to 80%
#6 ’ ~ Lens

2.3 Advantages Fig. 2.2 Configuration of the multi-camera system.

The advantages of this System arc as follows:
(1) SuitabMty for a Line handling diverse products
The greater freedom for the camera position relative to the line of
flow realized by the adoption of the image processor (where the
camera can be located above, below, by or in front of the line,) the
diverse functions attained by the combination with a number of
lenses, the excellent performance due to its ability to process
objects by capturing them on a two-dimensional plane, make the
system compatible to the diversity of objects in combination with
thc following advantages:
(2) Greater tolerance for the location of the bar-code labels
Although the zooming function of an ordinary camera is one way
of enabling the system to read and iecognue small images but it is
not suitable because of the slow processing speed. The expansion
of the field of view was instead achieved by inventing a recognition
algorithm to take the advantage of the characteristics of the bar-
code layout. As a result, the width of the vision was enlarged to
€00 mm by using six cameras (ref. Fig. 2.3.)

570
 W idrh of the field o f v k w
- 600mm
In order to be able to read a bar-code despite irregular orientation
(360 deg) from the direction of flow of the line. an algorithm to
compensate for the orientation of the bar-code calculated from a
I
set of coordinates is incorporated into the procedure. (Fig. 2.6). It

W idih W idlh
I W idrh
provides the needed tolerance to remove the restriction on the
direction of the bar-code.
(view field) (view field) (view field)
cnmcra U1 cnmcra W3 camern U5

I I
Width Width Width
(view field) (view field) (View field)
camera W2 camera U4 cninera Y6

Fig. 2.3 Width o f t h e field of view

(3) Non-stop high speed processing

o f the multi-camera
8 = tali - 1 (, I ye-ys I
xe-xs I
)
To stop a line in order to read bar-codes off labels pasted at
random on products passing below a multi-camera unit not only Fig. 2.6 Calculation of the brrcode orientation
lowers the processing cffciency of the line but also complicates the
Lie control process. With this System. a series of label detcction
(5) Distance between objects and the camera
processes a n performed ranging from choosing candidate labcls to
It is generally the case for handling processes in the distribution
judging labels in real time cycles of 33.4 ms from photo images
sector that the camera should stand at a distance from the conveyor
taken by a number of cameras.
Line carrying objects for reading due to physical restrictions or that
It enables detection processes to be carried out without stopping
the distance between the object and the camera keeps on constantly
the flow of the Line passing below the multi-camera.
changing because of the different sizes of items with bar-code
m a #1 labels to be read.
It is, however, possible to overcome the difficulty with a great
margin of freedom by rarying on the lenses and lighting used,

3 Evaluation of the performance

Detectable 3.1 Verification of the success rate of recognltfon
It will be necessary tn define the configuration of the system and
the optimum environmental parameters to suite each local
environment in order to ensure stable operation of this System. On
the other hand, the algorithms used for both label detection and
bar-code recognition will have to be reinforced in consideration of
the characteristics of the object items (dimensions, colon,
background pattems. etc.) as well as the printed fomac of the bar-
code.
overlapping Evaluations are, therefore, made on the following items to defme
0 : ~orderoflabelde~timprocesyw: such values to enable setting up both values at the highest levels
possible.
: Bam~lelabcl
Fig. 2.5 33.4 ms cycle label detection
Tolerating irregular inclination of the bar-code

571
 Table 3.1 Evaluation items
3.2 Improvement of recognition success rate
Detallsd i t e m Contents
Unpredictable elements of disturbance can occur in practical
application which could not be detected by logical evaluation. 'We.
To be determined accordink l o the therefore, investigated causes and possible measures by examining
needed field of view and distance
from the object i t e m images that proved to be unrecognizable in our preliminary
evaluation.

Aperture lDecision on the best aperture

Instnlled position Decision on (he localion to obtain
the best view
]Decision on (he most suitable equipmeui
Number of lights Decision on the suitable number
. f cameras
o . ..~~ ~

Range Such that the camera's field of view

c m be cffectivcly illuminated
Brighmess Sccurin suitable lunlinous intcnsit and
not bc affected by the surrounding gghts.
Temperature Adjustment of changes in thc ambient ~ -~~~ ~ ~~

temperature Elements oreventine recormition

:ut out
Installed position Decision on the most suitable locativu
Barcode size To identify the mea Operating errors Changes in environmental conditions
1
(area) when it IS regularly CUI out
-Distorted lahels .External lights
Barcode sham To identify the shape (width x height)
when it is rerruIatly cut out *Flawsin lahels * Temperature
I Background To CUI out the background of
\several kinds of objects.
*Wronglypositioned * Relative humidity

Angle of Regular cut out at 8 different angles

placement (+/- O,+/- 45.+/- go,+/- 135,+/- 180)
Failure in detection Others
'Detected pnrts oumide Mixed barcode out of standards
Pasted position Regular cut out within thc ficld
of view of ail cnmeras che label Wrong
Recognition Contents of Rcco nition of barcodes *Timingw nnve and stop
barcode of dl&erent conlenh
- * Vibration
Angle of barcode Normal recognition at 8 an le6
placement (+/- O,t/-45.+/- go.+/- 13f+/- 180)
Fig. 3.1 Proportion of elements preventing recognition
Pasted position Normal reco nition within the ficld
of view of alfcctmcraa

Ievaluated
Number of
I
items
.. .
Evaluation of angles in 5 0 cases.
1 Operational .mprovements in practical application were achieved

I I
Clear indication of optimum vnlun
Initial value Specified value
for applicable parameters.
Parameter I NCW item (Tonormalize cbanncs and settinm.
Interruption Operating status To initiate norinalizing process
by intcnuptmn.
To regularly Iran6m.t recognition
(results through RS-232C.
Employing a quantitative evaluation method to evaluate the
above listed items, the optimum adjustment procedure has been
established on the basis of the applicable environmental
conditions by identifying the possible limit of recognition by this
System through investigation of the influence of the varying
conditions on the accuracy of recognition.
We have repeatedly gone through the cycle of "test ->
identification of probtems -> countermeasures" since the thorough
study and clarification were indispensable especially on
relationships between "the depth of focus and shutter speed",
"position of lighting equipment", and "variation of lurninous
intensity and success rate of recognition".
Furthermore, in connection with image processing, a number of
evaluations were made on different combinations of iniage
processing commands to atrive at conditions under which stable
rccognltion can be achleved regardless of prevajling environment a1
conditions.
I
by evaluating the effectiveness of various measures including the
reinforcement of algorithm and the judgment of rationality of the
1 results of recognition by using unrecognizable images produced
1 and collected in the course of practical operation.
Bar-code labels are often attached manually and the success rate
I of recognition may be hampered depending on the quality and skill
of manual workers. To correct such situation, plans were made to
prepare handling manuals specifying procedures for pasting and
handling bar-code labels to reduce such errors. Furthermore,
optimum pasted sample would also be provided to help improve
the results.
Improvements to realize a success rate of 98% to 99.9% have
actuauy been achieved elsewhere by application of similar
measures.
3.3 Future Issues
It will be necessary to bring the actual situation as close as
possible to the evaluated conditions in order to produce a stable
recognition success rate under practical operating conditions. In
order to avoid deterioration of the recognition success rate under
local conditions, it will be necessary to prepare sufficient lighting to
provide constant luminous intensity as required along with the
evaluation of the configuration of the overall installation of the
system.

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