RFID technology keeps developing further. To ensure that Schreiner Group’s customers will continue to benefit from state-of-the-art technology, Schreiner’s LogiData competence center continuously optimizes existing products and makes them fit for the future. Specifically, that means the ground’s been cleared for the UCODE 9 family!

The high-performance UCODE 9 chip family from NXP takes center stage in the current conversion process. However, the previous antenna designs were no longer adequate for tapping the full potential of these new chips. “For optimal results, we implemented newly developed—partly proprietary—antenna designs,” explains Hartmut Wiederrecht from Schreiner’s LogiData competence center. As a result, different variants are now available that are precisely adapted to the properties of the new chips— and they truly pack a punch.

 

Tailored to Suit Any Use Case

The team has developed different sizes and geometries for them that deliver top performance according to their uses and substrates. Whether metallic surfaces (On-Metal), a wide variety of plastics, ESD environments, or glass—the capabilities of the UCODE 9 family can be systematically exploited where they’re needed. Typical examples are applications in manufacturing, logistics, or the sensitive electronics and medical device technology.

The Chip that Thinks for Itself

A central feature of the new chip family is its “self-adjust technology.” When the reader responds it analyzes the signal quality and, for instance, automatically adjusts reception amplification. “As a result, readability remains stable even under changing conditions and read errors are significantly reduced—a clear advantage for process reliability,” Wiederrecht emphasizes. In addition, the higher read and write sensitivity combined with the new antenna designs enables more compact, resource-saving RFID tags and generates new prospects for smart manufacturing and sustainable projects.

 

The newest-generation chips are ideally suited for use in logistics, manufacturing, healthcare, and other sectors. The UCODE 9 family creates additional potential for optimizing processes, enhancing efficiency, and reducing costs. Especially use cases such as inventory management, asset tracking, or seamless tracking along the supply chain benefit from that. RFID tags that, thanks to tailored antenna technology, precise material selection, and customized development, are perfectly tailored to their task and enable seamless integration—that’s what Schreiner Group stands for, also with this newest chip generation.

Whether they’re filled with insulin, anti-thrombosis medication, or other medicinal substances—injection pens have versatile uses and become firmly established in healthcare. When it comes to dispensing drugs, not only the pen’s content plays a key role but so does the related NFC label enabling a medication to be identified, authenticated, and tested for its expiration etc. by means of a smartphone and app. To ensure truly trouble-free readability of the smart pens from any angle, the experts from Schreiner LogiData have achieved a decisive evolution of the label antennas.

In many cases, the inscription “Scan here” indicates where users need to position their smartphones for reading the label. But what if there’s no such description? “That’s when readability must be ensured from truly any position,” said Team Leader Hartmut Wiederrecht, explaining the situation prompting the further technological development and the requirement from the Schreiner MediPharm business unit as the expert in the pharmaceutical sector.

 

Emission Characteristics of Inlays

To obtain a precise idea of what inlay has what kind of emission characteristics, the team used various NFC antennas, software specifically developed for that purpose, and a highly complex design that the experts developed and optimized over a longer period of time based on in-depth technical knowledge. “It was fascinating to see the differences in the antennas’ performance in various orientations,” Wiederrecht recalled. “And I’m honest, a particularly small antenna did pose a few challenges to us.” Yet the extensive photogrammetric image makes it possible for the RFID experts to enhance the design and to precisely optimize the NFC antennas for pen labels.

 

Valuable Findings

The measurement setup provided the Schreiner LogiData team with valuable findings. Not only serving as the basis for current projects, they also drive the development of future solutions to ensure that customers will enjoy reliable NFC data transmission even under challenging conditions.

For more than 20 years, Schreiner Group has been offering its customers a wide variety of customized RFID solutions. Obviously, our experts from Schreiner LogiData are focused on the various antenna production technologies as well. Their knowledge of the variety of methods enables the development of tailored solutions for the customers’ specific requirements.

A brief overview:

Etching remains the dominant technology for mass production of RFID antennas. It is used for aluminum and copper antennas and offers high resolution at comparatively low costs. Another commonly used method is cutting—both mechanically and by means of lasers. It is particularly wellsuited for specialty applications in the UHF range and laser cutting enables rapid implementation of design modifications. Printing of RFID antennas enables the utilization of different carrier materials and is particularly well-suited for specialized applications such as stretchable substrates, on paper, or void structures. For smaller volumes and quick design changes, this method is ideal despite slightly higher costs and disadvantages in terms of conductivity.

But innovative and more eco-friendly alternatives to conventional antenna production exist as well:

One option, for instance, is to press metal-coated films onto a 3D printing plate and to remove raised surfaces by means of abrasion, which requires less chemicals and enables quick design changes. Another variant of antenna production uses a design that is sprinkled with metal powder, sintered, and compacted, because of which it can be used on paper and hence is free of plastics. Another existing plastics-free, digital technology uses a laser to write on a metal foil which is subsequently ablated. However, there is currently a downside to all those alternatives: they are costly and the number of available suppliers is still very small at the moment.

A comparison shows that each manufacturing technology has its own cost structure and not every technology is suitable for all materials. Some offer flexibility in design while others reduce the environmental footprint. By the same token, the choice of the suitable technology also depends on the specific requirements of the application and the production volume. Our experts include all that, paired with solid industry knowledge, in their planning process of developing new RFID applications.

RFID labels are perfectly suited for fast product identification and tracking. But what if products must be stored at extremely low temperatures? Schreiner LogiData has found a solution: RFID labels that still work at -80 °C.

RFID labels are practical: They store a wealth of information, can be read in a contactless process, and are highly tamper-proof. But they are not really made for harsh conditions—normal RFID labels work only at up to 50 °C. However, several years ago, Schreiner Group achieved a breakthrough at very high temperatures: The company’s sophisticated RFID specialty label developments work even at temperatures of up to 230 °C.

Now, Schreiner LogiData has developed a high-tech innovation for freezing temperatures as well. Conventional RFID labels are designed only for freezing temperatures down to -40 °C. Extremely low temperatures pose a major problem, though: Cold has a massive impact—both on the electric properties of an RFID label and on the material and substrates. That in turn affects adhesiveness, range, and even the frequency of the label. Despite these factors, the Schreiner LogiData competence center managed to develop a UHF RFID label that works even at -80 °C.

That the label needs to deliver equally good performance at both normal room and at very low freezing temperatures posed a major challenge during the label development project. To achieve that, the experts developed a special UHF antenna design that considers the frequency shift at various temperatures. In addition, read ranges were optimized accordingly.

Moreover, the label was tested under real-world conditions. Consequently, it had to be dispensed and cooled down to -80 °C—while being permanently maintained at that temperature range—for performing measurements and tests. That is why the utilization of a normal freezer was no option: if it were kept open all the time it would heat up; if it were kept closed the metallic environment would affect the RFID functionality. Instead, the developers at LogiData created extreme refrigeration conditions in a non-metallic environment with great success: the RFID label remains refrigerated and achieves good read results at -80 °C according to our tests.

It’s hardly visible, has a size of just a few micrometers, but is of crucial importance: the connection between the antenna and the chip in an RFID inlay. A glitch in that connection has a significant impact on the entire RFID system. To offer customers consistently high quality of high-tech labels with RFID functions, the Schreiner LogiData competence center has now established another voluntary inbound goods inspection.  

Quality differences can occur in any production operation. “That’s why we agree specifications with our inlay suppliers that must be complied with and checked,” explains the responsible project engineer in the Schreiner LogiData competence center. “However, they’re not visually detectable in the case of our RFID antennas with microchips. Because we depend on perfect material for our products we’ve extended our previously existing close quality inspection by an additional inbound goods inspection.”

The die shear test is focused on the reliable transmission of electrical signals between the chip and antenna that can be proven by means of special tensile forces. The test, which only takes a few minutes, involves pull-off forces of roughly 20 to 60 Newtons, depending on the area of the chip. Possible reasons for faulty connections could be a wrong or excessive adhesive, wrong contact pressure, or wrong processing temperature.

Another potential cause is a delay in maintenance of the manufacturer’s production machines. Especially with throughput rates of up to 45,000 inlays per hour which might lead to minimal variations with maximum effects. That’s why for Schreiner LogiData’s developers, it was particularly important to understand why an inlay does not work perfectly, and the die shear test is a logical consequence. “With this additional quality inspection, we practically intervene in what’s happening before any problems occur later, ensuring that our RFID labels deliver perfect performance in the downstream processes.” The system was quickly and easily integrated in Schreiner Group’s internal inbound goods inspection—so that the antenna and chip form a perfect unit supporting the RFID megatrend.

The Schreiner LogiData competence center stands for innovative, customized RFID developments. Now the experts have designed something for themselves—of which customers of course are ultimately going to benefit. The team has had a small specialized helper since this year: 3DM, a fully automated 3D measuring robot assists the developers in measuring the radiation pattern of RFID inlays.

There’s a little bit of jerking at the beginning but then the measuring robot’s arm starts moving smoothly and, following a defined route, keeps sweeping across the RFID chip placed on a rotary plate. All that is happening in a nearly silent and highly precise way. “The robot’s arm doesn’t get tired while making measurements,” project leader Dirk Probian, Senior Development Manager at Schreiner LogiData,” comments on the process with a smile. And that exactly was the objective of developing 3DM—obtaining reproducible, valid measurement results.

The basic idea,” says team leader Hartmut Wiederrecht, “was for us to obtain an auto­mated 360-degree view of RFID performance because radiation varies, depending on the direction of the measurement.” “Using the measuring robot, we always have the same angle, always the same gap, and as a result, can find out at which point and in which direction the inlay delivers the highest per­formance,” adds Dirk Probian. That’s a key quality characteristic because it’s the only way for the customer to know where the RFID label must be placed for optimal reading.

3DM owes its existence to the creativity of Schreiner’s experts: “The desire for reliable measurements was coupled with a sound play instinct. The available, fully automated industrial systems are simply not designed for our scale and that’s why the idea was born to develop one in-house—and the robotic ver­sion was very charming,” says Wiederrecht.

The charming 3DM with a mere size of 30 cm was created in collaboration with a college student. It took about half a year before the system was finished. The special characteris­tic of the automated helper is that the reader functionality was already integrated into the control software. “Of course, there were stages in the development, such as the selec­tion of the stepping motor, that cost time,” explains Dirk Probian. “After all, the project was about robotics, inverse kinematics, com­plex matrix calculations—but the outcome is respectable and now state-of-the-art.”

It’s the first fully automated measuring robot to have been developed by Schreiner Logi­Data. The readings it generates in the RFID laboratory are clearly more precise than those that any employee could deliver with man­ual measurements. Currently, the reliability of 3DM is still being officially validated.

Customized products and solutions are a specialty of Schreiner Group and the field in which the experts at the Schreiner LogiData competence center are active. So, what are the requisite steps to turn an initial idea into a real product? Here’s a brief look at the work of the RFID developers.

The small coffee corner on the second floor is something like an unofficial, creative communications center. Because even though the final fine-tuning takes most of the time in the development process chain, Hartmut Wiederrecht, the leader of the RFID development team at Schreiner LogiData, puts the situation in a nutshell: “Without the spark of an idea you’ve got nothing.”

A total of three product developers and three process developers are currently engaged in the complex process of developing RFID inlays. An inlay not only consists of the RFID chip but also of the antenna. Because Schreiner Group has increasingly evolved into a supplier of customized solutions the work includes not only a high level of technical knowledge and experience but also plenty of creativity. And that’s exactly what makes our job so attractive, says Wiederrecht: developing something that doesn’t exist on the market yet exactly according to the customer’s wishes and requirements.

Once the developer’s initial idea has been realized considering factors like size, shape, and operating conditions, the finalization stage begins. It involves the specific design of the antenna and selection of the chip. The required frequency, desired read range, and the necessary storage capacity are fed into the process at that time. For the developer, that means it’s time to boot the PC!

With the help of simulation software, the expert can simulate the relevant ambient conditions and other details. The simulation incorporates the key aspects of the customer’s real-world environment that will affect the performance of the RFID label. “That’s the major advantage of a simulation calculation,” says Wiederrecht. “You can come very close to the final design without the complex need of having to make a real-world sample. In addition, you can find out very fast what impact the change of a parameter has on the inlay and in that way optimize it step by step.

The best three concepts are turned into prototypes. To enable quick response in development projects, Schreiner Group has an in-house system for making RFID inlays. The next stage is the measuring chamber. These tests are also performed on the customer’s real objects in order to consider the future ambient conditions and ensure that the RFID inlay optimally conforms to the respective requirements. In that stage, several variants are made again from which the best one can be selected. Finally, the inlay with optimal characteristics can go into mass production.

By the way, the information gained from the test runs is fed back into the simulation software. That helps create increasingly better databases for future development projects which in turn leads to continuous improvements of the simulation results—thus increasingly approaching the real-world inlay.

Whether round, angular, with first-opening indication, for metallic substrates, or for curved objects: The development of RFID inlays is a challenging process for which careful planning, design and production processes are of crucial importance to ensure that the final product will meet the customer’s needs. For the team from Schreiner LogiData that means sustaining its know-how on a high level, continuing to advance RFID technology, and opening up new fields of application: with plenty of competence, creativity—and certainly an occasional cup of coffee.

RFID technology has become firmly established in logistics, but what if the conditions for the utilization of conventional RFID labels are less than perfect? In that case, the process and product developers from Schreiner LogiData are challenged to come up with a solution. Their most recent development is a specialty antenna for applications in metallic surroundings—as well as the first RFID label from Schreiner Group with UL and CSA certification!

The objective was to find a customer solution for industrial applications in metallic surroundings. The available space was very small and the environment anything but ideal. “The label was supposed to be utilized in a harsh industrial environment with a lot of metal in which our existing onMetal RFID solutions were not usable,” explains Alexander Bohlender, product and process developer at the Schreiner LogiData competence center.

The beginning of the development involved many simulations but the initial idea for a novel kind of Near Metal RFID-Label emerged quickly. The space available to the developers for accommodating the entire technology was only 4 mm! The exacting requirements regarding readability were another aspect. “No matter in which position the rotating component is,” says Bohlender, “readability must be ensured for the customer at all times, which in plain terms means readability of 360°, in other words from any angle.”

The new RFID label is attached on the side of the rotating component and thanks to its design does not need the typically used spacers and ferrite materials. The special attraction of this solution is its readability in operation by means of a smartphone and without removing the component, which avoids downtime. The label is programmed and printed directly at the customer’s site.

The certifications awarded to the label also show the ruggedness and high quality of this solution: it is the first RFID label from Schreiner Group to have been certified according to UL and CSA. Underwriters Laboratories (UL) are the world’s leading provider of testing and certification services.

UL-certified products are independently tested for compliance with exacting safety and quality requirements and enable delivery of the products to the United States. The CSA certificate is the Canadian counterpart enabling exports to that country. The 360-degree readable RFID label is small, compact, and robust, and, above all, shows how the experts at Schreiner LogiData make customer wishes a reality—from any angle, if applicable.

Be it tickets for ski lifts, admission control at the office, or contactless payment in supermarkets—RFID has been part of our everyday lives for many years. A look at RFID antennas shows that they have one thing in common: they are flat. However, a special challenge arises when a curved RFID antenna is supposed to be read in axial direction, i.e., along its axis. The Schreiner LogiData competence center has now developed a solution for that purpose.

Schreiner LogiData recently presented an antenna for narrow curvature radii. Such an antenna has a beam direction crosswise to the axis, which is typically desirable. It corresponds to the upright position of the object vis-à-vis the RFID reader. The situation is different when reading should occur in axial direction. That requires an antenna with maximum sensitivity in the axial direction. The experts at Schreiner LogiData have now managed to develop a heavily curved RFID antenna with axial characteristics for integration into labels for small round components. The labels are also suitable for bulk reading.

RFID technology (Radio Frequency Identification) enables contactless and automatic reading of data transmitted to a reader by means of electromagnetic waves. The labels, consisting of an antenna and a chip, are supplied with energy in that way. UHF (Ultra-High Frequency) labels are primarily used in logistics and supply chain applications because they enable long read ranges and bulk reading, i.e., near-simultaneous reading of larger numbers of labels.

The new RFID label for round components developed by the Schreiner LogiData competence center takes advantage of those characteristics as well. What makes this label special is the axial beam in combination with its application to round objects with very small radii. That required the experts from Schreiner LogiData to solve two different problems. On the one hand, the antenna needs to achieve long read range in axial direction despite its small size. On the other hand, antennas cannot normally be curved so heavily without severe functional impairments. The specialists mastered both challenges: by using an all-new approach to antennas, the labels can be read in the direction of the axis, i.e., upward and downward, while offering read ranges of up to 30 centimeters.

RFID labels have long become part of everyday life and the retail sector is also increasingly using these labels enabling contactless readability. When all the merchandise of a store is tagged in this way, customers don’t have to place any items on checkout conveyor belts and employees don’t have to scan them. While the error rate drops, checkout speed increases dramatically. Even so, DIY stores haven’t been using RFID on single screwdrivers, stationery shops haven’t applied it to pencils sold separately, and kitchenware departments haven’t been marking individual glass straws with RFID so far. One of the reasons is that up until now no RFID labels with long read range that can be applied to small round objects have been available. Now, Schreiner LogiData has managed to create such labels.

For the experts from Schreiner LogiData that have been pioneering the development of RFID labels for many years, this was anything but an everyday challenge. “We had to resolve several issues,” says Hartmut Wiederrecht, RFID development team leader at the Schreiner LogiData competence center. “The greatest challenge, no doubt, was the small space.” On small and very small round objects, the available width for the label is extremely limited. That’s a problem not only because the label has to accommodate the entire antenna with a chip but particularly because small antennas can only achieve short read ranges.

Especially the very small curvature radii made exacting demands on the development team. On the one hand, the label design and adhesive had to be tailored precisely to suit these conditions. The label has to permanently adhere to the heavily curved surface, which poses a much greater challenge than flat surfaces. On the other hand, the curvature radii required specialized antenna design expertise because the antennas have to achieve adequate read ranges for bulk reading. The RFID experts managed to resolve all of these challenges.

For Hartmut Wiederrecht, that’s a great success story: “Sometimes the small size is the biggest hurdle. We’re very proud of having achieved this RFID label development for very small round objects.” The label delivers yet another benefit: the processing specialists from Schreiner Services have developed an automated applicator for reliable processing of this miniature label. Even though it may not be adorning screwdrivers, pencils, or glass straws anytime soon, the small label is a big promise for the pharmaceutical industry, the automotive sector, and general industrials.