MAGNETORESISTIVE SCANNING SYSTEM
CROSS REFERENCES TO RELATED APPLICATIONS
This application claims priority of U.S. provisional patent application serial No.
0/038,547 filed on February 28, 1997.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to an array and system for scanning and analyzing magnetic
fields. More particularly, this invention relates to an array and system that is capable of
scanning magnetic fields in two-dimensional areas, generating two-dimensional data,
generating two dimensional images of the magnetic fields, and analyzing the data.
2. Description of Related Art
Magnetoresistive sensors are well known in the art for measuring or detecting
magnetic fields. These sensors utilize materials in which internal electrical resistance
changes in response to changes in applied magnetic fields. The output signals produced by
magnetoresistive sensors may be proportional to the intensity of the applied magnetic fields.
Magnetoresistive sensors have been adapted for use in a variety of applications. For
example, U.S. patent number 5,378,85,2 to Jones Jr. et al. discloses a device that is intended
for use with currency validation equipment. U.S. currency and other currencies utilize
magnetic ink to produce a distinctive magnetic signature. Figures 1 A and IB illustrate the
operation of a prior art one-dimensional magnetoresistive sensor, such as the sensor disclosed
in Jones Jr. et al., in currency validation. As the sensor moves across a bill 20 on a line 24, it
produces an output signal that is proportional to magnetic fields on the bill. The output signal
may be plotted to obtain a magnetic curve 22 in which spikes a-k correspond to magnetic ink
lines a-k on bill 20. Curve 22 may then be compared to a standard curve to determine the
validity of bill 20.
Prior art magnetoresistive devices, however, have failed to provide sensors and
systems that are capable of efficiently scanning two-dimensional areas and producing high
resolution two-dimensional data of magnetic fields. Although a one-dimensional line of data
across an object renders useful information, a much greater amount of information can be
obtained from two-dimensional data. In the field of currency validation, for example, a two-
dimensional "magnetic image" can be generated for verifying the authenticity of a bill.
Figure 2 A is an optical image of a zero on a 1997 U.S. $100 bill taken with a charge coupled
device camera with a magnification system. Figure 2B is a two-dimensional magnetic image
of the zero in Figure 2 A that may be produced by the present invention. Figure 2C is a two-
dimensional magnetic image of a portion of the portrait of a U.S. $100 bill. As can be seen
from Figures 2B and 2C, two-dimensional magnetic images are capable of generating optical
quality images. Although it is difficult for counterfeiters to reproduce a one-dimensional
magnetic curve of a bill (as seen in Figure 1 A), it is much more difficult to reproduce intricate
two-dimensional magnetic patterns. One-dimensional scanning systems are also more
sensitive to variations in printing, migration of magnetic material over time, and the
positioning of bills in the scanning system.
Two-dimensional magnetoresistive scanning systems may also be utilized in other
applications. For example, many computer printers utilize or can be adapted to utilize
magnetic toner. When the toner is deposited on a printed page, the letters and figures on the
page are capable of producing a magnetic image. Two-dimensional magnetoresistive
scanning systems may be used to efficiently scan the letters and figures on the page to
generate accurate two-dimensional data. Well known character and pattern recognition
techniques may then be used to analyze and manipulate the data.
A magnetoresistive scanning system can also be used to store and read data. Data can
be stored on an object by depositing magnetic material on the object in a predetermined
pattern and in predetermined densities. A scanning system can then read the data from the
object by detecting the location and intensities of the magnetic fields of the magnetic
material. Data stored in this way is more secure than other magnetic storage devices. For
example, disk drives and tape cassettes are vulnerable to strong magnetic fields that can erase
data stored on these devices. Since magnetoresistive scanning systems only rely upon the
location and densities of magnetic material, not polarity of magnetic fields, the data is not
vulnerable to strong magnetic fields. Thus, inexpensive media, such as paper or plastic, may
be used as permanent read only memory.
In many applications magnetoresistive scanners offer significant advantages.
Magnetoresistive scanners tend to be highly robust and durable. Unlike optical scanners,
magnetoresistive scanners are not subject to contamination from dust, oils, and other
substances. Magnetoresistive scanners also do not sense extraneous marks or optical
impurities that may be present on an object. Thus, magnetoresistive scanners can produce
more accurate data under many circumstances.
However, prior art magnetoresistive sensors cannot be efficiently used for two-
dimensional applications. For example, the device disclosed in Jones, Jr. et al. utilizes a four
sensor design that is intended to enhance the output signals of the device. However, the
sensors are positioned in line with the direction of motion of the sensors relative to a bill;
thus, they are not capable of scanning a two dimensional area during a single movement
relative to a bill.
U.S. patent number 4,98,850 to Masuda et al. discloses a device that is intended for
use with magnetic media readers. The device utilizes a magnetoresistive element array with
discrete and widely separated magnetoresistive elements. Unlike Jones, Jr. et al., the
elements are positioned in a parallel arrangement with respect to the direction of motion of
the magnetic media relative to the array. However, this device is intended to read separate,
discrete rows or lines of data from a magnetic card. The array is not intended to scan an area
and generate two-dimensional data capable of representing the magnetic fields in that area.
The distance between the sensors is at least twice the width of a sensor; therefore, a
continuous area could not be scanned during a single pass over a two-dimensional area.
Other devices have been developed for producing two-dimensional magnetic data.
The devices disclosed in U.S. patent numbers 3,978,450 to Sanner et al. and 4,058,706 to Kao
et al., for example, disclose read heads with a plurality of sensor elements. The elements are
arranged in two or more parallel arrays that are perpendicular to the direction of movement
over an object. The references are silent as to the type of sensor elements used. However, the
most likely reason why the devices use multiple parallel arrays of sensors instead of a simpler
single array is because they utilize inductive sensors. Unlike magnetoresistive sensors,
inductive sensors cannot be placed close to each other because of interference, cross coupling,
and other problems. To overcome these limitations both Sanner et al. and Kao et al. utilize
multiple parallel arrays of inductive sensors. The sensors in each array are widely spaced and
it is necessary to use a complex circuit to combine the signals of the arrays to obtain two-
dimensional data during a single sweep. Neither Sanner et al. nor Kao et al. suggests the use
of magnetoresistive sensors.
SUMMARY OF INVENTION
1. Objects of the Invention
It is an object of the present invention to provide a magnetoresistive sensor array
capable of scanning magnetic fields on an object.
It is another object of the present invention to provide a magnetoresistive sensor array
with differential pairs of magnetoresistive elements for reducing noise caused by ambient
magnetic fields.
It is a further object of the present invention to provide a magnetoresistive sensor
array in which the sensors are formed using integrated circuit manufacturing techniques to
provide a high-density array.
It is a further object of the present invention to provide a magnetoresistive scanning
system in which a sensor array provides data to a processor for performing various functions.
It is a further object of the present invention to provide a magnetoresistive scanning
system that is capable of authenticating currencies based on the magnetic material in the
currencies.
It is a further object of the present invention to provide a magnetoresistive scanning
system that is capable of generating two-dimensional images of magnetic fields on an object.
It is another object of the present invention to provide a nonvolatile read only memory
in which the two dimensional location of magnetic fields on an object is used to convey
information.
It is a further object of the present invention to provide a magnetoresistive scanning
system in which the scanning system may read data and programs by scanning magnetic
fields on an object.
These and other objects of the present invention may be realized by reference to the
remaining portions of the specification, claims, and abstract.
2. Brief Description of the Invention
The present invention comprises a magnetoresistive sensor array. The sensor array
comprises at least one substrate and a plurality of magnetoresistive sensors. Both the
substrate and sensors are formed by methods that are well known in the art. In the preferred
embodiment, the sensors are very small providing a high linear density with small distances
between the sensors. This provides high resolution which is necessary in many applications,
such as currency validation.
The sensor array may be designed in many different configurations. One
configuration provides pairs of magnetoresistive sensors in a differential configuration. The
differential configuration provides for the cancellation of ambient magnetic fields. The
present invention may also include a flux guide for directing magnetic fields to a sensor. The
sensor array may also comprise amplifying and multiplexing circuitry for conditioning the
output signals of each sensor. The amplifying and multiplexing circuit may receive impute
signals from a processor or other associated device.
The present invention also comprises a magnetoresistive scanning system for scanning
data from an object. The scanning system comprises at least one magnetoresistive sensor
array, at least one magnet, and a processor. The magnet is provided for magnetizing
magnetic material on the object before it is scanned by the array. The processor is adapted to
control the scanning system and analyze data obtained from the object. Analysis of the data
may include many methods that are well known in the art, such as character and pattern
recognition. The processor may also communicate with other devices for performing various
functions related to the scanning system.
One embodiment of the present invention is to provide a currency validation system
for verifying the authenticity of a currency object. The currency object may be a bill,
banknote, certificate, license, title, checks, or any other document that is capable of holding
magnetic material. The currency object is introduced into the system of the present invention and the sensor array scans data from the object. The processor then analyzes the data,
comparing it to a template or set of acceptable parameters. The system is also capable of
generating a high resolution image of the magnetic fields of the object and presenting this
image to users of the system.
The above description sets forth, rather broadly, the more important features of the present invention so that the detailed description of the preferred embodiment which follows
may be better understood, and contributions of the present invention to the art may be better
appreciated. There are, of course, additional features of the invention that will be described
below and which will form the subject matter of claims. In this respect, before explaining at
least one preferred embodiment of the invention in detail, it is to be understood that the
invention is not limited in its application to the details of the construction and to the
arrangement of the components set forth in the following description or as illustrated in the
drawings. The invention is capable of other embodiments and of being practiced and carried
out in various ways. Also, it is to be understood that the phraseology and terminology
employed herein are for the purpose of description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1A is substantially a schematic representation of a magnetic material bearing
$100 bill with a scanning path of a prior art one-dimensional magnetoresistive sensor
indicated thereon.
Figure IB is substantially a magnetic curve of the bill shown in Figure 1 A of a type
that may be produced by a prior art sensor.
Figure 2A is a magnified optical image of a zero from a 1997 U.S. $100.00 bill.
Figure 2B is substantially a two-dimensional magnetic image of the zero shown in
Figure 2 A that may be produced by the present invention.
Figure 3 is substantially a top schematic view of one embodiment of the sensor array
of the present invention.
Figure 4A is substantially a front schematic view of another embodiment of the sensor
array of the present invention that utilizes differential sensors and a permanent magnet.
Figure 4B is substantially a cross sectional schematic view of the embodiment in
Figure 4 A taken along line I-I.
Figure 4C is substantially an isometric schematic view of a differential sensor
configuration of the embodiment shown in Figure 4A.
Figure 5 is substantially a cross sectional schematic view of an another sensor array of
the present invention that utilizes a flux guide.
Figure 6 is substantially a schematic view of a multiplexing circuit in use with a
sensor array of the present invention.
Figure 7 is substantially a side schematic view of a scanning system of the present
invention.
Figure 8 is substantially a block schematic diagram of a scanning system of the
present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As seen in Figure 3, the present invention comprises a magnetoresistive sensor array
generally indicated by reference number 30. Sensor array 30 comprises a plurality of
magnetoresistive sensors 32 attached to a substrate 34. Sensors 32 and substrate 34 are
shown in simple block form for purposes of illustration; many shapes and configurations may
be utilized. Sensor array 30 also comprises conductive input connectors 36 for supplying
electrical current to each sensor 32 and output connectors 38 for transmitting output signals to
processing circuits.
In the preferred embodiment, sensors 32 and substrate 34 are formed using
techniques that are well known in integrated circuit and sensor manufacturing technology.
The individual magnetoresistive sensors 32 may comprise several layers that are deposited
either by vacuum vapor depositions, epitaxy, metalorganic vapor deposition, or sputtering, to
name a few. These films may comprise the actual magnetoresistive film, which may be NiFe
or FeCo, an electrical, nonmagnetic insulating layer, and a magnetically soft alloy, flux guide
layer. A magnetically hard layer may be deposited (which is essential a permanent magnet)
to bias the magnetoresistive film. Bias may be needed to bring the output signal of the
magnetoresistive film into a linear range. Electrical connectors 36 and 38 may be made out
of copper or aluminum. The layers may be deposited on substrate 34, which may comprise
ceramic material, after masks have been consecutively placed on the substrate by
photolithography. Additional shielding layers may be deposited to limit the sensitivity of the
magnetoresistive film to a small region.
Many different sensor designs are possible with these manufacturing techniques. For
example, it is possible to produce sensors that utilize the Giant Magnetoresistive Effect and
the ColossafMagnetroresistive Effect.
Once sensors 32 are deposited on substrate 34, the substrate is cut by a stylus and
functional groups are assembled on a second substrate, which could be made of other
material. Once the array is attached to a supporting structure, wire bonds are made that
connect power to individual groups of sensors. The finished assembly can be tested for
proper function and faulty connections may be corrected if necessary. The assembly may
then be inserted into a plastic molded object and embedded with an epoxy. After the epoxy is
cured, the device may undergo a final functionality test.
These and other manufacturing techniques now make it practical to form high-density
magnetoresistive sensor arrays with very small sensors and small sensor separations. Similar
techniques have been used to produce complex optical sensors that may be placed on a single
microchip. Sensors 32 may be placed on substrate 34 in sufficient densities to achieve high
resolution desired in many applications. For example, in bill validation and character
recognition, the linear density of sensors 32 is preferably at least one sensor per millimeter.
Densities of this magnitude are not possible with prior art sensor arrays, such as the one
found in Masuda et al. In order to achieve high resolution it is also desirable to minimize the
distance between sensors. In bill validation and character recognition, the distance between
sensors is preferably less than ten microns. Small sensor separations such as this cannot be
used with prior art inductive sensors because of interference, cross coupling, and other
problems associated with these sensors.
Sensor array 30 may be any length required to meet the needs of a particular
application. In bill validation applications, sensor array 30 is substantially the width of a bill.
However, the cost or difficulty of manufacturing long sensor arrays may require the use of
multiple sensor arrays or substrates of shorter lengths. It is recognized that the sensor array
of the present invention may take many different configurations. For example, the array need
not be placed in line or on a single plane. Furthermore, the structure of the individual sensors
need not be the same throughout an array. Smaller sensors may be used in some portions of the array to achieve finer resolution and flux guides may be used in some or all sensors to
direct magnetic fields.
The resolution of array 30 is defined as the ability of the array to distinguish between closely spaced small areas of magnetic ink on an object in both the x and y directions. The resolution in the direction of scan depends on the width of the sensor 32 the width of the flux
guide used to direct the field to the sensing element, and the sampling rate. Decreasing the
width will increase the resolution in this direction. The resolution of the array, Δ y, in the
direction perpendicular to the scan depends on the length of sensor 32 as well as the distance between sensors. Decreasing length and separation enhances resolution.
Figure 4 A and 4B disclose an alternative sensor array configuration 50 in which pairs
of sensors are used in a differential configuration. Upper sensors 52 and lower sensors 54 are
attached to substrate 56 in a substantially parallel arrangement separated by the height of the substrate. A permanent magnet or electromagnet 60 may be provided in close relative
proximity to sensors 52 and 54 for biasing the sensors and for magnetizing the magnetic field bearing substances on object 58. The entire array may be encased in a protective cover 62.
The differential configuration allows for the reduction of noise caused by ambient
magnetic fields. Lower sensors 54 sense magnetic fields from object 58. However, in this
embodiment the additional distance from the object of upper sensors 52 substantially weakens
the magnetic fields from the object. As seen in Figure 4C, a differential circuit is used in the
differential configuration to produce an output signal for each sensor pair. A common input
voltage 64 is provided for upper elements 52, a common ground is provided for lower sensors
54, and an output connector 68 is provided for each pair of sensors. As seen in Figure 5, the present invention comprises a sensor array 70 that is adapted
to use a flux guide 72 for directing magnetic flux onto sensors 74 and 76. Magnetic flux guides are well known in the art and many different configurations may be used to achieve
the objects of the present invention. In the preferred embodiment, flux guide 72 and sensors 74 and 76 are integrally formed on substrate 78 using integrated circuit manufacturing
techniques. Sensors 74 and 76 are provided in a differential configuration to provide a
differential output signal.
Figure 6 discloses an amplifying and/or multiplexing circuit that may be used with the
sensor arrays of the present invention. Sensor array 90 comprises a plurality of sensors 92.
In the example disclosed in Figure 6, differential sensor pairs are used to produce differential
output signals; however, a non-differential configuration may also be used. Each sensor pair
has an output connection 94 for transmitting output signals to amplifying and multiplexing
circuit 96. The circuit 96 amplifies sensor output signals and multiplexes the signals for
transmission to a processor. Circuit 96 may also receive input signals, such as clock signals,
synchronizing signals, and bias signals, from other devices. Although sensor array 90 and
circuit 96 are shown as separate elements, it is possible to integrate the two elements into a
single integrated device. Furthermore, it is possible to integrate sensor array 90 with a processor or other device.
As seen in Figure 7, the present invention comprises a scanning system generally
indicated by reference number 118. Scanning system 118 comprises sensor arrays 110,
processor 112, transport device 114, and magnet 116. Sensor arrays 110 may be any of the
sensor arrays discussed previously that are adapted to meet the needs of the particular application. Although two arrays are shown, any number of arrays may be used depending on
the application. Transport device 114 is provided to produce relative motion between a
magnetic material bearing object 58 and sensor arrays 110. Magnet 116 is provided to magnetize magnetic material on object 58 so that the magnetic material produces detectable
magnetic fields. The shape and orientation of magnet 116 may be altered and still achieve the
objects of the invention. In addition, a greater number of magnets may be used. Sensor
arrays 110 is operatively connected to processor 112. Processor 112 may be adapted to perform a number of functions that are related to the function of system 118. For example,
processor 112 may analyze and store data transmitted from array 110. Tensioning devices 120
may also be provided for placing object 58 in a preferred position relative to sensors 110.
Scanning system 118 allows object 58 to be used as a read only memory device. In this embodiment magnetic material is deposited on object 58 in a predetermined two-
dimensional pattern with predetermined densities. The pattern and densities of the magnetic
material serves as a code that is capable of conveying information to processor 112. Because
it is the pattern of the magnetic material that conveys information and not the polarity of the
material, object 58 is capable of permanently storing data. As object 58 passes between
magnet 116, the polarity of the magnetic material is adjusted to a predetermined orientation. Sensor array 110 is then able to read the two-dimensional pattern of the material.
Scanning system 118 may also comprise any number of other sensors and devices.
For example, system 118 may comprise a photodiode array or charge couple device array
121, a photo transistor 122 with an opposing ultraviolet light source 123, and a photo diode
125 with an opposing infrared or visible light source 124. Any one of these sensors or a
combination of these sensors with other sensors may be used by system 118 to read additional
data from object 58. For example, in currency validation photodiodes and a light source may
be used to analyze certain patterns, materials, and structures on the currency.
One of the advantages of the present invention is that data or programs may be conveniently entered into processor 112. Object 58 may be a preprogrammed read only
memory device that is inserted into system 118. As sensor arrays 110 read the data, processor
112 recognizes the data as data or programs to be added to the processor. Processor 112 then
performs the necessary functions to either store the data or reprogram itself. In this way, an
untrained operator may easily and efficiently reprogram or add data to system 118. This may be especially advantageous to currency validators that must be reprogrammed when new currencies are issued.
Another advantage of the present invention is that changes in currency do not require
modifications of scanning system 118. Governments periodically change the properties of
their currencies to hinder counterfeiting. If a system relies upon one-dimensional sensors, it may be necessary to reposition the sensors to obtain appropriate data. Since the present
invention is capable of scanning the entire surface of a currency object, there is no need to
modify the scanning array of the system to accept modified currencies. It is only necessary to
update the standard data of the system. This may be done using object 58 as discussed above.
As seen in Figure 8, system 118 may comprise a processor 130 that is operatively connected to transport mechanism 114, sensor array 110, other sensor 148, memory 140, and
analog to digital converter (ADC) or comparator 138. Processor 130 is capable of controlling the scanning process as well as performing other tasks associated with the scanning
application. Processor 130 controls transport mechanism 114 so that object 58 and sensor
array 110 move relative to each other at a predetermined rate. Transport mechanism 114 may
also be made to reject object 58. Processor 130 may communicate with sensor array 110,
sensor 148, and ADC 138 to provide synchronization signals and other data.
As the sensor array scans data from object 134, it multiplexes the data and transmits
the data to ADC 138. ADC 138 may convert the multiplexed data to serial eight bit data and
transmits the data to memory device memory device 140, processor 130, or both. Process
130 and memory device 140 may be any of a large number of devices that are well known in
the art. Alternate sensor 148 may be provided for scanning object 58 for a type of data not
provided by sensor array 110. After scanning the data, the data may be transmitted to ADC 138 for conversion to serial eight bit data.
Analysis software and data 144 may be provided to processor 130 by erasable
programmable read only memory (EPROM) 142. This allows analysis software 144 to be changed by switching EPROM 142 with another programmed EPROM. Many other methods
and devices may also be used for introducing new software and data into system 118. For
example, a communication network may be provided for loading software remotely or object
58 may be used as a read only memory as discussed above.
Analysis software may comprise a large number of methods that have been devised in
the art for recognizing patterns and comparing features. For example, analysis software may
comprise a very fast two-dimensional template-patching algorithm. This algorithm takes into
account printing/plate tolerances and known irregularities. Templates may be based on known
binary (black and white) patterns, such as the one shown in Figure 2B. Additionally, full
eight bit gray level image information (not shown) may be used during the analysis
procedure. System 118 may be used to analyze the entire surface of object 58 or, because it is
capable of high resolution, small individual features of the object may be analyzed. Once the
analysis is complete, system 118 may perform other appropriate tasks and functions.
Processor 146 may also be adapted to communicate with device 146. Device 146 may
be any device that is relevant to the operation of system 118. For example, device 146 may
be a display device, such as a monitor or printer, for displaying magnetic images. In the field
of currency validation, it may be very useful to display a magnetic image of object 58. This may be particularly useful to closely examine known counterfeit currency.
It is recognized that some or all of the components and elements shown in Figure 8 may be integrated into a single embedded device. This may facilitate efficient manufacturing
and maintenance.
SUMMARY
It may now be seen from the above specification that the present invention comprises
a novel magnetoresistive sensor array and scanning system. The present invention comprises:
1. A magnetoresistive sensor array that is capable of efficiently scanning
magnetic fields on at least a two-dimensional area of an object during a single
movement by the object; 2. A system for collecting magnetic field data on a two-dimensional area of an
object;
3. A system for analyzing magnetic field data on a two-dimensional area of an
object;
4. A system that may be reprogrammed by scanning the pattern and intensities of magnetic fields on an object; and
5. A system for recognizing and validating currency objects.
While the above description contains numerous specificities, these should not be
construed as limitations on the scope of the invention but rather as exemplifications of some of the presently preferred embodiments thereof. For example:
1. The number and type of magnetoresistive sensors comprising an array may be
varied;
2. The shapes, sizes, and arrangements of the magnetoresistive sensors may be
varied singly or in combination;
3. The number, shapes, sizes, and arrangements of the magnets can be varied
singly or in combination; and
4. The shape, number, and configuration of the magnetic flux guides may be
varied; and
5. The sampling rate of each sensor may be varied independently or in unison
with other sensors in a scanning movement.
Thus, the scope of the invention should be determined by the appended claims and
their legal equivalents rather than by the examples given.