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Beyonics Technology is migrating from 1D linear and stacked codes to Cognex’s 2D Dataman identification (ID) readers.

As electronic devices are constantly shrinking in size, the printed circuit boards (PCBs) that go into these gadgets have also downsized in terms of overall design and form factors.

As a result, it is increasingly challenging for manufacturers to adhere barcode labels onto these PCBs.

Beyonics faced the following two challenges: first, customers’ product designs had shrunk in size over the years, translating to less real estate for barcode labels on the PCBs; and second, the increasing demand of product traceability required more manufacturing-related information to be labelled onto every PCB.

Information such as lot code, vendor ID, product number and serial number all need to be encoded onto a smaller label size.

Beyonics realised that the way to resolve these issues would be to migrate to a 2D ID code.

The Data Matrix symbology was chosen for its high data capacity.

Within the plant itself, Beyonics has many in-circuit and functional testers with different reader configurations.

Its existing readers were in poor condition; they were nearly obsolete and could not read 2D codes.

Many of these systems required custom cabling to handle various triggering inputs, either from the PCs or the input/output modules.

Some were configured to communicate with different protocols and set to output non-standard types of string formatting.

The company wanted to find a reader that could handle these demands; the corresponding migration effort needed to be kept to a minimum in order not to take up too many resources.

Through a few sessions of onsite troubleshooting and testing, Cognex’s sales and engineering team performed a one-to-one direct replacement of Beyonics’ current fixed-position readers without altering any existing software programming codes or hardware wiring configurations.

‘The new readers had to be plug and play and the Dataman 100 from Cognex did exactly that,’ said Parthiban Periayah, an engineering specialist at Beyonics.

Shanker Kaneson, another engineering specialist at Beyonics, said: ‘We were impressed with the Dataman’s compact design, ease of use and features, so we put the Dataman readers through a series of trials and evaluations.

‘Prior to installing the Dataman readers, we were experiencing unacceptable read rates with the current readers.

‘Our operators often had to reload the PCBs when a no-read situation happened.

‘This caused the SMT machines to come to a halt until manual intervention took place.

‘With the Dataman 100 readers installed, we witnessed a production throughput increase of about 10 per cent,’ added Kaneson.

Beyond the deployment within the SMT machines, Beyonics also started to use the Dataman 100 for diagnostics operations.

In addition, the company replaced its existing handheld ID readers with the Dataman 700 series.

Shanker continued: ‘The Dataman 750 uses the same Setup Tool software as the Dataman 100 series, making our deployment so much easier since we don’t have to go through another new product orientation or training.

‘Moreover, compared with our existing handheld readers, the Dataman 750 is an electrostatic-discharge [ESD]-safe device that conforms to the specifications published in the IEC 61340 standard.

‘In the past, we had to wrap the handheld scanners with an ESD-safe jacket, which was awkward and non-IEC compliant,’ added Shanker.

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