The RFID data collection process uses tags, antennas, RFID readers, and software for tracking item-level events without scanning items with barcodes on an individual basis. This makes stocktaking faster, tracks movements, and generates meaningful data that’s sent to ERP, WMS, or MES.
An RFID reader can read the same tag multiple times. Meaningful RFID data gathering involves analyzing this raw data into useful events.
What Is RFID Data Collection?
RFID data collection is the process of collecting data from RFID tags and converting it into meaningful business data.
The reader collects the ID of the tag and other relevant information. This information is correlated with the correct item or activity using software.
A pallet moving through a receiving door can trigger multiple reads. The RFID system eliminates such duplicate reads and creates one receiving record.
How Does RFID Data Collection Work?
RFID data passes through several processes:
- Generate the read zone: The antenna will define the zone where detection is needed.
- Detects the tag: A passive tag uses the energy of the reader for its identification, while an active tag uses battery power.
- Read logging: The reader will log the tag ID, time, antenna port, and signal details.
- Data filtering: Middleware filters duplicate or unnecessary data.
- Generate the event:Rules from the zone and workflow will generate the event from the filtered read, such as Received, Picked, Loaded, or Returned, among others.
- Sending the event: The complete event is sent to the ERP, WMS, MES, database, or any other business application.
What Data Can RFID Systems Collect?
| Type of Data | Purpose | Example |
| Tag data | Identifier of tag or item | EPC, TID |
| Read data | Event of detection | Time, reader, antenna |
| Signal data | RF signal behavior | RSSI, phase |
| Location data | Link between read and zone | Door 10, Station 1 |
| Sensor data | Condition | Temperature, humidity |
| Business event | Event description | Pallet received |
The EPC is the identifier of the tagged item, and the TID is the identifier of the RFID chip. Usually, only the tag identifier is kept in the RFID tag, while product names, orders, batches, owners, and locations are stored in the back-end system.
RSSI and phase are RF signal behaviors, but they don’t represent precise distance. These values are influenced by metal, water, reflections, antenna position, and tag orientation.
Components of an RFID Data Collection System
There are five components involved in collecting and transferring RFID data:
- RFID tags:Store the identification number assigned to the item, pallet, tool, or asset.
- Antennas:Determine the region where the tags are read.
- Readers:Read the tag’s identification, timestamp, antenna data, and all other data.
- Middleware:Helps filter out duplicates and undesired data, as well as apply zoning and event rules.
- Business software:Receives the final data record in the ERP, WMS, MES, database, or a customized solution.
The design of the tag is also very important for the efficiency of the data collection process. Regular RFID labels can be negatively affected by metal surfaces; therefore, metal items require RFID on-metal labels. The same applies to products rich in moisture.
RFID Data Collection Methods
The collection process must be appropriate to the material flow:
- Handheld readers:Stock counting, item locating, asset identification, and order validation.
- Fixed readers:Automatic reading at receiving dock doors, loading docks, dispatch points, and production areas.
- Conveyor RFID:Reading of cartons during conveyance, sorting, or rejection.
- Smart shelves and cabinets:Record keeping for the removal and return of tools, stock, or reusable assets.
- Mobile and automated readers:Collection of data using fork trucks, AGVs, robotics, or vehicle-mounted systems.
Each system results in a unique read zone, and hence the filter criteria and placement of readers should match the material movement pattern.
How Is RFID Data Integrated with ERP, WMS and MES?
Integrating RFID data involves taking the business transactions that have been identified and bringing them over to the systems responsible for inventory management, order management, asset management, or production.
In receiving, middleware will map the EPC tag on the pallet to its order and create the receiving transaction. This receiving transaction will then be received by the WMS and update the inventory database.
Data transport may occur using REST APIs, MQTT, WebSocket, TCP/IP, databases, message queuing, or file transfer.
What Affects RFID Data Collection Accuracy?
There are two aspects of RFID accuracy: detection of the required tag and generation of the proper business event.
An RFID reader located at the entrance to the dock will detect the tag of a pallet placed next to the receiving dock area. While the read itself is valid, recording the receipt of that pallet generates an incorrect business event.
The following metrics should be monitored during a pilot: first-pass reads, misses, incorrect reads, event accuracy, data latency, and manual overrides.
RFID Data Collection Applications
Warehouse and Inventory Management
Receiving and dispatch doors collect ID information about cartons/pallets, passage time, and reader location. The WMS checks whether the event matches the scheduled shipment and signals shortages/excess items.
Manufacturing and WIP Tracking
Reader stations record information about the item ID, production stage, and time. The MES utilizes the collected information to track work-in-progress while the materials/assemblies pass through manufacturing.
Asset and Tool Tracking
Reader stations on tool cabinets and doorways record issue, return, and movement events for tools, equipment, containers, etc.
Retail Inventory
Item-level reads allow users to know which tagged SKUs are available during inventory counts, replenishment, return management, and product search processes. Frequent inventories become more efficient since barcodes no longer need to be scanned manually.
Healthcare
The movement of equipment, supplies, textiles, and medications is recorded by readers located in rooms and storage areas. The identification numbers of people need to be accessed in a secure manner.
Cold Chain and Sensor Monitoring
Sensor-enabled RFID combines the item identification number and the value of one of the supported measurements (temperature, humidity, shock, etc.). The application can warn when the measurement goes outside the specified storage/transportation range.
RFID vs Barcode Data Collection
Differences between RFID data collection and barcode data collection applies to how the data relating to the item gets into the computer system.
| Characteristic | RFID | Barcode |
| Line of sight | Not required | Required |
| Reading process | Multiple codes per zone | One per scan |
| Automation | Capture through gate or conveyor | Capture through scanner |
| Initial investment cost | Higher | Lower |
| Effect of metal and liquids | Weaken RF signals | Doesn’t affect RF signals |
| Application
| High-volume or automatic tracking | Low-cost manual scanning
|
Barcodes are suitable for low-volume situations where the process of scanning individual items isn’t heavy. RFID provides a useful advantage in situations where scanning in bulk or automated movement recording eliminates the need for manual work.
How to Choose an RFID Data Collection System
Consider this simple step-by-step checklist:
- Identify data:Specify the ID, timestamp, location, movement, or sensor data you want to collect.
- Indicate read position:Determine the location for the collection, a door, conveyor, work desk, shelf, or mobile process.
- Choose the right tag:Determine the frequency and form factor for your material and conditions.
- Design the read zone:Adjust your antenna and reader to your read distance, number of tags, and movement speed.
- Check data handling capabilities:Make sure you can filter duplicates, apply zone logic, create events, and restore data after disconnection.
- Make sure the system can be integrated:Connect the system with your ERP, WMS, MES, and database.
- Confirm compliance:Stick to the approved frequencies and reader power levels in your deployment country.
Frequently Asked Questions
Where is RFID data stored?
A tag holds an identifier such as an EPC. Other product, order, asset, and location information resides in the ERP, WMS, MES, database, or cloud system.
Can RFID collect data in real time?
Yes. A tag is recorded by the reader as it enters the read zone. Time lag from network delay, middleware processing, and response from the business system defines the time at which the update occurs.
How far can an RFID reader collect data?
Passive UHF can reach a few meters with a tuned system. Shorter ranges apply to HF and NFC RFID tags . Range depends on the tag itself, the material of the item being tagged, antenna configuration, reader power, environment, and local radio regulations.
How is RFID data sent to ERP or WMS?
Data from the reader is transformed into a business event by middleware, and the event is delivered by an API, database link, file transfer, or another business system integration interface.
Is RFID data secure?
Data security involves the tag, reader, network, API, and business application. More secure implementations have encrypted data connections, API authentication, restricted reader access, minimal tag data, and better tag security. An RFID access password isn’t strong encryption.
Conclusion
Proper RFID data collection is based on steady detection that results in accurate recording available for use by ERP, WMS, or MES. The tag, read area, reader, filters, and software integration are the factors influencing the outcome.
When launching a new project, please contact JLTRFID with the following information about your products: material of the items, distance for reading tags, number of tags, environment, and interface of the system you are using.
