Ulllted States Patent [19]
`Baker et al.
`
`US005862243A
`[11] Patent Number:
`[45] Date of Patent:
`
`5,862,243
`Jan. 19, 1999
`
`[54] SYSTEM FOR EVALUATING BAR CODE
`QUALITY ()N MAIL PIECES
`
`[76] Inventors: Christopher A_ Baker, 8732 Cottonta?
`La‘, Battleground, Ind~ 47920; Peter N-
`Baker, 932 N. Southland Dr., Lafayette,
`Ind' 47905
`[21] App], N()_j 611,777
`_
`Mar‘ 6’ 1996
`[22] Flledi
`[51] Int. Cl? .............................. .. G06K 7/10; G06K 9/00
`[52]
`382/101; 209/272; 235/462
`[58] Field of Search ................................... .. 382/100, 101,
`382/102; 209/272, 900; 235/462
`
`[56]
`
`References Cited
`
`U-S~ PATENT DOCUMENTS
`4606 660 8/1986 Bradshaw etal. ...................... .. 400/62
`4:632:252 12/1986 Haruki et aL
`209546
`4,641,347
`2/1987 Clark et a1_
`35/101
`4,660,221
`4/1987 Dlugos _ _ _ _ _ _
`_ _ _ _ __ 380/23
`4,688,678
`8/1987 Zue et al. ........ ..
`.. 209/552
`382/18
`5,073,954 12/1991 Van Tyne et a1
`571427482
`8/1992 Sansone ~~~~~~ ~~
`364/478
`532163620
`6/1993 Sansone """"" "
`364/478
`5:731:11? Z: :11‘ '
`32527136?
`5/1994 Rosenbaum ~~~~~
`'
`382/101
`2/1995 Mihm et al. .......................... .. 235/375
`6/1995 Allen et al. ........................... .. 364/478
`7/1995 Nishijima et al.
`..... .. 209/584
`8/1995 Oh et al. ......... ..
`.. 364/464.02
`9/1995 Cordery et al. ......................... .. 380/23
`
`5’311’597
`5:387:783
`5,422,821
`5,431,288
`5,446,667
`5,454,038
`
`5,475,603 12/1995 Korowotny ........................... .. 364/478
`5,485,000
`1/1996 Schneider
`..
`5,548,110
`8/1996 Storch et al.
`.
`5,602,382
`2/1997 Ulvr et al. ............................ .. 235/494
`5,617,481
`4/1997 Nakamura ............................. .. 382/101
`OTHER PUBLICATIONS
`Declaration of Christopher A. Baker Ser. No: 08/611,777.
`Primary Examiner—Joseph Mancuso
`Assistant Examiner—Jayanti K. Patel
`Attorney, Agent, or Firm—WoodWard, Emhardt, Naughton
`Mommy & McNe"
`[57]
`
`ABSTRACT
`
`_
`_
`_
`_
`A system for evaluating barcoded mail WhlCh includes an
`imaging device to provide an image signal corresponding to
`an image of a barcode or an address of a mail piece. The
`system also includes an output device for providing evalu
`ation results and a processor receiving the image signal from
`the imaging device' The Processor generates an address
`information signal corresponding to the barcode and an
`address block image signal corresponding to the address.
`The processor provides an output signal to the output device
`in accordance With the address information signal and the
`address block image signal. The output device responds to
`the output signal to provide an address information image
`corresponding to the address information signal and an
`address block image corresponding to the address block
`image signal for visual comparison. The system also evalu
`ates an image of a mail Piece barcode to detect and Catego
`rile barcode defects for reporting With a Visual facsimile of
`the barcode.
`
`31 Claims, 9 Drawing Sheets
`
`K20
`
`46\
`
`36
`
`EQ Processor 50
`
`CRT Display
`@
`
`PrinlerQ
`
`Speaker/Mic
`@
`
`Keyboard/Mouse
`Q
`
`@9
`
`Page 1 of 17
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`ROTHSCHILD EXHIBIT 1004
`
`

`
`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 1 of9
`
`5,862,243
`
`CRT Display
`@
`
`Printer Q
`
`E
`
`Processor @
`
`FIG. 1
`
`Speaker/Mic
`E
`
`Keyboard/Mouse
`6_4
`
`@
`
`Page 2 of 17
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`ROTHSCHILD EXHIBIT 1004
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`

`
`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 2 0f 9
`
`5,862,243
`
`@3 J00
`
`I
`
`I
`
`|
`
`Power-Up & I
`I
`Load Mail in Feed Bin 50
`
`I
`
`Operator Enters Customer Name & Sample Size QQQ I
`I
`System Starts sog
`I
`Feed Piece to Imaging Device & Generate Image of Mail
`Piece Face 51o
`I
`Print ID Number on Mail Piece and Route to Collection Bin 52
`I
`Process Image to Identify Bar Code & Evaluate Bar Code
`Readability by Comparison to Bar Code Requirements Data 53
`
`516
`
`524
`
`ar Code Defec
`Identified?
`
`Categorize & Store
`Defect Data with
`Bar Code Image
`as
`
`Accuracy Check
`Piece?
`
`Store Image of
`Address and Bar
`Code 522
`
`Sample Size
`Reached?
`
`NO
`
`FIG. 2A
`
`Page 3 of 17
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`ROTHSCHILD EXHIBIT 1004
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`

`
`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 3 0f 9
`
`5,862,243
`
`From
`FIG. 2
`
`Y
`ID and Decode Bar Code From Accuracy Check
`Image &
`Display On-screen Address Determined from the
`Bar Code @
`l
`Display Corresponding Image of Mail Piece Address
`on Screen with Alphanumeric Address
`Corresponding to Bar Code E
`l
`Prompt Operator to Make Visual Comparison of Mail
`Piece Image Address and Decoded Bar Code
`Address m
`
`534
`
`Fail Comparison?
`
`YES
`
`Store Mail Piece
`Address Image
`and Inconsistent
`Decoded Address
`
`Another Accuracy
`Check Image?
`
`536
`
`Print Report including Defective Bar Codes with
`Corresponding Defect Indicators and Image of
`Failed Accuracy Comparisons E
`
`Power Off 5 0
`
`Stop Process
`
`FIG. 2B
`
`Page 4 of 17
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`ROTHSCHILD EXHIBIT 1004
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`

`
`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 4 0f 9
`
`5,862,243
`
`340
`
`344
`
`v/ /
`Jane Smith / postage
`111 Broadway
`.
`Metropolls, State 000000
`
`3Q
`
`"N" IQ
`
`} 1234 Main Street
`/: Hometown, State 46220-2926
`
`|
`|
`I
`:
`
`_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___J
`
`
`
`_ _ _ _ _ _ ~ _ _ _ _ _ _ _ : I'IIIIIHIHIIIIllll‘lllllllilulllllilllllIIIIHIIH‘HHHII
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`1 1 1 1 1 l 1 I | | | | | |
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`|
`
`/ 4
`
`352
`
`FIG. 3
`
`350
`
`Page 5 of 17
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`ROTHSCHILD EXHIBIT 1004
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`

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`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 5 0f 9
`
`5,862,243
`
`60
`
`602
`
`/_6O4
`//
`
`/
`I
`
`654
`
`[i/Séilliékiéiéitééki EééINI
`
`ADDRESS FROM BAR CODE: ,’
`
`I
`/
`/
`/
`/
`/
`
`9999 Side Street
`Hometown, State 46220-7926
`
`\
`
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`FIG. 4
`
`Page 6 of 17
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`ROTHSCHILD EXHIBIT 1004
`
`

`
`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 6 of 9
`
`5,862,243
`
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`Page 7 of 17
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`ROTHSCHILD EXHIBIT 1004
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`Page 7 of 17
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`ROTHSCHILD EXHIBIT 1004
`
`

`
`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 7 0f 9
`
`5,862,243
`
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`Page 8 of 17
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`ROTHSCHILD EXHIBIT 1004
`
`

`
`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 8 0f 9
`
`5,862,243
`
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`Page 9 of 17
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`ROTHSCHILD EXHIBIT 1004
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`

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`U.S. Patent
`
`Jan. 19, 1999
`
`Sheet 9 0f 9
`
`5,862,243
`
`Page 10 of 17
`
`ROTHSCHILD EXHIBIT 1004
`
`

`
`1
`SYSTEM FOR EVALUATING BAR CODE
`QUALITY ON MAIL PIECES
`
`BACKGROUND OF THE INVENTION
`
`The present invention relates to evaluating barcodes, and
`more particularly relates to the detection and reporting of a
`defective barcode on a mail piece.
`Throughout the history of the mail delivery, there has
`been a gradual evolution Whereby the post office encourages
`mailers to prepare their mail in such a Way as to reduce the
`effort required on the part of the post of?ce for processing
`such mail. As an inducement to the mailer to prepare the
`mail in such a Way so as to bring about faster mail delivery,
`the post of?ce offers a postage discount to mailers for such
`items as presorted mail and printing of ZIP codes.
`Recently, the United States Postal Service (USPS) has
`adopted neW ZIP codes Which contain more detailed desti
`nation information than the original ?ve-digit ZIP code. One
`neW form of ZIP code (“ZIP+4”) contains an additional four
`digit extension Which generally identi?es an address Within
`a side of residential block. A further enhanced ZIP code
`system utiliZes ll-digit ZIP codes to specify a point of
`delivery.
`Discounts are also given When the mail is marked With a
`barcode corresponding to the ZIP code. Barcoding enables
`mail sorting machines to more rapidly sort and route mail
`from a mailer to a receiver. The Postal Numeric Encoding
`Technique (POSTNET) Was developed by the USPS to
`provide an optimiZed barcode system for encoding ZIP code
`information on mail.
`One problem that arises in determining Whether a mailer
`is deserving of a discount is the objective evaluation of
`barcode quality. One focus of this evaluation should be
`readability of the mail piece barcode. When a barcode
`cannot be effectively read or scanned by automation
`equipment, laborious manual handling of the mail piece
`typically results. Another troublesome barcoding defect is a
`barcode that does not correspond to the designated address.
`Such inaccurately barcoded mail pieces may be misdeliv
`ered and frequently result in additional manual handling. In
`addition to a more objective identi?cation of barcode
`defects, a concise method of visually reporting and summa
`riZing defects is needed to determine an effective corrective
`action. Also, such reporting is needed to support the refusal
`to aWard a discount to a mailer because of poor barcode
`quality.
`Thus, there is a need for an evaluation system to ef?
`ciently detect mail piece barcode defects, including barcode
`readability and accuracy determinations, With a minimum of
`laborious operator activity. Preferably, this system should be
`capable of classifying and reporting a summary of classi?ed
`defects to facilitate corrective action. Also, it Would be
`preferred for this system to reduce the need for subjective
`identi?cation and categoriZation of barcode defects by an
`operator.
`
`10
`
`15
`
`25
`
`35
`
`45
`
`55
`
`SUMMARY OF THE INVENTION
`
`One feature of the present invention is a process to
`evaluate mail piece barcodes Which includes: providing a
`barcoded mail piece for evaluation; generating an image of
`a barcode from the mail piece; evaluating the image With a
`processor to identify a barcode defect; and presenting a
`visual a marker indicating the location of the barcode defect.
`In another feature of the present invention, a method of
`evaluating a mail piece having a barcode is disclosed. This
`
`65
`
`5,862,243
`
`2
`method includes decoding the barcode to provide a decoded
`address corresponding to the barcode; generating an image
`of at least a portion of an address block appearing on the
`mail piece; and comparing the image With the decoded
`address to determine if the barcode is defective.
`In still another feature of the present invention, a barcode
`evaluation method for mail is provided Which includes
`feeding a mail piece to an imaging devide for evaluation and
`generating an image of a barcode on the mail piece. A
`processor is used to evalate the image and identify a barcode
`defect. A defect state is determined. The evaluation results
`are printed With an image of the barcode and a marker
`indicating the determined defect state.
`One aspect of the present invention is a system for
`evaluating barcoded mail Which includes an imaging device
`con?gured to provide an image signal corresponding to an
`image of a mail piece barcode. A transport device moves
`mail to the imaging device for evaluation. The system also
`has an output device for providing evaluation results and a
`processor Which receives the image signal from the imaging
`device. The processor compares the image signal to barcode
`requirements data to detect a barcode defect and provides an
`output signal to the output device if a defect is detected. The
`output device responds to the output signal to provide a
`visual barcode defect marker.
`Another aspect of a barcoded mail piece evaluation sys
`tem in accordance With the present invention is a processor
`Which generates a decoded address signal from an image
`signal. The image signal correspondes to a mail piece
`barcode and at least a portion of a destination address
`appearing on a mail piece. The processor provides an output
`signal to an output device in accordance With the decoded
`address signal and the image signal. The output device
`responds by providing a decoded address image correspond
`ing to the decoded address signal and an mail piece image
`corresponding to the image signal for visual comparison. In
`a variation of this aspect, the processor compares the
`decoded address signal and the image signal to detect a
`barcode accuracy defect and provides an output signal to the
`output device if a barcode accuracy defect is detected.
`Accordingly, it is one object of the present invention to
`provide a method and system to evaluate mail piece barcode
`defects.
`Another object of the present invention is to provide a
`method and system for categoriZing and reporting mail piece
`barcode defects.
`Further objects, features, and advantages of the present
`invention shall become apparent from the detailed draWings
`and descriptions provided herein.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a schematic top vieW of an evaluation station of
`one preferred embodiment of the present invention;
`FIG. 2A is a How diagram of one preferred process of the
`present invention performed With the embodiment shoWn in
`FIG. 1;
`FIG. 2B is a continuation of the How diagram of FIG. 2A;
`FIG. 3 is a depiction of one eXample of a mail piece face
`processed in accordance With the process of FIGS. 2A & 2B;
`FIG. 4 is a depicition of one eXample of a visual display
`in accordance With the process of FIGS. 2A & 2B;
`FIG. 5 is a depiction of one eXample of a report provided
`in accordance With the process of FIGS. 2A & 2B;
`FIG. 6 is a top partial vieW of a feeder system of the
`present invention;
`
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`
`3
`FIG. 7 is a top partial vieW of the feeder system of FIG.
`6 in another position; and
`FIG. 8 is an elevational vieW of a portion of the feeder
`system shoWn in FIGS. 6 and 7.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`For the purposes of promoting an understanding of the
`principles of the invention, reference Will noW be made to
`the embodiment illustrated in the draWings and speci?c
`language Will be used to describe the same. It Will never
`theless be understood that no limitation of the scope of the
`invention is thereby intended. Any alterations and further
`modi?cations in the illustrated device, and any further
`applications of the principles of the invention as described
`herein being contemplated as Would normally occur to one
`skilled in the art to Which the invention relates.
`FIG. 1 schematically depicts a mail piece barcode evalu
`ation station 10 of the present invention. As used herein,
`“mail” or “mail piece” includes an item entrusted With a
`postal service or private delivery organiZation for transport
`to a designated destination. Station 10 has mail handler 20
`coupled to processor 50 having various input/output devices,
`including keyboard/mouse 64 for interfacing With operator
`70.
`Mail handler 20 has bed 21 Which de?nes feed bin 22 for
`holding mail pieces in a mail roW 24 for evaluation. Trans
`port system 25 selectively moves mail a piece at a time from
`feed bin 22. Transport system 25 includes feeder 26, trans
`port path 28 and transport controller 30. Feeder 26 selec
`tively feeds mail from mail roW 24 to transport path 28.
`Transport of a mail piece, such as mail piece 34 shoWn in
`transport path 28, is controlled by transport controller 30. In
`FIG. 1, the direction of travel provided by transport system
`25 is generally from left to right, although in other
`embodiments, the direction of travel path of mail pieces may
`differ. Transport path 28 and transport controller 30 are of a
`conventional type commonly used in mail handling systems.
`Transport system 25 may include pinch rollers or belt
`conveyors.
`Imaging device 32 is con?gured to selectively provide a
`signal corresponding to an image of an item vieWed adjacent
`platten 36. Mail piece 34 is shoWn in this imaging position.
`Preferably, imaging device 32 is a line scan camera Which
`generates an electric signal corresponding to a scanned
`image. Alternatively, imaging device 32 may be an area
`camera, an array of optical sensors, or such other imaging
`device as Would occur to one skilled in the art.
`After traveling by imaging device 32, transport system 25
`provides for the passage of a mail piece to print head 38.
`Print head 38 selectively marks mail in transport path 28.
`Preferably, print head 38 is of the ink jet variety.
`Alternatively, another type of marking device could be used.
`Mail eXits transport path 28 into collection bin 42. Col
`lection bin 42 holds mail roW 44 after processing along
`transport path 28. Stacker 46 assembles and maintains
`evaluated mail roW 44 and is of a knoWn type. Alternatively,
`bins 22, 42 and stacker 46 may be considered components
`of transport system 25. Instead of collection bin 42, other
`embodiments may transport mail to a tray or other device
`after processing in mail handler 20.
`Processor 50 is used to coordinate and control various
`operations of station 10. Processor 50 includes barcode
`requirements data 52 Which provides information pertinent
`to acceptability of a barcode. Preferably, requirements data
`52 includes parameters to comparatively identify a variety of
`
`10
`
`15
`
`25
`
`45
`
`55
`
`65
`
`5,862,243
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`4
`barcode defect states and evaluate severity of a given type of
`defect. More preferably, defect states and associated severity
`levels are used to either fail the barcode as unreadable or
`provide a Warning about readability. It is preferred that at
`least four defect states are detectable. It is more preferred
`that at least 10 defect states are detectable. It is most
`preferred that at least 16 defect states are detectable.
`Furthermore, processor 50 includes a Look-Up Table
`(LUT) 54 con?gured to determine at least a portion of an
`address corresponding to a proper mail piece barcode.
`Preferably, LUT 54 is entered With data obtained from
`scanning a bar code to produce at least a portion of a
`corresponding multicharacter address. This decoded address
`may be further processed to verify accuracy of the bar code.
`Requirements data 52 and LUT 54 may reside in a store
`associated With processor 50. This store may be ?Xed or
`removable. Preferably, the store is a memory device of the
`electronic (e.g. solid state), magnetic, or optical variety,
`Which may be readily updated as bar code standards or
`address/barcode tables change. In one embodiment, data 52,
`LUT 54, or both are provided from a remote store or other
`source via a communication device for processing. In this
`embodiment, the source and communication device are
`considered to be a portion of processor 50 for the purposes
`of the present invention.
`Processor 50 may be an electronic circuit comprised of
`one or more components. Similarly, processor 50 may be
`comprised of digital circuitry, analog circuitry, or both. Also,
`processor 50 may be programmable, an integrated state
`machine, or a combination thereof. Preferably, processor 50
`is a ruggediZed industrial grade programmable personal
`computer With customiZed circuitry and softWare to inter
`face With various components of station 10. This preferred
`con?guration may include communication interfaces such as
`modem or netWork links, and subsystems to accommodate
`removable media, such as compact disks (CDs) or ?oppy
`disks.
`Processor 50 controls selected operations performed by
`mail handler 20 through mail handler interface 56. Mail
`handler interface 56 has operative links to feeder 26, trans
`port controller 30, imaging device 32, and print head 38.
`Processor 50 is also coupled to a number of Input/Output
`(I/O) devices common to personal computers via I/O inter
`face 58. I/O devices coupled to processor 50 via I/O inter
`face 58 include Cathode Ray Tube (CRT) display 60, printer
`62, speaker/microphone 66, and keyboard/mouse 64.
`Preferably, CRT display 60 is of the conventional color
`variety available for personal computer applications.
`Alternatively, a liquid crystal display or other visual display
`responsive to processor 60 may be used. Printer 62 is
`preferably of the laser variety, but could be of another type
`as Would occur to one skilled in the art. Speaker and
`microphone 66 preferably include interface circuitry to
`facilitate delivery and reception of audible commands by
`processor 50; hoWever, in other embodiments speaker/
`microphone 66 may be absent. The keyboard and mouse of
`keyboard/mouse 64 may be separate or combined units of a
`conventional variety. In alternative embodiments, only a
`mouse or keyboard is employed. In fact, in an embodiment
`having an audible command system via speaker/microphone
`66, keyboard/mouse 64 may be absent.
`FIGS. 2A & 2B illustrates process 500 of the present
`invention performed With the preferred embodiment
`depicted in FIG. 1. Process 500 starts With poWer-up at step
`502. Next, mail is loaded in feed bin 22 in step 504. In step
`506, operator 70 enters the name of the customer for Whom
`
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`5,862,243
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`5
`the mail piece barcode evaluation is performed using
`keyboard/mouse 64 or speaker/microphone 66. Step 506
`also includes the entry of the sample siZe of barcoded mail
`pieces for the bar code evaluation. Transport system 25
`begins to operate in step 508.
`Step 510 initiates singulation and feeding of a mail piece
`from mail roW 24 With feeder 26. Also, transport system 30
`delivers the mail piece along transport path 28 to platten 36
`for scanning by imaging device 32. After imaging, the mail
`piece is moved to print head 38 and a unique number (“N”)
`or other identifying mark is printed on the mail piece in step
`512. The mail piece is then routed to collection bin 42 by
`transport system 25.
`Referring additionally to FIG. 3, processed mail piece 340
`is shoWn. Face 341 of mail piece 340 includes postage Zone
`342, return address Zone 344, and address block 350.
`Address block 350 includes an alphanumeric destination
`address 352 and a barcode 354. Face 341 also includes an
`identi?cation number “N” at Zone 346. Identi?cation num
`ber “N” may be supplied by print head 38 to identify the mail
`piece in relation to the evaluation sequence. Step 512
`corresponds to this marking and also includes the routing of
`mail pieces to collection bin 42 after evaluation.
`In step 514, processor 50 receives a signal from imaging
`device 32 corresponding to the image of the face of a mail
`piece. Referring to mail piece 340 by Way of eXample, in
`step 514, processor 50 receives a signal from imaging device
`32 corresponding to an image of at least a portion of face 341
`of mail piece 340. Processor 50 locates address block 350
`and discriminates betWeen images corresponding to desti
`nation address 352 and the barcode 354. US. Pat. No.
`5,431,288 to Nishijima et al., US. Pat. No. 5,387,783 to
`Mihm et al., US. Pat. No. 5,249,687 to Rosenbaum et al.,
`US. Pat. No. 5,073,954 to Van Tyne et al., and US. Pat. No.
`4,632,252 to Haruki et al. generally disclose techniques to
`recogniZe addresses and barcodes in connection With image
`processing of mail.
`Processor 50 is con?gured to evaluate barcode readability
`by comparing the barcode image to barcode requirements
`data 52. If a defect has been identi?ed as queried in
`conditional 516, then preferably processor 50 categoriZes
`the defect using requirements data 52 in step 518. It is more
`preferred that processor 50 determine defect severity to
`further classify defects as either failures or Warnings. It is
`most preferred that processor 50 recogniZe and identify
`multiple defects and associated severity levels. The defect
`data and associated barcode image are stored for later
`reporting.
`After evaluating for readability defects, control ?oWs to
`conditional 520 to determine Whether the piece has been
`selected to perform an accuracy check. Preferably, the
`accuracy check is performed on a randomly selected subset
`of the sample siZe entered in step 506. If a mail piece is
`designated for an accuracy check, then the corresponding
`address block image is stored for later evaluation in step
`522.
`Conditional 524 determines Whether the sample siZe
`entered in step 506 has been reached. If the sample is not
`complete, control returns to step 504 to feed the neXt piece
`for evaluation. If the sample is complete, control ?oWs to
`step 526 (See FIG. 2B).
`Referring to FIG. 4, a sample screen 602 using display 60
`is illustrated Which presents results corresponding to the
`performance of the neXt three steps, 526, 528, and 530 of
`process 500. Screen 602 includes a banner 604 to indicate
`the nature of the operation. Speci?cally, the accuracy check
`
`10
`
`15
`
`25
`
`35
`
`45
`
`55
`
`65
`
`6
`for a selected piece “N” is indicated. In step 526, the imaged
`barcode of a stored accuracy check piece is accessed and
`decoded to determine at least a portion of an address
`corresponding to the barcode. Preferably, processor 50 per
`forms this operation With LUT 54 using data corresponding
`to the scanned bar code for entry. This decoded address is
`then sent as a visual image to display 60. FIG. 4 shoWs
`decoded address 654 in output block 606. Decoded address
`654 is one eXample of an output Which corresponds to 526.
`Preferably, step 526 provides a decoded address in a discrete
`character-based teXt format such as ASCII, although other
`formats as Would occur to those skilled in the art are also
`contemplated.
`In step 528, the imaged address block is displayed on the
`screen of display 60 neXt to the decoded address generated
`in step 526. FIG. 4 presents one eXample of the output of
`step 528 as imaged address block 650 in output block 608.
`Imaged address block 650 is for the same mail piece having
`decoded address 654. In one embodiment, imaged address
`block 650 is presented in a graphical format Which readily
`accommodates hand-Written addressing. In alternative
`embodiments, imaged address block 650 may be converted
`into a character format or presented as a miXed character and
`graphical presentation. US. Pat. No. 5,475,603 to
`KoroWotny, US. Pat. No. 5,431,288 to Nishijima et al., US.
`Pat. No. 5,422,821 to Allen et al., US. Pat. No. 5,249,687 to
`Rosenbaum et al., and US. Pat. No. 5,031,223 to Rosen
`baum et al. provide various Optical Character Reader (OCR)
`mail piece processing methods Which may be adapted to
`convert an imaged address block into at least a partial
`character format.
`In step 530, the operator 70 is prompted to indicate
`Whether on-screen images of the decoded address and the
`destination address appearing on the face of the mail piece
`match. If there is no match, then the barcode is usually
`inaccurate. This step avoids the laborious task of culling
`through evaluated mail pieces to verify barcode accuracy of
`a sampled sub-set. Output block 610 of screen 602 provides
`one eXample of such a prompt With regard to the comparison
`of decoded address 654 and imaged address block 650.
`Operator 70 may input this data by using mouse cursor 612
`With the “YES” or “NO” button. Alternatively, a keyboard
`entry or an audible command may be used to input the
`operator response.
`Conditional 532 queries Whether a failed comparison (no
`match) is indicated. If the comparison fails, step 534 pro
`vides for storage of the decoded address and corresponding
`address block image of the mail piece for later reporting in
`step 538. Control then ?oWs to conditional 536 to determine
`if additional accuracy checks need to be performed for other
`mail pieces. If further checks remain, then control loops
`back to step 526. OtherWise, a report is printed With printer
`62 in step 538. In step 540, the system is poWered doWn and
`process 500 stops.
`Notably, the steps and conditionals of process 500 may be
`con?gured to generally correspond to various signals or
`variables associated With station 10. For example, in the case
`of processor 50, various output signals may result in con
`nection With the generation of defect reports and other
`signals correspond to data and operations Within processor
`50. Also, various devices of station 10 eXchange signals With
`processor 50 Which may correspond to one or more elements
`of process 500.
`In one alternative embodiment, evaluation by processor
`50 of barcode accuracy includes the utiliZation of OCR.
`Speci?cally, in this embodiment, processor 50 determines
`
`Page 13 of 17
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`ROTHSCHILD EXHIBIT 1004
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`

`
`5,862,243
`
`7
`the characters of at least a portion of the destination address
`on the face of a mail piece from its image. This discrimi
`nated destination address is then compared by processor 50
`to the decoded address from the mail piece barcode. This
`process may avoid the need to involve the operator in the
`accuracy check determination. In a variation of this
`embodiment, the operator is prompted to perform barcode
`accuracy comparisons only When the OCR process cannot
`be performed Within a predetermined amount of time. For
`example, because some OCR processes perform poorly for
`handWritten destination addresses, these addresses may be
`candidates for selective operator comparison.
`Preferably, a report is provided by station 10 Which
`includes a visual reproduction of the decoded address and
`address block image appearing on each mail piece Which
`fails the accuracy check. Also, it is preferred that a copy of
`unreadable barcodes With defect category indicators be
`printed for each failed barcode. In an alternative
`embodiment, barcode Warnings are also supplied. In another
`embodiment, the sensitivity of the barcode defect detection
`is adjustable and may be tailored to examine barcode
`process trends for quality control purposes.
`Referring to FIG. 5, one type of barcode readability report
`700 is depicted. This report includes a banner 702 indicating
`the customer and the readability rate. In this case tWo failed
`barcodes, 710 and 720 are depicted. “Piece 23” and “Piece
`99” correspond to the piece ID numbers “N” placed on the
`mail pieces by print head 38, for barcodes 710, 720, respec
`tively. In accordance With indicator key 730, defect markers
`include loWer case letters to indicate Warnings and upper
`case letters indicate a failure. Also, in this example, 5
`Warning defects have been selected to result in a failure.
`Each block 714, 724 of report 700 provides loWer case
`characters “b” to indicate the location of offending indi
`vidual bars of each corresponding barcode 710, 720.
`Speci?cally, these characters are aligned beneath bars Which
`are believed to be too short (see indicator key 730). Also,
`“B” is shoWn beneath the ?fth “b” of each block 714, 724
`to indicate a failure due to an excess number of Warnings. In
`addition, indicators 712, 722 correspond to other defect
`states resulting in failure that are generally not location
`speci?c (see key 730). TWo markers are shoWn in indicator
`722 corresponding to the detection of tWo defect states for
`piece 99 Which are not location speci?c. Various other report
`indicator keys 730 and markers are contemplated as Would
`occur to one skilled in the art.
`Report 700 may be varied in length and number of pages
`to correspond to the number of defective barcodes detected.
`In one embodiment, report 700 is prepared for presentation
`on display 60. Other visual display media for reporting
`barcode defects With corresponding images or facsimiles are
`contemplated as Would occur to one skilled in the art.
`Furthermore, the storage and transfer of barcode defect data
`and reports on non-visual electronic, magnetic, or optical
`media in corresponding formats is contemplated. Notably, in
`one embodiment, the imaging information is stored on a
`portable disk for subsequent doWnloading and evaluation by
`processor 50 Without otherWise coupling to imaging device
`32. Also, processor 50 may be used to generate and report
`various statistical information associated With barcode
`evaluation.
`In another embodiment, defects may be indicated by
`printing an appropriate indicator on the corresponding
`defective mail piece With print head 38 after evaluation. In
`one version of this embodiment, a de?ector under the control
`of processor 50 is included betWeen transport path 28 and
`stacker 46 to segregate failed mail pieces into a