Scanner and method for sweeping a beam across a target

Abstract

A scanner such as a bar-code scanner includes a scan-beam generator, a beam reflector having a first magnet, and a beam-sweep mechanism having a second magnet. The beam-sweep mechanism causes the reflector to sweep the scan beam across a target such as a bar-code symbol by exerting a force on the first magnet with the second magnet. In one example, attraction between the magnets holds the reflector steady in a non-sweep position. Conversely, in a sweep position, repulsion between the magnets causes the reflector to oscillate and sweep the scan beam across a target such as a bar-code symbol. Because it does not include a motor for rotating a beam-sweep mirror, the scanner is often smaller and uses less electrical energy than motorized bar-code scanners.

Description

FIELD OF THE INVENTION

The present invention relates to optical imaging systems and, more particularly, to an imager that employs one or more scanned beams of light to image all or a portion of a target object.

BACKGROUND OF THE INVENTION

A typical bar code system may employ components that include a light source, a scanner, an optical detector and a processor. The light source projects a light beam at an oscillating scanner that sweeps the light beam in a scan pattern onto a bar-code symbol. The optical detector receives light reflected from the bar-code symbol and generates a signal that the processor converts into a data stream. The data is analyzed to determine a particular meaning for the scanned bar-code symbol.

A typical width-modulated linear bar code symbol includes parallel bars and spaces of varying widths extending in a common direction (Y). By scanning a beam of light across the bars and spaces along an axis roughly perpendicular to their long axes (X), and analyzing the light reflected, the scanned bar code symbol can be associated with a particular symbology. A particular bar code symbology comprises a set of encoding and decoding rules; rules for recognizing the symbology, and, rules for error detection and correction. The encoding rules associated with the particular symbology may include provision for encoding letters, symbols and other types of information.

Symbols are not necessarily limited to one-dimensional patterns. Recently, two-dimensional (2D) symbologies have gained favor due to their generally higher data capacity, higher encodation efficiency, and forward error correction. Two current types of 2D symbols are 2D stacked symbols and 2D matrix symbols.

2D stacked symbols generally comprise a plurality of width modulated segments, the segments usually being stacked vertically such that their individual bars and spaces extend along a Y axis with data encoded in their widths along an X axis. In addition to encoding data, each segment often includes means for encoding its position in the stack of segments, for instance by its parity pattern or by location characters appended to the beginning and/or end of the segment. Thus, according to the decoding rules associated with a 2D stacked symbology, a 2D stacked symbol constructed according to those rules may be decoded after scanning each of its segments, with such scanning being performed in no particular order. The inclusion of location data with each segment allows a wide variety of data collection devices to be used to read 2D stacked symbols, including those capable of making measurements along only a single axis.

2D matrix symbols encode their data by the presence or absence of marks across a two-dimensional array of locations or cells, such presence or absence determining the value of a particular cell. The encoding and decoding rules for a 2D matrix symbology include at least one defined method for determining the presence of a symbol within a two-dimensional field-of-view (FOV), determining the extent of the symbol within that FOV, and determining the position of each cell within that extent. Additional rules then define at least one procedure for assembling the detected cell values into data words, and the data words into one or more messages encoded within a symbol. Because data is encoded in locations along both axes of a symbol, 2D matrix symbols are readable only by devices that can detect, or at least infer, two axes within an FOV. In contrast to a 2D stacked symbol, the data in a particular row of most matrix symbols does not, in itself, contain information as to its whereabouts within the symbol.

Many readers compatible with 2D symbols and particularly 2D matrix symbols include two-dimensional detector arrays, for instance CCD or CMOS arrays, that produce a digital representation of a region of a target object. The reader then employs signal processing, such as finder algorithms and decode rules to locate and decode any symbols on the object.

Structurally, common commercial hand held scanner systems typically include a hand held unit that includes a light emitter, scanner, and detector in a single unit. A remote base unit carries a battery that powers the handheld portion. Usually, the operator wears the remote base unit in a hip pack or another similar arrangement. The base unit often includes a processor that analyzes and decodes symbols and controls the handheld portion through a wiring harness.

Variety of approaches have been demonstrated for handheld bar code scanning. Some of these approaches are presented in U.S. Pat. Nos. 5,671,374, 5,665,956, 5,583,331, 5,521,367, 5,519, each of which is incorporated herein by reference.

SUMMARY OF THE INVENTION

In an embodiment of the invention, a scanner includes a scan-beam generator, a beam reflector having a first magnet, and a beam-sweep mechanism having a second magnet. The beam-sweep mechanism causes the reflector to sweep the scan beam by exerting a force on the first magnet with the second magnet.

Such a scanner can scan targets such as bar codes, and typically uses less electrical power and is smaller than bar-code scanners that have a motor to spin the beam-sweep reflector.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-20 are described in the Description Of The Invention below.

FIG. 21 is an exploded view of a handheld scanner that sweeps a scan beam using kinetic energy supplied by an operator according to an embodiment of the invention.

FIG. 22 is an isometric view of the beam source of FIG. 21 where the beam-reflector assembly is in its home position according to an embodiment of the invention.

FIG. 23 is an isometric view of the beam source of FIG. 21 where the beam-reflector assembly is in its zero sweep position according to an embodiment of the invention.

FIG. 24 is an isometric view of the beam source of FIG. 23 showing the scan beam and the reflected return beam according to an embodiment of the invention.

FIG. 25A shows the beam-reflector assembly and the home and sweep positions of the beam-sweep-mechanism magnet according to an embodiment of the invention.

FIG. 25B is an isometric view of the beam-sweep-mechanism magnet of FIG. 25A according to an embodiment of the invention.

FIG. 26 is side view of the beam-reflector assembly and the beam-sweep mechanism of FIGS. 22-24 according to an embodiment of the invention.

FIG. 27 is an isometric view of the magnet, magnet holder, and magnet retainer of the beam-sweep mechanism of FIGS. 22-24 according to an embodiment of the invention.

FIG. 28 is an isometric view of the beam source of FIGS. 21-24 having a trigger mechanism in an up position according to an embodiment of the invention.

FIG. 29 is an isometric view of the beam source of FIG. 28 where the trigger mechanism is in a down position according to an embodiment of the invention.

DESCRIPTION OF THE INVENTION

FIG. 1 illustrates one embodiment of a bar code scanning system 100 that includes an optical emitter 104, a scanner 102 that is user powered, a detector 108 and a processor 112 within a controller 135. The emitter 104 includes light source that is enabled by the trigger and powered by a battery. The emitter 104 emits a light beam 130 toward the scanner 106 and the scanner redirects the light beam 130 toward a symbol 190 on a target object 192. As is typical, the symbol 190 includes a number of regions of differing reflectivity, as described previously.

The optical emitter may generate optical energy at a particular wavelength that may or may not be visible with a light emitting diode (LED) or laser diode. Also, the emitter may include a full spectrum light source such as a mercury vapor lamp, short arc lamp or a white laser diode. Other types of emitters include electro-luminescent, incandescent, vacuum emissive, fluorescent, chemical emissive, phosphorescent, and field-emissive.

The symbol 190 reflects a portion of the light from the light beam 130, depending upon the respective reflectivities of the regions struck by the beam 130. As represented by the arrow 135, a portion of the reflected light is gathered by a gathering lens 111 and strikes the detector 108. The amount of reflected light incident upon the detector 108 is dependent upon several factors including wavelength, scanner position, detector position, any associated gathering optics, and the reflectivity of the symbol 190. The detector 115 may be a conventional electronic device, such as a photodiode or a CCD. Responsive to the light 135, the detector 108 produces an electrical signal.

The processor 112 receives the signal and converts the received signal into a digital representation of an image of the symbol 190, i.e., the areas of the symbol that reflect the scanned light beam 135 onto the detector 108. The processor 112 or another component such as a digital signal/image processor identifies information represented by the symbol 190, responsive to the digital representation. For example, the processor 112 may identify the target object 192 or may determine characteristics such as a shipping date, destination, or other information. Alternatively, the identified information may be not pertain directly to the target object 192. For example, where the target object 180 is an identification card, the symbol may provide information about the holder.

FIG. 2 shows diagrammatically one embodiment of a user powered scanner 102 that includes a mirror 107 carried by an oscillating body 108. The scanner 102 does not require a separate electrical power source for operation, but instead is initiated into oscillations by mechanical energy that a user applies by depressing a trigger 110. In other embodiments, the scanner 102 may be powered by electrical energy derived from the user's input mechanical energy. Though FIG. 2 shows the coupling between the trigger 110 and the oscillating body 108 as a simple member 120 for clarity, a variety of structures and approaches for transferring energy may be within the scope of the invention.

FIG. 3 shows one approach to driving a scanner 302 with user supplied energy. In this approach, the member 120 drives a slider bar 122 guided by track 124. The upper edge of the slider bar 122 includes a series of rounded teeth 126A that move longitudinally as the member 120 drives the slider bar 122 along the track 124, as indicated by the arrow 128 and the broken lines 126B, 126C. The slider bar 122 and teeth 126A are injection molded from a durable, substantially rigid plastic.

A flexible member 135 of injection molded flexible plastic is positioned above the slider bar 122 and carries a mirror 132. A finger 134 projects downwardly from the flexible member 135 to engage the teeth 126A. The finger 134 is a plastic selected for relatively low sliding friction as the finger 134 engages the teeth 126A.

As the teeth 126 a slide longitudinally, they drive the finger 134 through a periodic up-and-down path. The moving finger 134 bends the member 120 correspondingly and thereby drives the mirror 132 through a series of positions and orientations defined by the teeth 126A and the member 135, as indicated by the broken line drawings of the member 135 and mirror 132. As described above, as the mirror 132 moves through its series of positions and orientations, and scans the beam 130 through a scan path.

A similar approach is shown in FIG. 4 in which the member 135, mirror 132, and finger 134 are structured similarly to those of FIG. 3. However, in this embodiment, the member 120 is replaced by placing teeth 140 directly on a trigger 142. As the user to presses the trigger 142 by applying a force 144 the trigger 142 pivots about an axle 146, thereby carrying the teeth 140 is passed the finger 134, as indicated by the arrow 148. As with the embodiment described above with reference to FIG. 3, the moving teeth 140 push the finger 134 to drive the mirror 132 through a series of positions and orientations. As the mirror 132 moves, it scans the beam 130 periodically.

And still another approach, shown in FIG. 5, the user applies a force to 50 on a lever arm 252 to cause a lever assembly 254 to pivot about an axle 256. As the user begins to compress the lever arm 252, a torsion spring 258 provides a resistive force in biases the lever assembly 254 outwardly as indicated by the arrow 259. Initially, the lever assembly 254 pivots about the axle 256 causing a distal portion 260 to push on a tab 262 at a distal end of the flexible member 120. As the distal portion 260 pushes on the tab 262, the flexible member 120 bends downwardly providing additional resistance to the lever arm 252. As the user increases force on the lever arm 252, the flexible member 120 bends sufficiently to strike a stop 264. As the flexible member 120 strikes the stock 264, it actuates a switch that turns on a laser assembly 266. The laser assembly 266 is oriented such that light emitted by the laser assembly reflects off of the mirror 132 and travels to a box generator 268. The box generator is an optical element that converts the beam 130 to a recognizable finder pattern that allows the user to more easily align the reader to the target object (not shown).

When the user increases force again, the lever assembly 254, guided by a slot 270 slides longitudinally along the axis indicated by the arrow 272. As the lever assembly 254 slide longitudinally, the distal portion 260 releases force on the tab 262, thereby releasing the flexible member 120. Upon release, the flexible member springs toward its original rest position pivoting the mirror 132 through a series of positions and orientations. The moving mirror 132 sweeps the beam 130 through a scan path that exits through a window 274 toward the target object (not shown). In one approach, the laser assembly remains activated until the flexible member 120 moves the mirror 132 to its rest position. Alternatively, a simple timing circuit maintains power to the laser assembly for a selected time period sufficient to allow the mirror 132 to scan the beam 130 through the scan path.

While the previously described embodiments utilize a mirror 132 carried directly by the flexible member 120, an alternative approach utilizes a resonant scanning assembly 280 carried by the flexible member 120 as presented in FIG. 6. In this embodiment, the user applies a force 282 to a button 284 pivotably or flexibly coupled to a housing 286 by an arm 288. As the user depresses the button 282, a distal tip 290 flexes the flexible member 120. Once the flexible arm on 20 is depressed sufficiently such that the distal tip 290 no longer engages the flexible arm 120, the flexible arm becomes free to spring back to its original position. When the flexible arm on 20 reaches the original position and strikes a stop 292 where it stops abruptly.

Because the motion of the resonant scanning assembly 280 is interrupted abruptly, a portion of its kinetic energy causes resonant motion of the scanning assembly 280. To improve the energy transfer, the resonant scanning assembly 280 includes a mass 601 that is off center from its center of rotation. Once the resonant scanning assembly 280 begins rotating about its center of rotation, the resonant scanning assembly 280 “rings” for a period of time and with the amplitude defined by its parameters, including its Q. As will be described below, the resonant scanning assembly 280 includes a mirror that sweeps through a series of positions as part of the resonant movement. In a similar fashion to the above described embodiments, the reader can use the resonant motion of the mirror to sweep the beam 130 through a scan path.

Another approach to actuating the resonant scanning assembly 280, shown in FIG. 7, includes a ratchet wheel 602 with several fingers 604 spaced along its periphery. The user actuates the ratchet wheel by depressing a button 606 that drives a rack 608 having several gear teeth 610 along one edge. The user's force pushes the rack longitudinally such that the teeth 610 engage complementary teeth 612 on an axle 614. The traveling rack 608 and thus imparts rotational motion to the axle 614. The turning axle 614 rotates the ratchet wheel 602.

As the ratchet wheel turns, it bends a flexible arm 616 that carries the scanning assembly 280, until a distal end 618 of the flexible arm 616 reaches one of the fingers 604. As the distal end 618 passes the fingers 604, the flexible arm 616 straightens driving the distal end 618 against the ratchet wheel 602. The distal end 618 strikes the ratchet wheel 602, thereby abruptly stopping travel of the distal end 618. Because the flexible arm 616 carries the scanning assembly 280, the scanning assembly 280 moves as the flexible arm 616 bands and returns to its original position as the flexible arm 616 straightens. The impact of the distal end 618 on the ratchet wheel 602 stops the scanning assembly 280. However inertia causes the weight 601 to continue along the return path causing a central portion 622 to pivot. The central portion 622 oscillates about its axis of rotation and amplitude and frequency defined by the parameters of the scanning assembly 280.

Another embodiment of a user powered scanner, shown in FIG. 8, the user depresses a button 702 to move an actuator arm 704 days pivotably coupled to the actuator 702 and a first end 706. In opposite and 708 of the actuator 704 moves through a guide groove 710 as the user depresses the button 702. As the user begins depressing the actuator 702, a tab 712 near the second end 708 of the actuator arm 704 depresses a finger 714 days coupled to a flexible beam 716. Because a base end 719 of the beam 716 is held securely to a housing 724, the depressed finger 714 causes the flexible beam 716 to bend. As the flexible beam 716 bends, it carries a mirror 718 from a rest position to a flexed position.

As the user presses the button 702 farther, the guide groove 710 guides the tab 712 away from the base end 719 until the tab 712 disengages the finger 714, releasing the flexible beam 716. Upon being release, the flexible beam 716 travels back through its rest position and bends in opposite direction, carrying the mirror 718 with it. The beam 716 continues to flex back and forth sweeping the mirror 718 repeatedly through a diminishing scan path.

In another embodiment, shown in FIGS. 9A-9D, a flexible arm 802 once again carries a mirror 804. The user actuates scanner by depressing a button 806 to pivot a drive arm 808 about an axle 810. As the drive arm 808 pivots, a tab 812 bends the flexible arm 802 by pushing the finger 814, thereby moving a mirror 801 about the axle 810, as shown in FIG. 9B. As the user depresses the arm even farther, the flexible arm 808 reaches a stop 820 that precludes further movement of the distal end of the flexible arm about the axle 810, as is visible in FIG. 9C. In response to further depression by the user, the distal end of the flexible arm 808 moves longitudinally along the stop 820 as indicated by the arrow 822 in FIG. 9D. As the distal end moves longitudinally, the tab 812 releases the finger 814. Energy stored in the flexible arm 802 causes the mirror 801 to sweep through a scan path as indicated by the arrow 824. To provide additional energy, a helper spring 826 is coupled between the frame and the flexible arm 808.

The resilient supports and flexible arms described above are designed to have a high “Q”, typically greater than 1000, such that relatively little energy is lost from sweep to sweep. The design of high Q mechanical structures is generally well-known to one of skill in the art.

The mirrored surface oscillates back and forth on the oscillating member 156 at a relatively constant frequency due to the high “Q” of the oscillating member. The optical energy is reflected off of the mirrored surface 760 as it oscillates causing the reflected optical energy to scan over a scan angle (θ) forming a scan path on a target.

FIG. 10 to shows one type of micro-electromechanical systems type of scanner 758 (MEMS scanner) suitable for this application. The MEMS scanner 158 is configured for uniaxial scanning with the mirrored surface 760. Design, fabrication and operation of such scanners are described for example in the Neukermans '790 patent, in Asada, et al, Silicon Micromachined Two-Dimensional Galvano Optical Scanner, IEEE Transactions on Magnetics, Vol. 30, No. 6, 4647-4649, November 1994, and in Kiang et al, Micromachined Microscanners for Optical Scanning, SPIE proceedings on Miniaturized Systems with Micro-Optics and Micromachines II, Vol. 3008, February 1997, pp. 82-90 each of which is incorporated herein by reference. The scanner 758 includes integral sensors 762 that provide electrical feedback of the mirror position to terminals XXXX, as is described in the Neukermans '618 patent.

The MEMS scanner 758 is constructed on a silicon substrate with a high reflectivity element 760 located on a central member 762. A set of support beams 763 and 764 suspend the central member 762 within a frame 766. The support beams 763, 764 define an axis (x) relative to the frame 766 about which the central member 762 rotates. A mechanical impact will set the MEMS scanner 758 into an oscillating condition. To improve the response of the scanner 758 to an impact, the central member 762 is positioned a symmetrically relative to the support beams 763 and 764. Once driven into motion, the high Q characteristic of the MEMS scanner 758 allows the MEMS scanner 758 to mechanically oscillate at a particular frequency or in a relatively narrow frequency range, thereby pivoting the central member 762 mechanically through an angular sweep.

A mechanical impact or vibration transfers mechanical energy to the MEMS scanner 758, causing it to oscillate. The scan angle (θ for the x-axis) is a function of the oscillation range of the MEMS scanner 758.

Examples of MEMS scanners are described in U.S. Pat. No. 5,629,790 to Neukermans et al., entitled MICROMACHINED TORSIONAL SCANNER, U.S. Pat. No. 5,648,618 to Neukermans et al., entitled MICROMACHINED HINGE HAVING AN INTEGRAL TORSIONAL SENSOR and CITE DICKENSHEETS PATENT INSTEAD, each of which is incorporated herein by reference. Additionally, the scanning system may be configured to incorporate a non-MEMS mechanically resonant scanner such as disclosed in U.S. Pat. No. 5,557,444, Melville et al. entitled MINIATURE OPTICAL SCANNER FOR A TWO-AXIS SCANNING SYSTEM, which is incorporated herein by reference.

FIG. 11 shows the front and rear of an alternative scanner 900 that may be formed using injection molding or similar techniques. Initially, he scanner 900 is formed as an integral piece having a frame 902, a central body 904, and arms 906. Once the integral piece is formed, a suspension wire 910 is coupled between the frame 902 and central body 904 under a relatively high tension and held in place by a set of guide pins 912. Once the suspension wire 910 is in place, the arms 906 are removed, as indicated by the cross hatching, thereby leading the central body 904 suspended relative to the frame 902 by the suspension wire 910.

As best seen in FIG. 12, the central body 904 includes an offset weight 914 so that upon impact, as described above, the central body 904 will oscillates about the suspension wire 910. While the offset weight 914 is shown as an integral piece, other asymmetries can be introduced to the central body 904, such as added masses, hollowed portions, or non homogenous sections.

Each of the previously described embodiments includes a central body that pivots about a torsion arm or a body that travels in response to a flexible member. FIGS. 13 and 14 show to an alternate scanning assembly 1200 where a lead screw 1202 drives a polygon 1204 carried on axle 1206 by a bearing 1208. The scanning assembly is similar to many children's toys in which a user depresses a pushbutton 1212 causing a lead screw 1202 to slide through a drive disk 1212. As the lead screw 1202 slides through the drive disk 1212, the spiral surfaces of the lead screw 1202 causing the drive disk to rotate about the axle 1206. As the drive disk rotates, it causes reflected surfaces of the polygon 1204 to travel about the axle 1206. The reflected surfaces can scan the beam in a similar fashion to conventional barcode scanners.

Another spinning polygon approach is shown in FIG. 15 in which a user activated button 1502 drives a gear rack 1504. The gear rack pivots a pinion 1506 that transfers motion to a polygon 1510 through a pair of bevel gears 1512, 1514. To allow the polygon 1510 to continue spinning after the user releases the button 1502, the lower bevel gear 1514 is coupled to the polygon 1510 by a one-way clutch.

While a variety of approaches have been described herein to actuating a scanning system using user power, the invention is not so limited. The in fact, in some applications, the user power may be replaced by an escapement mechanism as is shown in FIGS. 16 and a 17. In this embodiment, a user or a spring mechanism applies relatively constant longitudinal force to a rack 1610. The force causes an escape wheel 1612 to pivot about axle 1614 such that teeth 1616 sequentially engage drive pins 1618, 1620. The drive pins cause a Y-arm 1622 to oscillate back and forth about a support arm 1624. The Y-arm 1622 drives a support shaft 1632 cause a balanced wheel 1633 to pivot back and forth, while a hairspring 1636 provides return force. While one type of escapement is presented in FIGS. 16 and 17, one skilled in the art will recognize that a variety of similar structures as are commonly found in spring driven watches could be adapted for such an application.

Still another approach to actuating a mirror 1900 is shown in FIG. 19, in which a thumb lever 1902 drives an arm 1904 downwardly as guided by a finger 1906 in a slot 1908. The arm 1904 pulls an elastomeric support 1910 causing it to band about a

FIG. 24 is an isometric view of the beam source 3012 of FIG. 23 with the scan button 3020 omitted to expose the laser diode 3062 and including the scan beam 3070 (solid line) and the return beam 3072 (dashed line) according to an embodiment of the invention. The laser diode 3062, photo diode 3064, and straw 3065 are positioned so that the beams 3070 and 3072 converge at a predetermined convergence distance from the scan window 3008 (FIG. 21). In one embodiment, this distance is or approximately is six inches. Consequently, the operator typically learns to hold the scanner 3000 (FIG. 21) such that the scan window 3008 is or approximately is the convergence distance away from the target (FIG. 1). Alternatively, one can reposition the laser diode 3062, photo diode 3064, and/or straw 3065 to change the convergence distance of the beams 3070 and 3072.

The operation of the scanner 3000 according to an embodiment of the invention is discussed below in conjunction with FIGS. 21-24.

To deactivate the scanner 3000 such that it does not scan a target (not shown), an operator (not shown) releases the scan button 3020 or merely allows the scan button to remain in its unpushed position as shown in FIG. 22. When the scan button 3020 is released, the reflector assembly 3040 and sweep mechanism 3042 are in their respective home positions as shown in FIG. 22. Specifically, the mechanism 3042 positions the magnet 3052 such that it attracts the magnet 3048. Because the assembly 3040 is free to rotate about its shaft 3050, this magnetic attraction forces the mirror 3046 to face away from the mirror 3066, and thus prevents the mirror 3046 from sweeping the scan beam 3070 or directing the return beam 3072. Furthermore, the pad 3026 does not contact the printed circuit board 3010, thus cutting off power to the laser diode 3062 and the detector 3064. Consequently, the scanner 3000 cannot generate or sweep the scan beam 3070 while the scan button 3020 is released.

To activate the scanner 3000 to scan a target (not shown), the operator (not shown) pushes the scan button 3020 as shown in FIGS. 23 and 24. When the scan button 3020 is pushed, the printed circuit board 3010 provides power from the battery (not shown) in the holder 3016 to the laser and photo diodes 3062 and 3064 via the pad 3026; consequently, the laser diode generates the scan beam 3070. Furthermore, the reflector assembly 3040 oscillates to sweep the beam 3070 across the target and to direct the return beam 3072 to the photo diode 3064. Specifically, referring to FIGS. 23 and 24, the pushed button 3020 moves the members 3058 and 3060 downward, and thus causes the members to position the magnet 3052 such that it repels the magnet 3048. Because the assembly 3040 is free to rotate about its shaft 3050, this magnetic repulsion forces the magnet 3048 away from the magnet 3052, and thus forces the mirror 3046 toward the magnet 3052. The stable (after a settling time) sweep positions, i.e., the zero sweep positions, to which the magnet 3052 respectively forces the mirror 3046 and magnet 3048 are shown in FIGS. 23 and 24. But because the shaft 3050 encounters little resistance, the magnet 3048 and mirror 3046 oscillate back and forth about these respective zero sweep positions for a period of time, typically a few seconds. This oscillation is further discussed below in conjunction with FIGS. 25A and 25B. During this period, the oscillating mirror 3046 sweeps the beam 3070 across the target at least once, and typically sweeps the beam back and forth across the target multiple times. In an alternative embodiment, a spring (not shown) may be attached to the reflector assembly 3040 to reinforce or dampen the oscillations.

Still referring to FIGS. 21-24, if the scan is successful, the scanner 3000 signals the operator (not shown), who then releases the scan button 3020 to reset the scanner and ready it for another target (not shown). Specifically, the remote device (not shown) coupled to the scanner 3000 via the cable 3028 reads the detected return beam 3072 and determines whether a valid target is detected. If so, the remote device signals the scanner 3000, which lights the LED 3018, generates a beep with the piezo-electric crystal, or does both in a recognizable pattern to let the operator know that the scan was successful.

If the scan is unsuccessful, the scanner 3000 signals the operator (not shown), who then releases the scan button 3020 to reset the scanner and ready it for rescanning the target. Specifically, if the remote device determines that a valid target was not detected within a predetermined period of time, the remote circuit signals the scanner 3000, which lights the LED 3018, generates a beep with the piezo-electric crystal, or does both with a predetermined pattern to let the operator know that the scan was unsuccessful. Alternatively, the remote device may send no signal, and the operator recognizes that an unlit LED 3018 and/or no beep within a predetermined period of time indicates an unsuccessful scan. The operator then can rescan the target according to the scan procedure described above.

FIG. 25A is a cross-sectional view of the reflector assembly 3040 in its home position and of the magnet 3052 in its home and sweep positions according to an embodiment of the invention. In one embodiment, the magnet 3052 is a flexible multi-pole magnet that is rectangular and that has two opposite poles at each end. For example purposes, assume that the magnet 3052 has the labeled North (N) and South (S) pole configurations, although it may have the opposite pole configurations where all N's become S's and vice-versa. The magnet 3046 may be made from the same material as the magnet 3052, but is a standard dipole magnet in the disclosed embodiment. The three-dimensional pole pattern of the magnet 3052 is shown below in FIG. 25B.

When the magnets 3048 and 3052 are in their respective home positions as shown in FIG. 25A, the N and S poles of the magnet 3052 are aligned with the S and N poles, respectively, of the adjacent end of the magnet 3048. Therefore, the magnets 3048 and 3052 attract one another. Because the sweep mechanism 3042 holds the magnet 3052 in a fixed position and the assembly 3040 is free to rotate, the attraction between the magnets moves the magnet 3048 to its home position when the magnet 3052 is in its home position regardless of the initial position of the magnet 3046. In their respective home positions, the magnets 3048 and 3052 may be touching one another.

When the magnet 3052 moves into its sweep position as shown in FIG. 25A, its N pole is aligned with the N pole of the magnet 3048. Therefore, the magnets 3046 and 3052 repel one another. Because the sweep mechanism 3042 holds the magnet 3052 in a fixed position and the assembly 3040 is free to rotate, the repulsion between the magnets moves the magnet 3046 as far as possible away from the magnet 3052. Because the reflection assembly 3040 is underdamped, this repulsion also causes the reflection assembly to oscillate back and forth and sweep the scan beam 3070 (FIG. 24) for a period of time as discussed above in conjunction with FIGS. 21-24.

To prevent the magnet 3052 from pushing and/or scraping against the magnet 3048 as the magnet 3052 moves from its home position to its sweep position, the sweep mechanism 3042 (FIGS. 22-24) moves the magnet 3052 along a path 3080 or along a similar path. Specifically, the mechanism 3042 directs and keeps the magnet 3052 away from the magnet 3048 until the magnet 3052 is below the bottom level of the magnet 3046. Then, the mechanism 3042 moves the magnet 3052 beneath the reflector assembly 3040 so that the magnets 3048 and 3052 read one another. How the mechanism 3042 moves the magnet 3052 is discussed below in conjunction with FIGS. 26 and 27.

FIG. 25B is an isometric view of the magnet 3052 of FIG. 25A according to an embodiment of the invention. The magnet 3052 has the same pole configuration as two dipole magnets stacked one atop the other, even where the magnet 3052 is a single piece of magnetic material.

FIG. 26 is a side view of the reflector assembly 3040 and the magnet guide 3057 of the sweep mechanism 3042 (FIGS. 22-24) according to an embodiment of the invention. The guide 3057 includes a guide channel 3082, which forces the magnet 3052 to move between its home and sweep positions without scraping or pushing against the magnet 3048 as described above in conjunction with FIG. 25.

FIG. 27 is an isometric view of the magnet 3052, magnet holder 3054, and magnet retainer 3056 of the sweep mechanism 3042 (FIGS. 22-24) according to an embodiment of the invention. The magnet 3052 is attached to the holder 3054 with adhesive or via another conventional technique. The holder 3054 can slide horizontally within tracks 3084 of the retainer 3056, and thus allows the magnet 3052 to move toward and away from the reflective assembly 3040 as discussed above in conjunction with FIG. 25. The retainer 3056 can move up and down within the guide 3057 (FIGS. 22-24 and 26), and thus allows the magnet 3052 to move above and below the bottom level of the magnet 3048 as discussed above in conjunction with FIG. 26. The holder 3054 includes posts 3088 (only one post shown in FIG. 27), which ride within the guide channel 3082 of FIG. 26. Consequently, the magnet 3052 moves between its home and sweep positions without scraping the magnet 3048 as described above in conjunction with FIG. 25.

Although FIGS. 25-27 describe a technique for preventing the magnet 3052 from pushing against and scraping the magnet 3048 as it moves between its home and sweep positions, other techniques can be used.

FIGS. 28 and 29 are isometric views of the beam source 3012 of FIG. 21 according to another embodiment of the invention. The beam source 3012 of FIGS. 28 and 29 is similar to the beam source 3012 of FIGS. 22-24 except for the addition of a trigger mechanism 3100, which includes a spring-loaded lever arm 3102 and a trigger spring 3104. As discussed below, the trigger mechanism 3100 causes the sweep mechanism 3042 to move the magnet 3052 (FIGS. 22-25) between its home and sweep positions at the same or approximately the same speeds regardless of the speed or force with which an operator (not shown) pushes the scan button 3020 (FIGS. 22-24). Referring to FIGS. 22-24, the operator can push the button 3020 at any speed and to any distance he desires. If the operator does not push the button 3020 all the way in, then the magnet 3052 may stop somewhere between its home and sweep positions, and thus not activate the reflector assembly 3040. Or, if the operator pushes the button 3020 too slowly, then the amplitude of the mirror 3046 oscillation may be too small to adequately sweep the beam 3070 across the target (not shown). The disclosed embodiment of the trigger mechanism 3100 prevents these potential malfunctions by moving the magnet 3052 the full distance and at a predetermined speed when the lever arm crosses the home-to-sweep and sweep-to-home trigger thresholds as discussed below. The trigger mechanism 3100 also provides a “click” or other sound or vibration that notifies the operator that he has pushed the button 3020 far enough to commence a scan of the target.

Referring to FIG. 28, the lever arm 3102 is in its up position (shown) when the scan button 3020 (FIGS. 21-24) is released. As the operator (not shown) presses the scan button 3020, it pushes against the lever arm 3102, thus forcing the arm downward. As the arm 3102 moves downward, the spring 3104 extends. As the arm 3102 passes the home-to-sweep trigger threshold, which, in one embodiment, is the point where the arm is horizontal, the extended spring 3104 quickly pulls the magnet-moving member 3060 downward. This causes the magnet 3052 (FIGS. 22-25) to move in a single motion from its home position to its sweep position, where the magnet causes the mirror 3048 to sweep the scan beam 3070 as discussed above in conjunction with FIGS. 22-25.

Referring to FIG. 29, the lever arm 3102 is in its down position (shown) when the scan button 3020 (FIGS. 21-24) is fully pushed. As the operator (not shown) releases the scan button 3020, a spring (not shown) forces the lever arm 3102 upward. As the arm 3102 moves upward, the spring 3104 extends. As the arm 3102 passes the sweep-to-home trigger threshold, which, in one embodiment, is the point where the arm is horizontal, the extended spring 3104 quickly pulls the magnet-moving member 3060 upward. This causes the magnet 3052 (FIGS. 22-25) to move in a single motion from its sweep position to its home position, where the magnet causes the mirror 3048 to move to and stay in its home position as discussed above in conjunction with FIGS. 22-25. Because the arm 3102 is spring loaded, the members 3058 (FIGS. 22-24) and 3060 need not be spring loaded.

The foregoing discussion is presented to enable a person skilled in the art to make and use the invention. Various modifications to the embodiments will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention as defined by the appended claims. For example, a variety of mechanisms may be employed to move one magnet relative to the other. Additionally, in some configurations, the mirror may sweep only one or very few times in response to operator activations. Moreover, the scanning mechanisms described herein may be applied to targets other than bar-code symbols. Further, while the scanner embodiments described herein include a processing circuit 3013, the processing circuit or other components may be located remotely or incorporated in other devices. In some configurations, the scanner 3000 may be coupled directly to a portable computer, PDA, or cellular phone. In such configurations, the scanner 3000 may provide unprocessed data and use processing power in the remote devices to identify information about the target. Additionally, for some applications, it may be desirable to use a linear array in place of the photo diode 3064 to image more than a single line. Additionally, although the embodiment described herein scans along a single axis, in some applications, the mirror support may be configured such that the mirror sweeps the beam through a two dimensional scan pattern, such as an ellipse or a more complex pattern. Also, although the magnet 3048 is shown as being discrete from the mirror 3046, the invention is not so limited. In an alternative configuration, the mirror 3046 may be mounted directly on the magnet 3048 or the mirror 3046 may be formed on a face of the magnet 3048. Furthermore, any combination or subcombination of the disclosed embodiments is possible. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

Claims

1-29. (canceled)

30. A hand-held bar code scanner comprising:

a planar circuit board having a scan engine and electronic circuitry mounted thereon;

a housing comprising a top cover and a bottom cover configured to internally mount the planar circuit board substantially at a plane defining the half thickness of the housing;

a window configured to allow the passage of a laser beam and scattered light from the laser beam respectively from and to the inside of the housing to and from an external scan field, the window being formed at a front end of the housing; and

a scan button positioned in the top cover approximately one-third of the length from the front end of the housing to the back end of the housing, closer to the front end of the housing; and

wherein the housing has a first length region with a tapering width between the mid-point of its length and the back end of the housing, a second length region with a convexly varying width wider than the width of the first region between the scan button and the front end of the housing, and a tapering transition length region between first and second regions smoothly transitioning from the first tapering width to the second convexly varying width.

31. The hand-held bar code scanner of claim 30 wherein the top cover along its centerline is substantially equidistant from the planar circuit board along the length of the first region and forms a smoothly convex top surface along its centerline along the length of the transition region and the second region, the maximum distance from the circuit board being approximately at a distance from the front of the housing corresponding to the scan button.

32. The hand-held bar code scanner of claim 30 wherein the bottom cover along its centerline is substantially equidistant from the planar circuit board along the length of the first region and forms a smoothly convex bottom surface along its centerline along the length of the transition region and the second region, the maximum distance from the circuit board being approximately at a distance from the front of the housing corresponding to the scan button.

33. The hand-held bar code scanner of claim 30 wherein the top cover substantially across its width forms a smoothly convex surface having a maximum distance from the planar circuit board along its centerline.

34. The hand-held bar code scanner of claim 30 wherein the bottom cover substantially across its width forms a smoothly convex surface having a maximum distance from the planar circuit board along its centerline.

35. The hand-held bar code scanner of claim 30 wherein the first, transition, and second length regions of the housing form an ogee having substantially no discontinuity between the front and back ends of the housing.

36. The hand-held bar code scanner of claim 30 wherein the first tapering and transition length regions of the housing form a concavely varying width; and wherein the transition and second convexly varying length regions form a convexly varying width.

37. The hand-held bar code scanner of claim 30 further comprising a bezel circumjacent the scan button and where the bezel and the scan button are configured to cooperate to guide a user's thumb toward the scan button when the housing is grasped by the user.

38. The hand-held bar code scanner of claim 30 wherein the housing further is configured to have rounded corners between the top and the sides, the radius of the corners being substantially less than the radius across the top of the housing.

39. The hand-held bar code scanner of claim 30 wherein the housing is further configured to have rounded corners between the bottom and the sides, the radius of the corners being substantially less than the radius across the bottom of the housing.

40. The hand-held bar code scanner of claim 30 wherein the first, second, and tapering length regions are configured to cooperate to guide varying hand sizes to comfortably grip the housing with a thumb resting on the scan button.

41. The hand-held bar code scanner of claim 30 further comprising an LED opening in the housing between the scan button and the front of the housing.

42. A housing for a portable bar code scanner comprising:

a bottom cover; and

a top cover having a scan button aperture formed therein;

wherein the bottom cover and the top cover are configured to join along a substantially planar midline having a front portion and a rear portion, the front portion having greater lateral extent than the rear portion.

43. The housing for a portable bar code scanner of claim 42 wherein the top cover and bottom cover are configured to support a planar circuit board substantially along the planar midline.

44. The housing for a portable bar code scanner of claim 42 wherein the front portions of the top and bottom covers describe a convex outward shape along the midline.

45. The housing for a portable bar code scanner of claim 42 wherein the rear portions of the top and bottom covers describe a concave outward shape along the midline.

46. The housing for a portable bar code scanner of claim 42 wherein the front portions of the top and bottom covers are configured to have a convex outward shape along the midline between the covers and the rear portions of the top and bottom covers are configured to have a concave outward shape along the midline between the covers.

47. The housing for a portable bar code scanner of claim 42 further comprising a window configured to be captured between the top and bottom covers at the front end of the housing, the window being wider than the width of the back end of the housing.

48. A portable bar code scanner having a flattened body for gripping with a hand comprising:

a bilaterally symmetric housing having top and bottom surfaces with a scan button formed in the top surface, configured for holding in the hand of a user with fingers wrapped around the bottom surface and a thumb resting on the scan button in the top surface, the housing forming concave and convex curved sides along a length of the housing relative to a plane of symmetry in vertical and longitudinal dimensions, wherein the convex curvature forms a widened region corresponding to the position of the thumb and the concave curvature forms a narrowed region corresponding to a heal of the hand.

49. The portable bar code scanner of claim 48 wherein the bilaterally symmetric housing forms a convex curvature on the top and bottom of the housing relative to a horizontal plane of symmetry, the convex curvature being formed across the width of the housing.