System for inspection and separation of defective RFID tags in batch conversion of RFID tag to RFID label

A system comprising a RFID detection and separation device to detect and separate a defective RFID tag for a RFID Conversion system, the system having:

• a RFID inspection unit;
• a RFID separator;
• and
• a RFID positioning unit;
• wherein said RFID Positioning unit positions the RFID tag accurately with respect to the REID inspection unit and RFID separator in the detection and separation of a RFID tag for embedding onto a liner to produce a RFID label and in the detection and non-separation of a defective RFID tag from an RFID inlay reel if a defective RFID tag is found.

A method to detect and separate defective RFID tags comprising the steps of:

• providing a RFID detection and separation device for a RFID Conversion system, said RFID Conversion system having a microcontroller, a liner unwinding station, a RFID reel unwinding station, a RFID feeding station, a liner feeding station, an RFID tensioning unit having a pair of inlay reel brakes, an RFID separator, and a RFID positioning unit, said microcontroller controlling the movement of an inlay reel of RFID tags from the RFID reel unwinding station into the RFID feeding station, said microcontroller also controlling the movement of a reel of liner mounted on said Liner Unwinding station, through said liner feeding station, for the separation of the RFID tags from said inlay reel for embedding onto the liner to produce RFID labels,
• Inspecting a RFID tag as it goes under said RFID Positioning Unit;
• sending an electronic signal from a RFID reader to read the RFID tag;
• identifying a defective RFID tag and sending a signal to said microcontroller, which continues to move said RFID inlay reel containing said defective RFID tag;
• until it reaches said RFID separator,
• sending a signal to said pair of inlay reel brakes of said RFID Tensioning unit to stop movement of said RFID inlay reel, when the defective RFID tag goes over said RFID separator 9,
• retracting said RFID separator so it is no longer in an extended state,
• allowing said RFID inlay reel with the defective RFID tag 7 on it to go over the retracted RFID separator, said RFID inlay reel forming a free loop, so that the defective RFID tag would not be dispensed onto said liner, and instead returns to a winding station;
• sending a signal to said pair of inlay reel brakes of said RFID Tensioning unit to release said RFID inlay reel,
• extending said RFID separator so that it moves back to its normal extended position,
• so that the next RFID tag is moved forward to the inspection unit to be inspected,
• and thereby continuing the RFID Batch conversion process until said microcontroller detects either the end of said RFID inlay reel or said liner is reached and after which the RFID Batch Conversion process is stopped.