Dr. Jürgen Klie
Unexchangeable:Gauges and tools with 2D codes
Scalable two-dimensional codes and new developments for their reliable mounting and reading even under difficult boundary conditions have replaced the transponder as a data medium for the automatic identification of gauges and measuring tools.
Gauges with 2D codes (DataMatrix) are a joint development of:
I. General
Ident numbers as unique "names" of gauges and measuring tools are read again and again and transferred to other documents,
e.g. at :
Ident numbers as unique "names" of gauges and measuring tools are read again and again and transferred to other documents,
e.g. at :
- Export and import from a magazine
- Calibration calls
- Data queries of all kinds
- Collections for output to a calibration laboratory
- Calibrations in the calibration laboratory
- Returns after calibrations
Codecard to identify system user
Automatic identification of gauges and measuring tools not only excludes the otherwise almost inevitable errors, e.g. by number-wrench, but includes in the multiplicity and frequency of the listed processes also a great savings potential.
In combination with a likewise automatic identification of the users, a computer-controlled management system can be set up without manual input, which knows at any time the current location of all gauges and measuring tools and their calibration dates.
The site-selective calibration calls derived from this guarantee compliance with the relevant requirements of current QA systems (eg DIN ISO 9000 series) with the least possible effort.
In combination with a likewise automatic identification of the users, a computer-controlled management system can be set up without manual input, which knows at any time the current location of all gauges and measuring tools and their calibration dates.
The site-selective calibration calls derived from this guarantee compliance with the relevant requirements of current QA systems (eg DIN ISO 9000 series) with the least possible effort.
II. Identification media / state of the art
An implementation of this solution was not considered, however, because the adhesive strips are not sufficiently robust and because they take up too much space in small gauges.
Glued memory chips
This solution also could not push through in practice, probably because the pill-shaped memory chips were too big to be permanently applied on all objects with
no risk of destruction and also had to be loaded first before use with the respective information.
Implanted Miniature Transponder
Unfortunately, a problem-free implantation to new gauges and measuring tools was accompanied by a partly difficult and expensive retrofitting of older objects.
In particular, incorporation into hardened steel materials (e.g., into thread rings and adjust rings) required specialized machinery and tools and was time- and money-expansive.
EAN-Barcode
As early as 1994, Dr. Jürgen Klie GmbH has presented a thread ring with an EAN barcode glued on at the fair MTQ in Dortmund.
An implementation of this solution was not considered, however, because the adhesive strips are not sufficiently robust and because they take up too much space in small gauges.
Glued memory chips
This solution also could not push through in practice, probably because the pill-shaped memory chips were too big to be permanently applied on all objects with
no risk of destruction and also had to be loaded first before use with the respective information.
Unfortunately, a problem-free implantation to new gauges and measuring tools was accompanied by a partly difficult and expensive retrofitting of older objects.
In particular, incorporation into hardened steel materials (e.g., into thread rings and adjust rings) required specialized machinery and tools and was time- and money-expansive.
Thread ring with Barcode, MTQ 1994
Thread plug gauge with miniature transponder
III. Identification by 2D codes (matrix gauges)
III.1 General
Compared with the EAN barcode, such a 2D code has considerable advantages as data carriers for the identification of measuring tools and gauges of all kind :
- less space required
- higher information capacity
- Integrated error correction (Reed Solomon)
- Universal applicability
- Comparatively simple retrofitting with existing
gauges / measuring tools
2D- Codes as Labels enlarged, see scale
III.2 Suggestion of unified coding
The only requirement for the code thus remains unambiguous: each encoding should be used only once. The following proposal ensures this:
Encoding format: HHLLJJxxxxxx (example: PMDE09004711) with:
- HH: two-digit manufacturer code (alphanumeric)
- LL: two-digit country code (alphanumeric)
- JJ: two-digit year code (numeric)
- xxxxxx: six digit sequence (numeric)
This coding "fits" on a data matrix format ASCII 14 x 14, which can be applied to the objects by various methods with an edge length of about 4 mm.
III.3 Application of the Codes
According to the very different materials and designs of the gauging and measuring tools, the application of various methods offers:
- direct application to the objects, e.g. by laser or needle punch preferred for solid gauges of all kinds, even with hard materials
- Application of a firmly bonded metal shield, e.g. for gauge blocks and test pins in a box
- Application of a plastic sticker, e.g. for very large objects, measuring instruments, storage containers and objects with low load or damage hazard
- KLIESOFT Identifiy Labels.
KLIESOFT Identify Labels are a further developed special form of plastic stickers. They consist of a scratch-resistant, heavy-duty layer construction and are separated with standard punch pliers from cards with (usually) 50 labels. The labels are firmly anchored with high-strength adhesive in 5 mm diameter counterbores. So arranged, the labels are virtually indestructible. They are very easy to find and very readable. With a diameter of 5 mm x 0.4 mm thick, the labels can be inserted virtually anywhere. A further advantage is that the labels additionally have three independent optical distinguishing features due to the largely free choice of the circle color as well as the matrix and the matrix basic color.
2D- Coding with a Laser
Metal lable
Coding of an old gauge with a needle embossing machine
Plug gauge with KLIESOFT Identify Label anchored in the handlebar
2D- Coding with a needle embossing machine
Coding in hard material
Coding of a snap gauge
Card with 50 KLIESOFT Identify Labels
IV. Readout and processing of the codes
The further processing steps are carried out as with all traditional gauge and measuring tool management or calibration systems only on the basis of these ident numbers.
By retaining the previous identification numbers, the automatic identification can be easily integrated into all existing systems.
The KSTUNIS software is required to create assignment tables, to handle them, and to create user permissions. However, the actual administration and/or calibration software can always be kept unchanged and reused, with the ID numbers being generated by KSTUNIS subprogram KEYBSIM instead of using keyboard.
KEYBSIM ("Keyboard Simulator") is a background program contained in KSTUNIS, which transfers the assigned ID number to the computer each time a code is read, as if it had been entered via the keyboard.
The processing of the code strings is already integrated in the KLIESOFT products KSVAMP (management software for measuring tools and gauges) and KSPUMA (calibration software). KEYBSIM is not needed here.