промышленное считывание штрихкодов

How to Select a Barcode Reader

Selecting the perfect barcode reader starts with a careful examination of your code-reading application. What types of codes are you reading, how fast is the line, and how durable do you want the solution? Where will the reader be located, and with what physical restrictions? How will the reader communicate?


six barcode examples 1d and 2d codes

Data requirements for your inventory or track and trace application may be only a few kilobytes today, which may make a 1D barcode seem the most logical choice. But data requirements are likely to grow along with the size and complexity of your operation. It is worthwhile to anticipate future requirements that would benefit from a 2D code or the ability to read compromised barcodes. You may own your distribution channels today, but growth or new clients in remote locations may necessitate a third-party logistics company, leaving you no longer in control of the code-marking quality. Investing in better technology today may minimize future equipment upgrades.

Read rates

cognex software reading 6 different damaged barcodes 1d and 2d codes

Read rate is the number of successfully read barcodes divided by the number of attempts. The read rate is usually expressed as a percentage and the closer to 100%, the better. Every time a machine or person handles your products there is a chance that the machine-readable code could be damaged. This problem isn’t limited to paper and plastic packages. Even codes etched into metal can be distorted or damaged. So if supply chain accuracy is important to your business, make sure your reader can read noisy codes—such as those that are printed on cardboard or are scratched, deformed or low contrast—not just perfect codes fresh off the printer.

Barcode reading environment

Types of Barcode Readers - fixed-mount, handheld, mobile

The scanning environment will also indicate which type of reader you need. If your application calls for reading cartons of various sizes traveling at high speed down a conveyor, then a small fixed reader will be the best choice. Fixed-mount barcode readers enable automated, hands-free scanning of codes from a mounted position, usually on a production line.

If the reader is the final inventory check for dock workers loading incoming materials or outgoing product, a handheld barcode reader will be ideal. Handheld barcode readers are held in the hand of an operator and can be corded or wireless.

If it’s a courier or technician working in the field, a mobile barcode reader with built-in code reading capability will help quickly scan packages or check equipment specifications. Mobile barcode readers are also held in the hand of an operator and can be purpose-built for a particular application or smartphone-based with a rugged mobile terminal enclosure.



After marking the part or product and reading the code, the data is stored or used within a plant or distribution center network. Image-based barcode readers offer a full range of industrial communication protocols including Ethernet, USB, RS-232, discrete I/O, Ethernet/IP, PROFINET and Modbus TCP/IP. This simplifies integration between reader and network, which is critical not only for reading and sending product tracking information, but also for storing archived images in the event of a no-read or misread.

Cost of ownership

With the additional power and flexibility of image-based barcode readers, you might expect the cost to be considerably more than laser scanners. While that was true in the past, the latest image-based readers cost about the same as industrial laser scanners that have far less functionality. New microprocessors and CMOS digital sensor chips also mean image-based systems can be nearly as fast as the fastest laser scanner. And these developments come in addition to the traditional benefits of image-based readers: no moving parts, resulting in a longer life than laser scanners; ability to read 2D codes as well as damaged and omnidirectional codes; and the ability to store images for audits and tracking.

Read rate No-reads Maximum number of packages/day Total rework time (man hours/day) Number of operators required to handle rework Cost of operators (USD/year)
97% 3,802 122,918 95.05 11.9 $499,012.50
98% 2,535 124,185 63.38 7.9 $332,718.75
99% 1,268 125,452 31.7 4 $166,425.00
99.50% 634 126,086 15.85 2 $83,212.50
99.90% 127 126,593 3.18 0.4 $16,668.75
Four Sigma 89 126,631 2.23 0.3 $11,681.25
Five Sigma 26 126,694 0.65 0.1 $3,412.50
Six Sigma 1 126719 0.03 0.00 $131.25
Экономическое влияние неудачного считывания можно изучить на примере распределительного центра большой пропускной способности, обрабатывающего в день более 125 000 упаковок. Если показатели скорости считывания на этом объекте повысятся с 99 до 99,9 % за счет применения считывателей с технологией машинного зрения, можно будет избежать более 1100 случаев несчитывания в день и сэкономить на оплате труда до 150 000 долл. США ежегодно, исходя из того, что среднее время на повторную обработку несчитанных штрихкодов — 1,5 минут, а почасовая оплата труда составляет 15 долл. США в час. И это только финансовые затраты. Также необходимо учитывать нематериальные последствия, например, ухудшение отношений с клиентами и представителями корпоративных брендов.

Когда на карту поставлено так много, а долговечность оборудования играет большое значение, не следует забывать о том, что эксплуатационные расходы на применение автоматизированных сортировочных систем намного превышают затраты на их приобретение. Таким образом, выбирая решение потребительского класса для промышленного применения, помните, что вы вполне можете разочароваться. Ищите надежные решения, которые позволяют минимизировать последствия конструкторских ошибок.
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