WO2002035760A2

WO2002035760A2 - Inventory tracking system

Info

Publication number: WO2002035760A2
Application number: PCT/US2001/051003
Authority: WO
Inventors: John Rodenrys; Mark Raptis; Erik Barnes; Joseph Calabro; Laird Broadfield; Brad Odenkirk
Original assignee: Pyxis Corporation
Priority date: 2000-10-23
Filing date: 2001-10-23
Publication date: 2002-05-02
Also published as: AU2002231349A1; WO2002035760A3

Abstract

An inventory tracking system and method having a handheld unit (20) with a housing (34, 36), a battery (24) disposed within the housing (34, 36), a chip (75) having identification information, and at least one contact element (22, 39) connected to the battery (24) and the chip (75). The system having a receptacle unit (30) placed at a storage location of items, the receptacle unit (30) having at least one contact element (22, 39), a chip (75) having receptacle-identifying information, and a transmitter (30) for transmitting signals to a processing unit (40) when the handheld unit contact element (22) touches the receptacle unit contact element (39). The processing unit (40) has a receiver (30) to receive transmitted signals from the receptacle unit (30) and uses the information in the signals to update the inventory information about the items at the storage location.

Description

INVENTORY TRACKING SYSTEM

Field of the Invention

The present invention generally relates to an inventory control system and, more specifically an inventory control system that includes handheld units, autonomous receptacle units and a processing unit to manage, control and track inventory.

Background and Summary of the Invention

Others have tried to manage and control inventory with various sytems. U.S. Patent No. 5,805,455 to Lipps discloses an apparatus to dispense medical supplies from a locked storage cabinet. This system uses button bars in a cabinet that are hardwired to a computer that records when the buttons are pushed by a user. Par Excellence offered a supply system that is used with a hand held touch probe that reads information from a "button" on totes that sit on shelves. This system does not send signals via an RF communications link from the storage location, provide confirmation to the storage location that the system recorded the taking or returning of an item, send handheld unit ID information from a handheld unit to a receptacle unit at the storage location, nor transmits receptacle unit ID information from the storage location to a processing unit. Radio frequency identification (RFID) chips are used for security or inventory purposes when attached to an item such as an article of clothing. When the item with the RFID chip passes through a doorway with an antenna, the antenna detects the presence of the RFID tag and sets off an alarm (if for security purposes) or records the passing of an item from a room (if for inventory purposes). These types of RFID chips are usually passive with no power to the chip until energy is obtained from the signal of the antenna. The range of these passive RFID chips is small. Active RFID chips may have batteries that need to be replaced when the batteries go dead, which can be a very time-consuming job if there are RFID chips on each separate item in inventory.

There is a need for an automated inventory control system that can monitor, track and record inventory on open shelves, bins, containers, drawers, compartments, pegs, hangers and the like as soon as the user takes an item from or returns an item to inventory and where such open shelves, bins, drawers, compartments, containers, pegs, hangers and the like make it difficult to have hard wires connected to them. There is also a need for an automated inventory control system that will automatically send data to a remote computer from the storage location via RF signals and get a quick confirmation at the storage location where the user took or returned the item to inventory, as well as updating the information and recording all transactions regarding the inventory.

The present invention meets these needs. The present invention is an automated inventory control system and method having a handheld unit with a housing, a battery disposed within the housing, a chip having handheld unit ID information, and at least one contact element connected to the battery and the handheld unit chip. The system has a receptacle unit placed at a storage location with items, the receptacle unit having at least one contact element, a chip having receptacle unit ID information and a transmitter and/or receiver for transmitting and receiving signals to and from a processing unit when the handheld unit contact element touches the receptacle unit contact element. The processing unit has a receiver and/or transmitter for receiving transmitted signals from the receptacle unit and for transmitting confirmation signals to the receptacle unit. The processing unit has memory for storing information about the inventory stored in various storage locations such as the open shelves, bins, containers, drawers, compartments, pegs, hangars and the like. The processing unit extracts information from the signals it receives from the receptacle unit and updates the inventory information about the items (e.g., quantity, operator name, take or return, time, date, etc.) stored at the storage location.

Various objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention.

Brief Description of the Drawings

Figure 1 shows a diagram of the automated inventory control system in accordance with the present invention. Figures 2-5 show various views of the receptacle unit in accordance with the present invention.

Figure 6 shows the handheld unit with a cutaway portion and the receptacle unit in accordance with the present invention.

Figure 7 is a perspective view of a portion of the housing of the handheld unit in accordance with the present invention.

Figure 8 is a perspective view of a portion of the housing of the handheld unit in accordance with the present invention.

Figure 9 is an end view of the handheld unit showing the contacts in accordance with the present invention.

Figure 10 is a side view of a contact of the handheld unit in accordance with the present invention. Figure 11 is a cross-sectional view of the contact in Figure 10 in accordance with the present invention.

Figure 12 is a schematic of the circuitry of the handheld unit in accordance with the present invention.

Figure 13 is a schematic of the circuitry of the receptacle unit in accordance with the present invention.

Detailed Description of the Preferred Embodiments

The detailed embodiments of the present invention are disclosed herein. It should be understood, however, that the enclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as a basis for teaching one skilled in the art how to make and/or use the invention. Referring now to the drawings, preferred embodiments of the automated inventory control system of the present invention are shown in Figures 1-13. The present invention is an inventory tracking system in which receptacle units 30 are placed at storage locations where items in inventory are kept. These receptacle units 30 are preferably relatively small in size (could be 2" by 4" x 0.7") so that they can be easily placed at many different types of storage locations, including shelves, bins, compartments, cabinets, drawers, hangars and the like. These receptacle units 30 are secured on or near the storage locations by any suitable means of attachment, including but not limited to adhesives, velcro, glue, screws, nails, etc. The overall automated inventory control system is shown in Figure 1 which shows the handheld unit 20, a receptacle unit 30, and a processing unit 40. When the contacts 22 (as shown in Figure 6) of the handheld unit 20 touch the contacts 39 of the receptacle unit 30, a signal 42 is sent from the receptacle unit 30 to the processing unit 40. When the processing unit 40 receives a signal 42 from the receptacle unit 30, the processing unit 40 sends a confirmation signal 44 back to the receptacle unit 30 that the processing unit properly received signal 42. The communication links between the receptacle unit 30 and the processing unit 40 are preferably RF communications that are sent and received by transceivers inside of the receptacle unit 30 and the processing unit 40. Another embodiment of the present invention is that there could be hardwired links between the receptacle units 30 and the processing units 40 to communicate the appropriate information.

The handheld unit 20 has a housing that is preferably made up of two portions 34 and 36 that mate together to form a case for the handheld unit 20. The housing of the handheld unit 20 could be one integral piece as well. The handheld unit 20 has a battery 24 or other power source (as shown in Figure 6) disposed within said housing and a chip 23 having identification information about the handheld unit 20, and at least one contact element 22 (as shown in Figure 6) connected to the battery 24 and the chip 23. hi a preferred embodiment, the handheld unit 20 has two contact elements 22 extending beyond the housing of the handheld unit 20. The receptacle unit 30 has at least one contact element 39 (preferably two), a chip 33 having receptacle-identifying information and a transceiver or a separate transmitter or transceiver for transmitting signals to a processing unit 40 when the handheld umt 20 contact element 22 touches the receptacle unit's 30 contact element 39. The receptacle unit 30 also has an LED 32 that lights up into various colors depending upon whether an item is being returned to the storage location or whether an item is being taken from the storage location. The LED also lights up upon receiving a confirmation signal 44 from the processing unit 40.

The processing unit is preferably a computer with a screen, keyboard or other input device, bar code scanner, biometric ID or badge reader and software program with memory to maintain information about the items in inventory (e.g., type, size, quality, quantity, location, etc.). The processing unit 40 also has a transceiver (or a transmitter and transceiver) that is configured to receive signals 42 from the various receptacle units 30 that are placed near various storage locations as well as the configuration that will send confirmation signals 44 back to the proper receptacle unit 30 when a handheld unit 20 mates with the receptacle unit 30. The software program of the processing unit 40 includes a means for identifying the receptacle unit ID (preferably six bytes) to a storage location and the handheld unit ID (preferably six bytes) to an operator or other entity. The software program of the processing unit 40 also has logic to determine what type of transaction the operator will be performing, i.e., is the issue from stock, a work order issue, an unplanned issue or kanban issue, etc. The processing unit 40 will track the name of the operator who has a particular handheld unit 20, so that the system will know from the handheld unit ID code, who is removing or returning items. In a preferred embodiment, the handheld unit 20 has two contacts 22 and the receptacle unit 30 has two contacts 39 that are both spaced the same distance apart so that the contacts 22 can mate or touch the contacts 39 when an operator wants to take an item from the storage location or return an item to the storage location. The housing of the handheld unit 20 may be comprised of two housing components 34 and 36, in part, because these housing components 34 and 36 are preferably two different colors. The reason for the two different colors is that color 1 could indicate the removal of an item from the storage location and color 2 could indicate the return of an item to the storage location. The operator determines which type of transaction they will be performing (talcing an item or returning an item) and then orients the handheld unit 20 so that either color 1 is on top or color 2 is on top. The handheld unit 20 is then preferably inserted into the cavity 38 of the receptacle unit 30 so that the contacts 22 of the handheld unit 20 touch the contacts 39 of the receptacle unit 30. If successful contact is made, a colored light in the LED 32 of the receptacle unit 30 illuminates in either color 1 or color 2, depending on which side is on the top. Another possibility is that the receptacle unit 30 could give a beep tone or other sound when it receives the confirmation signal 44 from the processing unit 40. The power from the battery 24 of the handheld unit 20 powers the transmitter in the receptacle unit 30 and information is sent to the processing unit 40. The information sent to the processing unit 40 by RF communication 42 includes the type of insertion (take or return), the insertion unit ID, the receptacle unit ID and possibly other types of information. The processing unit 40 then identifies the operator (or other entity), the location of the receptacle unit 30 and the type of transaction (take or return) and updates the database in the processing unit 40. The processing unit 40 preferably also sends a confirmation signal 44 back to the receptacle unit 30 to again light the LED 32 to either a different color than color 1 or color 2 (or to the same color that was lit up when the handheld unit 20 contacted the receptacle unit 30). The confirmation signal could also blink the LED signal 32 or give other indications to the operator that the processing unit recorded the transaction. It is also possible to have multiple LEDs on the receptacle unit or on the handheld unit to confirm fransmittals of signals or reception of signals.

An alternative embodiment of the handheld unit 20 could be that instead of using two different colors on the housing components 34 and 36, one side of the handheld unit 20 could have the word "TAKE" displayed prominently to the operator and the other side of the handheld unit could have the word "RETURN" prominently displayed to the operator, i this embodiment, when the word "TAKE" is on top when the contacts 22 touch the contacts 22 of the receptacle unit 30, the operator will know that this orientation corresponds with the taking of an item from the storage location. Similarly, when the word "RETURN" is on the top of the handheld unit 20 when the contacts 22 touch the contacts 39 of the receptacle unit 30, the operator will know that this orientation corresponds with the returning of an item to the storage location.

The preferred embodiment of the present invention is to use a wireless RF link between the receptacle units 30 and the processing unit 40. A problem with wireless RF is how to maintain power at the receptacle units 30 so that RF signals can be sent and received by the receptacle units 30. If a separate battery 24 is installed in each receptacle unit 30 in all of the various locations of storage units (which could be hundreds if not thousands in a large area where items are stored, such as a warehouse), each of these individual batteries in the receptacle units 30 would have to be periodically replaced when the batteries go dead. It is also not practical in most situations to have a power cord to each of the receptacle units 30. In fact, the preferred embodiment herein is that the receptacle units are self-contained and autonomous and can be moved from storage area to storage area as needed. A unique feature of the present invention is to have the battery or power source kept in the handheld unit 20 so that when mated with a receptacle unit 30 with contacts 22 and 39, the power from the battery 24 of the handheld unit 20 will power the circuitry and the transceiver of the receptacle unit 30. hi this manner, one avoids having batteries in each of the numerous receptacle units 30. This also allows an operator to power the circuitry in the receptacle units 30 only when items are taken from inventory or returned to inventory. A standard 9-volt battery may be used in the handheld unit 20 for this purpose. The benefit of the present invention in being able to use a 9-volt battery or a battery with more power is that the signal sent by the receptacle unit 30 can be sent relatively long distances (over 200 feet) versus the typical passive RFID tag being able to transmit only about 20 feet or so.

Figure 12 shows the circuitry in the handheld unit 20. BT1 indicates that battery/power source, SW1 indicates the switch, REG103 is a voltage regulator, PIC12C506 is a microcontroller chip, Ql is a MOSFET, D2 is a zener diode and the block with 12 on the right hand side of the schematic shown in Figure 11 indicates two contacts on the handheld unit. The voltage regulator RG103 regulates the voltage going into the pin of the microcontroller chip 75, which allows the circuitry of the handheld unit 20 to send a handheld ID code that is stored within the microcontroller chip 75 through the contacts 22 on top of the power signal.

Figure 13 shows a schematic of the circuitry in the receptacle unit 30. h the front end of the circuitry of the receptacle unit 30, there is a diode bridge D3 that enables the handheld unit 20 to be oriented either way with the contacts 22 and 39 touching to power up the receptacle unit 30 circuitry. This circuitry of the receptacle unit 30 sends the signal 42 with the handheld unit 20 ID code and receptacle unit 30 ID code to the processing unit 40. The circuitry rectifies the signal from the handheld unit 20, runs it through a regulator 80 and powers the microcontroller chip 85 in the receptacle unit 30. The signal comes off of one of the input leads and goes through a resistor Rl to an input in the microcontroller chip 35. When the handheld unit 20 is oriented one way, it will be ground and when the handheld unit 20 is oriented the other way, the signal is going to be high. Since the power source may be 9-volts from the 9-volt battery 24 and a microcontroller chip 85 can only handle 5 volts, there is a diode in the circuitry to prevent the voltage from going over 5 volts. This is how the microcontroller knows that the power is being provided. On the output section of the handheld unit 20, there will be a 9-volt signal and the handheld unit will also have a MOSFET which will pull the bottom of the output signal to ground. If that MOSFET is turned off, it will power the zener diode D2 and it will reduce the voltage by a couple of volts. So, by turning the MOSET on and off, the inventors have determined that the circuitry can modulate the output signal by whatever the zener voltage is. For example, if there is a 3-volt zener, then the output signal will vary between 6 and 9 volts. There are other alternatives besides a zener diode that can be used such as a pair of diodes in series. This would provide about a 1.5 volt change, so the output signal would vary between 7.5 and 9 volts. This would provide an additional data stream that can be used. On the other side, there is a divider 83 and a comparator 84 and there is also a capacitor Cl so a user can end up generating a time differential between the two. This will help restore the data signal off the power signal. This delay may be useful to make sure the signal is stabilized before it is transmitted from the receptacle unit 30 to the processing unit 40. Resistors R4 and R5 do not have a capacitor with them, so they act as a fact acting toggle for the comparator 84. The digital data stream with the handheld unit ID code of the handheld unit 20 comes in through the contacts 39 and through the microcontroller 85. A digital data stream goes out of pin 5 of the microcontroller chip 85 through the data out portion of Figure 13 and is sent via RF communications to the processing unit 40. A digital data stream can also be received from the processing unit 40 through the data in port on pin 5 of the microcontroller chip 85. Preferably, the receptacle unit ID code and the handheld unit ID code are six byte serial numbers to give each receptacle unit 30 and each handheld unit 20 a unique code. The data transmitted and received from the receptacle unit 30 will be of a radio link and will be an RF frequency that might be in the ISM band of frequencies or other suitable radio frequency. The LEDs are also shown in the schematic in Figure 13.

The processing unit 40 will have a suitable transceiver that can receive and transmit RF signals and communicate with the various receptacle units 30. A standard RS45 communications bus may be hooked up to the processing unit 40 which would enable receivers to be spaced apart and to transmit signals from one to the other. The processing unit will contain memory having details of the items at the various storage locations, such as quantity, quality, type, size, weight, bar code, numbers, color, price, etc. The processing unit 40 will have a database of operator names, which will have unique codes and the system will have know which operator had which particular handheld unit 20. Then, that handheld unit ID code will correspond to the particular operator who is either removing or returning items from the storage locations. These items could be of any type including parts, components, supplies, materials, pharmaceuticals, IC chips, jewels, etc. The memory in the processing unit 40 will also have details of the number of units at each storage location so that it will know when the inventory for a certain item is running low or is empty so that new items can be refilled at that storage location. The processing unit 40 may give an alert signal or sound that items in inventory are getting low, are ready to expire, are expired, etc.

When the contacts 22 of the handheld unit 20 touch the contacts 39 of the receptacle units 30, the circuitry/chip in the handheld unit 20 will send an embedded code from the handheld unit to the circuitry/chip of the receptacle unit 30. This embedded code that is sent is the handheld unit's 20 ID signal on top of the power signal (from the battery 24), so that the power and ground signal has the data with the handheld unit 20 ID signal. The receptacle unit 30 has its own ID code for that particular storage location from which an operator is removing or returning items. The information from the handheld ID code is transmitted to the receptacle unit 30 across the power and not via radio waves at this point. The power from the battery 24 of the handheld unit 20 goes into the receptacle unit 30 to provide power to the circuitry/transceiver/microcontroller chip 85 of the receptacle unit 30. This power then causes the chip 85/microcontroller/circuitry to decode the handheld unit's 20 ID code, add receptacle unit 30 ID information, and transmit that information in an RF link to the processing unit 40. The transfer of information from the handheld unit 20 to the receptacle unit 30 and then from the receptacle unit 30 to the processing unit 40, as well as the confirmation signal 44 back from the processing unit 40 to the receptacle unit 30 happens very quickly (e.g., about 100 to 200 milliseconds).

One possible embedded microcontroller/chip that could be used in the handheld unit 20 and the receptacle unit 30 is Microchip PCI 12C508 that is made by Microchip Corporation of Tempe, Arizona. There are other chips with embedded microcontrollers that also may be suitable for use with the present invention. Various integrated circuit chips that can store a unique ID from which information can be transmitted may be acceptable for use in the present invention. One possibility is an ASIC (Application Specific Integrated Circuit) which will be smaller in size and lower in power than required. It is also possible that the microcontroller, regulator and drive circuitry could be combined into one integrated circuit chip.

Another unique feature of the present invention is that the handheld unit 20 can power the circuitry of the receptacle unit 30 in either orientation (in a return mode or in a take mode) and provide different signals to the receptacle unit 30 that corresponds with whether an article is being removed or returned. See the schematic diagrams in Figures 12 and 13.

Having described the invention in detail, those skilled in the art will appreciate that, given the present disclosure, modifications may be made to the invention without departing from the spirit of the inventive concept herein described. Therefore, it is not intended that the scope of the invention be limited to the specific and preferred embodiments illustrated and described. Rather, it is intended that the scope of the invention be determined by the appended claims.

Claims

What is claimed is:

1. An automated inventory control system comprising: a handheld unit having a housing, a battery disposed within said housing, a chip having handheld unit ID or operator ID information, and at least one contact element connected to said battery and said handheld unit chip; a receptacle unit placed at a storage location of items, said receptacle unit having at least one contact element, a chip having receptacle unit ID information, and a transmitter for transmitting signals to a processing unit when said handheld unit contact element touches said receptacle unit contact element; and said processing unit having a receiver to receive transmitted signals from said receptacle unit wherein said processing unit records the information sent in said transmitted signals and updates an inventory database about the items at the storage location.

2. The system of claim 1 wherein the touching of said contact elements enables the transfer of information between said handheld unit and said receptacle unit.

3. The system of claim 2 wherein the information transferred from said handheld unit to said receptacle unit includes handheld identification or operator identification data.

4. The system of claim 1 wherein the information sent in said transmitted signals from said receptacle unit to said processing unit includes handheld unit ID information and receptacle unit ID information.

5. The system of claim 4 wherein the information sent in said transmitted signals from said receptacle unit to said processing unit also includes information regarding whether an item was taken or returned.

6. The system of claim 1 wherein said receptacle unit chip contains information regarding said the items at the storage location.

7. The system of claim 1 wherein said processing unit sends a confirmation signal back to the receptacle unit after receiving a valid signal from said receptacle unit.

8. The system of claim 1 wherein said receptacle unit has an LED that lights when contact is made between said handheld unit and said receptacle unit.

9. An inventory tracking system comprising: a handheld unit having a housing, a battery disposed within said housing, a chip having handheld unit ID or operator ID information, and at least two contact elements connected to said battery and said handheld unit chip; a receptacle unit placed at a storage location of items, said receptacle unit having at least two contact elements, a chip having receptacle unit ID information, and a transmitter for transmitting signals to a processing unit when said handheld unit contact elements touches said receptacle unit contact elements; and said processing unit having a receiver to receive transmitted signals from said receptacle unit; wherein said receptacle unit has circuitry configured so that the receptacle unit can detect the orientation of the contact elements of said handheld unit.

10. The system of claim 9 wherein the orientation of the contact elements of said handheld unit determines whether an item is taken from the storage location or returned to the storage location.

11. A method of tracking inventory of items at a storage location, comprising the steps of: providing a handheld unit having a housing, a battery disposed within said housing, a chip having handheld unit ID or operator ID information, and at least one contact element connected to said battery and said handheld unit chip; providing a receptacle unit placed at a storage location of items, said receptacle unit having at least one contact element, a chip having receptacle- identifying information, and a transmitter for transmitting signals to a processing unit when said handheld unit contact element touches said receptacle unit contact element to indicate the addition to or removal of an item from the storage location; and providing said processing unit having a receiver to receive transmitted signals from said receptacle unit.

12. The method of claim 11 further comprising the step of updating inventory information about the items at the storage location in memory of the processing unit.

13. A method of inventory control, comprising the steps of: placing a handheld unit with its own power source in contact with a receptacle unit that is at a storage location of items when an item is added to or removed from the storage location; transferring power and a handheld unit ID code to said receptacle unit; and sending an RF signal from said receptacle unit to processing unit, said RF signal having the handheld ID code and a receptacle unit ID code, wherein said processing unit updates inventory information regarding items at the storage location.

14. The method of claim 13 wherein said processing unit sends an RF confirmation signal to the receptacle unit after said processing unit receives the RF signal from said receptacle unit.

15. The method of claim 13 wherein said receptacle unit has indicia to indicate when there is contact between said handheld unit and said article receiving unit.

16. The method of claim 15 wherein said indicia is an LED lighting up or a sound when there is contact between said handheld unit and said article receiving unit.

17. The method of claim 13 wherein said handheld unit has indicia to indicate to an operator the proper orientation of said handheld unit to track the removal of an item from the storage location or the return of an item from the storage location.

18. The method of claim 13 further comprising the step of transmitting a confirmation signal from said processing unit to said receptacle unit after said processing unit receives a valid signal from said receptacle unit.

19. The method of claim 18 wherein said receptacle unit has indicia to indicate when said receptacle unit receives the confirmation signal from said processing unit.