Contactless smart card high production encoding machine

• US 6,394,346 B1
• Filed: 10/07/1999
• Issued: 05/28/2002
• Est. Priority Date: 10/07/1999
• Status: Expired due to Term

• Current Assignee: Cubic Corporation
• Original Assignee: Cubic Corporation
• Inventors: Miller, Gregory E., Blodgett, Neal, Lombardi, Katarzyna, Bonneau, Walter C. Jr., Pearson, Richard A., Hilton, Graham H.
• Primary Examiner(s): Lee, Michael G.
• Assistant Examiner(s): FUREMAN, JARED
• Application Number:
  US09/414,055
• Time in Patent Office: 964 Days
• Field of Search: 235/380,375,435,437,438,439,440,444,492,449 324/76.77 73/847,848,849
• US Class Current: 235/438
• CPC Class Codes: G01N 3/20 by applying steady bending forces G01N3/26, G01N3/28 take precedence
• CPC Class Codes: G01R 31/01 Subjecting similar articles in turn to test, e.g. "go/no-go" tests in mass production; Testing objects at points as they pass through a testing station testing of cables continuously passing the testing apparatus G01R31/59; testing dielectric strength or breakdown voltage G01R31/12
• CPC Class Codes: G01R 31/311 of integrated circuits G01R31/31728 takes precedence
• CPC Class Codes: G06K 17/00 Methods or arrangements for effecting co-operative working between equipments covered by two or more of main groups G06K1/00 - G06K15/00, e.g. automatic card files incorporating conveying and reading operations
• CPC Class Codes: G06K 19/077 Constructional details, e.g. mounting of circuits in the carrier
• CPC Class Codes: G06K 7/0095 Testing the sensing arrangement, e.g. testing if a magnetic card reader, bar code reader, RFID interrogator or smart card reader functions properly testing of electrical circuits G01R31/28

Abstract

An apparatus automatically analyzes and culls-out defective contactless smart cards. Analysis of smart cards may include RF ranging for both near and far ranges, card type decoding for sorting or encoding using a multi-protocol reader, full memory reading and writing, concave and convex card flexing, optical graphics verification of both sides of card, reading and verifying printed serial numbers, and matching encoded serial numbers with printed serial number. The apparatus also provides high speed encoding and initializing of contactless smart cards. Contactless cards moved through machine serially without belts and rollers. The testing and encoding sequence includes bending and flexing the smart cards followed by RF testing. Self-positioning capability provides accurate card positioning over RF antennas.

Claims

1. An apparatus for testing a plurality of smart cards, the apparatus comprising:

a processor for controlling a test of the plurality of smart cards;

a serial test line having a plurality of test positions, the serial test line controlled by the processor, the plurality of test positions comprising;

at least one write antenna for writing a first test pattern to each smart card of the plurality of smart cards;

at least one read antenna for reading the first test pattern from each smart card;

at least one optical surface reading assembly for comparing a template image with an image of each smart card; and

at least one flexion means for flexing each smart card, the flexion means providing a mechanical integrity test of each smart card;

a card input means for feeding the plurality of smart cards into the serial test line; and

a sorting means for sorting the plurality of smart cards, wherein the sorting means is controllable by the processor.

2. The apparatus as in claim 1, wherein the plurality of smart cards are contactless smart cards.

3. The apparatus as in claim 1, wherein the at least one read antenna and the at least one write antenna comprise:

at least one functional read/write antenna;

at least one long range antenna; and

at least one short range antenna.

4. The apparatus as in claim 3, further comprising a reading range test to ensure field functionality.

5. The apparatus as in claim 3, wherein the at least one long range antenna and the at least one short range antenna are adjustable over a range of distances from the smart card.

6. The apparatus as in claim 5, wherein the range of distances for the at least one short range antenna is 5-20 millimeters, and wherein the range of distances for the at least one long range antenna is 50-100 millimeters.

7. The apparatus as in claim 1, wherein the at least one optical surface reading assembly compares a top surface template image with an image of a top surface of each smart card.

8. The apparatus as in claim 1, wherein the at least one optical surface reading assembly comprises a high intensity lamp for creating a shadow image of internal features of each smart card.

9. The apparatus as in claim 1, further comprising a printing assembly for marking each smart card with reject information or with initialization and personalization data.

10. The apparatus as in claim 1, wherein the at least one flexion means comprises a roller and transport belt assembly, and wherein the transport belt bends a smart card around a portion of the roller.

11. The apparatus as in claim 10, wherein the at least one flexion means bends each smart card in a concave manner with respect to a first surface of each smart card.

12. The apparatus as in claim 11, further comprising a second flexion means for bending each smart card in a convex manner with respect to the first surface of each smart card.

13. The apparatus as in claim 1, further comprising means for communication protocol determination for reading/writing to the plurality of smart cards according to a communication protocol utilized by a smart card of the plurality of smart cards.

14. The apparatus as in claim 1, wherein the at least one write antenna is further utilized to encode each smart card of the plurality of smart cards with a desired application according to an intended use of each smart card.

15. A method for testing a plurality of smart cards;

the method comprising the steps of;

feeding a plurality of smart cards into a test line, each card of the plurality fed serially into the test line;

writing to each smart card as it moves into a write test position;

performing a first flexion test by flexing each smart card in a first direction;

reading from each smart card as it moves into a read test position;

performing a second flexion test by flexing each smart card in a second direction;

comparing card surface features of each smart card with a first template;

illuminating each smart card to create a shadow image of the internal features of the smart card;

comparing the internal features with a second template;

identifying each smart card of the plurality of smart cards as a passing smart card or a rejected smart card; and

sorting the plurality of smart cards according to the identification.

16. The method as in claim 15, wherein the steps of writing and reading to each smart card is performed utilizing a first and a second functional read/write radio frequency antenna.

17. The method as in claim 16, further comprising steps of:

writing to each smart card utilizing a long range antenna; and

reading from each smart card utilizing a short range antenna.

18. The method as in claim 15, wherein the step of identifying each smart card further comprises the step of printing the identification of the passing smart card or the rejected smart card on each smart card after completion of the testing.

19. The method as in claim 15, further comprising step of sensing movements of each smart card in the test line utilizing a plurality of sensors.

20. The method as in claim 15, wherein the step of reading is performed after either of the first or second flexion test.

21. The method as in claim 15, further comprising the step of encoding each smart card according to the intended use of each smart card.

22. The method as in claim 15, wherein each smart card is a member of a specific card-type, and wherein the step of sorting the plurality of smart cards further comprises the step of sorting each smart card according to the specific card-type.

23. The method as in claim 15, wherein the steps of performing a first and second flexion test by flexing each smart card in a first and second direction comprises the steps of concavely flexing each smart card around a first roller and convexly flexing each smart card around a second roller.

24. The method as in claim 15, further comprising the step of encoding each smart card of the plurality of smart cards with an application of a plurality of applications according to an intended use of each said smart card.

25. The method as in claim 15, further comprising the step of determining a communication protocol utilized by each smart card of the plurality of smart cards, wherein the communication protocol is utilized in the steps of writing to and reading from each smart card.

26. An apparatus for testing function and durability of a smart card comprising:

a computer-controlled serial test line comprising a plurality of stations comprising;

means for moving the smart card through the serial test line;

a first station writing to the smart card;

at least one flexion device for applying a bending force to the smart card;

a second station for reading the smart card;

a third station for writing to the smart card;

at least one fourth station for optically inspecting the smart card;

a fifth station for reading the smart card; and

a sixth station for marking the smart card according to test results derived from the second, fourth and fifth test stations.

27. The apparatus of claim 26, wherein the at least one fourth station comprises two optical inspection devices, a first optical inspection device comprising a light source and a first camera for generating an image of the smart card, and a second optical inspection device comprising a backlight source and a second camera for generating a shadow image.

28. The apparatus of claim 26, wherein the at least one flexion device comprises a first flexion roller for flexing the smart card in a first direction, and a second flexion roller for flexing the smart card in a second direction opposite from the first direction.

29. The apparatus of claim 26, wherein the first station and the second station each comprise a functional read/write antenna.

30. The apparatus of claim 26, wherein the third station and fifth station each comprise one of a short range antenna and a long range antenna.

31. The apparatus of claim 26, wherein the means for moving comprises a belt and a plurality of transport rollers.

32. The apparatus as in claim 26, further comprising means for determining a communication protocol utilized by the smart card.

33. The apparatus as in claim 26, wherein the third station for writing to the smart card comprises means for writing an application to the smart card according to an intended use of the smart card.