St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech

Project #10 RFID in Manufacturing

In this module you will be introduced to the basic principles of RFID, Radio Frequency Identification, and how it can be used in a manufacturing application. By researching various kinds of RFID applications and learning some RFID terminology, you will discover how a manufacturing problem can be solved with the use of this growing technology. RFID technology is somewhat similar to bar code labels that you see in retail stores everyday; however, RFID does not rely on line-of-sight reading like bar code scanning requires but rather a Dedicated Short Range Communication (DSRC) technology.


Problem Scenario for RFID

You work for a liquid cleaner manufacturing company. Your team has been given the charge to design a RFID system that tracks the company’s major manufacturing product from start to stock. The company has a fully functional automated filling line that is configured as shown in Figure 2. The company wants to capture the following data:

  1. When an empty bottle is placed on the conveyor
  2. Which head fills the bottle
  3. When the bottle gets capped.
  4. What box the bottle gets packed into
  5. Random QC checks to ensure the bottle is receiving the correct amount of fluid and to record which head filled it

Your team is to do the following to complete the task:

  1. Choose the right RFID equipment to capture the data.
  2. Develop the logic for the location of the equipment and how it will interact with the software to fulfill the requirements of the customer.
  3. Compose a written proposal that details your design that will be presented to the manufacturing company.

RFID Terminology

Active tag—These RFID tags include a tiny battery or internal power source, and actively transmit a signal.

Auto-ID—Automatic Identification

Auto-ID Center—A global research project established in 1999 at the Massachusetts Institute of Technology (MIT) focusing on designing, building, testing and deploying the infrastructure for EPC technology.

Auto-ID classification—Widely accepted system of classification for RFID tags/readers

EAN—Electronic Article Numbering Association: responsible for issuing product bar code numbers outside the USA – see also UCC for USA.

Note: for the new EPCnumbers to be used on RFID chips, EAN/UCC now run a joint venture called EPCglobal

EAS—Electronic Article Surveillance. This was an early forerunner to RFID, developed as the first commercial application in the 1960s to counter theft in retail stores.

EPC Manager—Second section of the EPCnumber on an RFID tag – This is used to indicate the company and/or manufacturer. It is similar to the company identifier in GTIN formats.

EPCglobal—EAN International and the UCC have jointly established EPCglobal, Inc. which is charged with developing GTINs and specifications for EPC standards in order to ensure global interoperability.

EPC—Electronic Product Coding – This is the standard, interoperable data label that is written onto RFID tags and it consists of the Header, EPC Manager, Object Class, and Serial Number

GTIN—Global Trade Identification Number – This is the current interoperable data format that UCC and EAN numbering systems conform to (e.g. EPC bar codes).

Header—First section of the EPC number on an RFID tag – Used to indicate EPC version and may identify variant naming schemes. This section can also be used for future labeling extensions.

ISM band—License-free radio frequency waveband aimed at Industrial, Scientific and Medical (ISM) users

ISO 18000-6—International air-interface standard, compatible with any RFID license-free spectrum (applies to RFID tags and readers)

Middleware —Software that enables connectivity between the EPC data from RFID readers and descriptive information via the ONS. It is designed to manage the data and produce user reports.

Object class—Third section of the EPC number on an RFID tag – This identifies the product group and is identical to the GTIN product number

ONS—Object Name Service – An ONS database looks up EPCs and points the computer via the internet to comprehensive information about the product held on another server.

Passive tag—These RFID tags draw their power from the RF field emitted by the interrogator (reader or scanner). The tag can be programmed to either wait for data signals to come from the reader (Reader Talk First) or to identify itself to the reader (Tag Talk First).

PML—Physical Mark-up Language – an XML-based language for databasing information about physical objects. PML is designed to standardize descriptions of physical objects for use by both humans and machines.

Reader—A device designed to periodically emit an RF signal at a given frequency to communicate with the tags that respond, and receive the data they transmit. The reader then translates the tag data into events that are understandable by the middleware component of the RFID system.

RFID—Radio Frequency Identification (RFID) tagging allows an object to carry identification and descriptive information in a form that can be read at a distance using a low-power radio frequency signal, transmitted from a reader.

Savant™—A type of software which removes duplications from the data stream, caused by many tags being read together or read many times. The product identifiers are then available for external product look-up or direct use in internal systems.

Scanner—Another term for a reader

Semi-active tag—Similar to active tags, but the battery is used to run the microchip’s circuitry but not to communicate with the reader. Some semi-active tags sleep until they are woken up by a signal from the reader, thereby conserving battery life.

Serial number—Final section of the EPC number on an RFID tag – This provides the unique product serial number and batch code.

Tag—An RFID tag typically consists of a microchip and an antenna that stores/transmits data, enclosed by protective packaging.

Transponder—Alternative term for an RFID tag

UCC—The Uniform Code Council is responsible for issuing product bar code numbers for the USA. See also EAN for Europe.

Note: for the new EPC numbers to be used on RFID chips, EAN/UCC now run a joint venture called EPCglobal

WM/RM—Write Many/Read Many – The chip inside this type of RFID tag has full delete capacity and data can be re-written.

WO/RM—Write Once/Read Many – A type of RFID tag that can only be programmed once

©2005 STLCC at Florissant Valley Gateway to Technology 1

St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech

Overview ofRadio Frequency Identification (RFID)

Radio Frequency Identification is a well established technology that is making news because of the demands of large chain stores and the Department of Defense. They are mandating a standard for their suppliers to follow in order to completely streamline their supply chain.

Basic RFID systems consist of RFID tags, RFID readers and tag encoders.

1. RFID tags consist of an integrated circuit that is typically printed or etched conductors on a thin sheet of plastic and an antenna. The data is stored on the integrated circuit and transmitted through the antenna. Tags can be either active (battery powered) or passive (no battery) as well as read-only, read-write or a combination. The many configurations of these tags creates a wide variation of functionality and price. A passive read-only tag that is built into the product label can be as cheap as 40 cents apiece whereas, a active read-write tag (ex. Mobile’s Speedpass) can be as much as 40 dollars apiece.

2. RFID readers can be built into a handheld unit or mounted at strategic points, such as the dock doors, facility entrances or assembly lines. In passive tags, the reader transmits an energy field that “wakes up” the tag and provides the power for the chip to transmit its data. Active tags provide their own power and periodically transmit a signal so that their data can captured by the readers as well.

3 RFID encoders are frequently built into label printers. This allows a company to print smart labels (a standard printed label with an embedded RFID tag) in a single pass. Combination reader/encoders are also available and are frequently used in active tag systems.

RFID Process in Visual Form

FIGURE 1

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©2005 STLCC at Florissant Valley Gateway to Technology 1

St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech

FIGURE 2

FIGURE 3

courtesy of Laran RFID White Paper

Research Links

Employers Seek RFID Expertise. Network World April 11, 2005: 58.

Fda Publishes Policy Guide For Rfid Technology Studies.Drug Industry DailyNovember 16, 2004 No. 224.

Field, Alan M. Eyes on the prize; RFID Users Should Look Beyond The Technology's Current Shortcomings, Analysts Say.Journal of CommerceFebruary 21, 2005: 10.

Miano, Anthony, SG Hart & Assoc. Beyond the Mandate Paper. Film & Foil Converter March 1, 2005: 48.

RFID in Manufacturing.RFIDA

RFID White Paper. Rockwell Automation

The Tech Museum of Innovation in San Jose Implements Hitachi's u-CHIP RFID Technology.Business WireApril 4, 2005
RFID: Team Proposal

PREWRITING: Team members must have done the homework for this module and understand the concepts behind it before trying to pull together a written proposal. Various parts of the proposal can be assigned to members of the team. Your team must have time to pull the materials together and edit the final paper, so delays in doing your work will hurt the team as a whole.

CONTENT:

A proposal is a process/problem-based report, usually five to six sections including a memo-type heading. You must show the results of your investigation of the manufacturing problem and propose a solution using RFID technology. You will want to include the overall dollar budget, perhaps in visual form.

Parts of a Proposal:

HEADING:

TO:

FROM:

DATE:

SUBJECT: (similar to a title) Proposal for ………….

INTRODUCTION:

Present main idea of report and summarize proposal in one paragraph. (Paragraph)

PROBLEM:

Summarize problem to be solved in one paragraph. Explain the present manufacturing situation and what is needed to solve the problem presented. (One short summary paragraph)

SOLUTION OR RECOMMENDATION:

Explain the RFID process you are planning to carry out to solve problem (what you want to do with the present space). You will want to include the following:

RESEARCH RESULTS: Show how you decided on particular RFID technology. (Table)

LIST OF MATERIALS NEEDED: You'll need to list the items needed to solve problem (List or Table)

COSTS: In this section you explain what the cost of each expense is and how the overall amount fits within the budget. A table is a good feature to use here. (Table)

SCHEDULE/TIMETABLE: In this section you show how much time your proposed process will take and on what schedule it will be completed. (Table)

Introduce all tables, charts or graphs with a sentence or two.

CONCLUSION:

Tell what you above proposal will accomplish and why it is a good idea to follow through with it. You may want to explain that budgeted costs may change, for example, in 60-90 days. (One short paragraph)

EVALUATION:by teaching team according to student team-created rubric.

RFID: Team Proposal Evaluation Criteria

(Example: to be decided upon by student and teacher teams)

1 = Weak 2 = Moderately Weak 3 = Average 4 = Moderately Strong 5 = Strong

Problem Solving

  1. The team first determines the facts of a problem and what additional information is needed to understand it.

1 2 3 4 5

  1. The team demonstrates that they have performed the necessary research to make appropriate design recommendations.

1 2 3 4 5

  1. The team’s problem solving employs the appropriate and accurate calculations

1 2 3 4 5

  1. The team’s problem solving shows an understanding of the concepts of RFID module.

1 2 3 4 5

Presentation

  1. The topic of the proposal meets the requirements of the assignments.

1 2 3 4 5

  1. The proposal is well organized and cohesive. Teamwork is apparent.

1 2 3 4 5

  1. The presentation indicates an understanding of RFID.

1 2 3 4 5

  1. The language of the proposal uses accurate RFID terminology and is clear, concise and understandable to the reader.

1 2 3 4 5

  1. The format of the proposal follows acceptable report format.

1 2 3 4 5

  1. The proposal uses correct standard English sentence structure, mechanics, grammar and spelling.

1 2 3 4 5

Additional Comments: ______

______

______

______

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Total Points/Grade: ______

©2005 STLCC at Florissant Valley Gateway to Technology 1