Optical Identification, Machine Vision, and Item Tracking Systems

This course provides technicians with the specialized skills needed to maintain, configure, and troubleshoot optical identification, machine vision, and material tracking systems in automated packaging environments. Students explore 1D and 2D barcode scanning technologies, optical character recognition, imaging optics, lighting geometry, and photo-sensor arrays. Emphasis is placed on real-time tracking methodologies, including shift registers, encoder verification, and automated divert confirmation tracking. Technicians learn to diagnose common read errors, align scan tunnels, program vision inspection tools for presence and orientation verification, and interface vision controllers with industrial networks. Through rigorous practical exercises and troubleshooting scenarios, students develop systematic fault-isolation techniques for resolving missing read triggers, image degradation, communication latency, and item tracking losses. By mastering these diagnostic procedures, graduates are prepared to optimize optical read rates and maintain reliable package tracking in high-throughput distribution and manufacturing facilities.

InstructorJacob Calhoun

Prerequisites

PKG 101

Course outline

Lectures, virtual labs, and graded assignments — completed in your browser.

01Lesson 1: Principles of Optical Barcode Scanning and Symbologieslecture

02Lesson 2: Fixed-Mount Scanners and Multi-Sided Scan Tunnelslecture

03Lesson 3: Photoelectric Sensors, Tachometers, and Trigger Synchronizationlecture

04Hands-on Lab: Scanner Alignment, Focal Calibration, and Trigger Tuninglab

05Lesson 5: Industrial Machine Vision Fundamentals: Optics, Lenses, and Lighting Geometrylecture

06Lesson 6: Vision Tool Programming: Part Presence, Orientation, and Optical Character Recognitionlecture

07Lesson 7: Real-Time Item Tracking: Incremental Encoders and Shift Registerslecture

08Hands-on Lab: Machine Vision Configuration, Lighting Adjustment, and Inspection Logiclab

09Lesson 9: Industrial Network Interfacing, I/O Mapping, and Controller Handshakinglecture

10Lesson 10: Sortation Tracking Logic, Divert Verification, and Windowinglecture

11Hands-on Lab: Encoder-Based Tracking Integration and Divert Fault Troubleshootinglab

12Lesson 12: Diagnosing No-Reads, Tracking Loss, Package Jams, and Optical Contaminationlecture

13Lesson 13: System Performance Metrics, Read-Rate Diagnostics, and Preventive Maintenancelecture

14Capstone Service Project: Full-Line Identification, Vision Inspection, and Tracking Validationassignment

Syllabus

["Week 1: Lesson 1: Principles of Optical Barcode Scanning and Symbologies", "Week 2: Lesson 2: Fixed-Mount Scanners and Multi-Sided Scan Tunnels", "Week 3: Lesson 3: Photoelectric Sensors, Tachometers, and Trigger Synchronization", "Week 4: Hands-on Lab: Scanner Alignment, Focal Calibration, and Trigger Tuning", "Week 5: Lesson 5: Industrial Machine Vision Fundamentals: Optics, Lenses, and Lighting Geometry", "Week 6: Lesson 6: Vision Tool Programming: Part Presence, Orientation, and Optical Character Recognition", "Week 7: Lesson 7: Real-Time Item Tracking: Incremental Encoders and Shift Registers", "Week 8: Hands-on Lab: Machine Vision Configuration, Lighting Adjustment, and Inspection Logic", "Week 9: Lesson 9: Industrial Network Interfacing, I/O Mapping, and Controller Handshaking", "Week 10: Lesson 10: Sortation Tracking Logic, Divert Verification, and Windowing", "Week 11: Hands-on Lab: Encoder-Based Tracking Integration and Divert Fault Troubleshooting", "Week 12: Lesson 12: Diagnosing No-Reads, Tracking Loss, Package Jams, and Optical Contamination", "Week 13: Lesson 13: System Performance Metrics, Read-Rate Diagnostics, and Preventive Maintenance", "Week 14: Capstone Service Project: Full-Line Identification, Vision Inspection, and Tracking Validation"]