CN101149792B - 使用移动盘存机器人来执行盘存的系统和方法 - Google Patents
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Abstract
当移动盘存机器人被手工地导航穿过商店以识别货架上的物品、货架上每个物品的位置、以及每个物品的条形码时，移动盘存机器人系统生成商店的盘存地图和产品数据库。所述系统通过以下步骤来执行对物品的盘存：经由盘存地图导航穿过商店、拍摄货架图像、从已拍摄的货架图像中解码产品条形码、从产品数据库中检索已解码产品条形码的产品图像、将已拍摄的货架图像分段以检测所述货架上的物品的图像、确定所检测的图像是否匹配已检索的图像、并且如果不匹配则针对所述物品设置脱销标志。
Description
技术领域
本发明一般涉及盘存(inventory)控制，并且特别地涉及检查存货库存(inventory stock)的自动方法。更为具体地，本发明涉及使用机器人来执行盘存任务。
背景技术
盘存包括在一个区域中维持物品的供给以供顾客检索。在零售商店里，商品被放置或“储放”在货架、搁物架和摊位上供陈列以及供顾客检索。储存架是零售商店的一个基本功能。未在货架上的物品不能被出售。当包装消费品公司(此处被称为公司)的产品不在货架上时，该包装消费品公司被特别地关注。如果消费者试用竞争品牌并更喜欢该竞争品牌，这预示着损失来自该消费者的未来的销售额，则该公司可能除了损失顾客外还损失销售额。
在促销期间，公司花费大量金钱给一个产品做广告。如果活动成功了，则新的顾客将购买所广告的产品、试用该产品、并且成为该产品和该公司的忠实顾客。如果所促销的产品不在货架上，则那些广告费就浪费了。
物品从货架上缺失的状态被称作脱销。脱销的物品可能在库房里并仅仅需要被储放在货架上。如果脱销的物品不在商店里，则从配送中心请求该物品或者从制造商那里补充该物品。物品可以位于商店里的若干个位置，因此在一个位置脱销的物品可以从商店里的其它位置被重新分配。
通常，商店的雇员被指派对货架上的产品进行盘存并补充脱销的产品的任务，这是被称为“面向货架”的一种动作。在包括例如具有数千物品的50,000平方英尺的大型商店里，许多雇员被要求检查脱销的物品并补充货架。这种劳动密集型的任务是昂贵的，并且如果不频繁地(即每夜)执行这种任务则可能导致商店以及提供产品的公司损失销售额和顾客。
商店管理员和产品制造商还关注货架上商品的外观(它们是否处于恰当地方，标签是否朝外以给购物者呈现理想的外观)。货架以及货架上的产品的状态反映出零售商店给顾客的印象；商店管理员和产品制造商期望维持给顾客一种高质量的印象。需要连续不断地察看货架上的商品以维持这种外观。
零售商和公司也会关注被放置在货架上的物品的位置。某些制造商为特定的产品布局(例如与眼睛同高)付费。可以雇公司来检查(审核)产品布局，以核实零售商店遵守了布局协定。对于大型连锁商店，公司办公室期望核实：地区性的商店处于良好的状态，可能会造成伤害的障碍物被清除出过道，以及商品的外观满足公司的标准。公司办公室依靠商店管理员的评估或者公司办公室雇员对商店状况的第一手印象。如果在地理上分散的位置处有数百个商店，则监视地区性的商店可能很昂贵。
货架的外观对于商店管理员也很重要，商店管理员可能没有时间将所有的过道都走一遍。被误放置的物品和混乱的货架降低了商店留给顾客的印象，由此会潜在地损失销售额和顾客。
仓储式商店常常使用非常高的货架(例如18英尺)并且在货架的顶部储存存货，该存货太高了以致从地面上看不到。为了实际检查库存，雇员需要使用移动梯子或叉式升降机设备。出于盘存的目的或者为了给顾客定位一件物品，在这种位置定位库存很费时间并且有潜在的危险。
检查货架存货的传统方法尽管对于维护产品的可购买性是必要的，但是该传统方法是劳动密集型的、昂贵且费时间。典型地，在零售商店内商店雇员察看每个货架，注意哪些产品正在减少或脱销。雇员可以使用无线联网的条形码读取器来标记减少或脱销的产品。一旦产品被标记，就从仓库库存中取回该产品或者从相应的公司订购该产品。
一种传统的方法使用射频识别(RFID)。RFID系统利用“智能货架”，“智能货架”是带有RFID内嵌天线的货架，该RFID内嵌天线通过无线地读取被应用到该货架上的每个物品的唯一的RFID标志来询问物品的存在。虽然RFID技术已被证明是有用的，但是提出替代性的方法以在零售商店里检测脱销的状态并执行盘存任务将是理想的。
货架上的每个产品接收一个可由RFID系统跟踪的RFID标志。RFID系统处理从库房到收银机的供应链管理的“最后十几英尺(last dozenfeet)”问题，监视直到货架的物品级的跟踪。然而，现在对于零售商店里的低成本物品而言RFID实现起来很昂贵。现在，每个RFID标志大约要花费0.25美元。当在诸如一管牙膏这样的2.00美元的物品上放上RFID标志时，RFID标志的成本与该物品的成本相比而言是相当大的。RFID读取器促成了商店中的每个物品的额外的开销成本。因此，主要由于会随着每个物品被丢弃的RFID标志的费用的原因，对于给低成本物品进行物品级做标志，RFID系统不是一个经济上可行的解决方法。
考虑到商店里的数千物品和大型商店里的极大尺码的货架(5万到25万平方英尺)，给物品做标志和给货架添加检测仪表是昂贵的建议。由此，需要的是一种用于使用移动盘存机器人来执行盘存的系统和方法，其中所述移动盘存机器人是自主或半自主机器人，其可在商店地板上行进并用照相机给货架照相以检测脱销的物品并报告货架上的产品的外观和布局。迄今，对于这种解决方法的需求尚未被满足。
发明内容
本发明满足这种需求，并且提出一种用于使用移动盘存机器人来执行盘存的系统和相关联的方法(此处统称为“系统”或“本系统”)。当所述移动盘存机器人被手工导航(navigate)穿过商店以识别货架上的物品、建立货架上每个物品的位置、读取并关联每个物品的条形码时，本系统生成商店的盘存地图。本系统生成包括物品、每个物品的位置、以及每个物品的条形码的产品数据库。
本系统通过以下步骤执行对物品的盘存：借助于盘存地图导航穿过商店、拍摄货架图像、从已拍摄的货架图像中解码产品条形码、从产品数据库中检索所解码的产品条形码的产品视像描述符、对已拍摄的货架图像进行分段以检测货架上的一个物品的图像、确定所检测的图像是否与所检索的产品视像描述符相匹配、并且如果不匹配就针对对应着所解码的产品条形码的物品设置脱销标记，由此执行对商店的货架上的物品盘存。
生成盘存地图包括：定位跟踪标志和路线点。跟踪标志被附着到诸如天花板瓷砖、横梁、柱子和货架之类的商店中的固定结构上，以帮助移动盘存机器人确定移动盘存机器人的位置。在一个实施例中，所述跟踪标志包括回射材料。所述跟踪标志用跟踪成像设备来识别。所述跟踪成像设备是具有大约640×480的VGA分辨率和大约10Hz帧率的数字照相机。在一个实施例中，路线点包括位于商店环境中的一个或多个红外发射器以及位于盘存机器人上的红外接收器。
生成产品数据库包括：拍摄众多货架的货架图像以及处理所述货架图像，以检测产品的条形码、产品的位置、产品的图像，以及生成产品的视像描述符。
导航穿过商店包括通过使用超声波设备执行障碍物避让。
拍摄货架图像是由成像设备来执行的。成像设备是具有大约3兆像素和大约1Hz帧率的数字照相机。
附图说明
参考以下描述、权利要求书和附图，将更详细地描述本发明的各种特征和实现它们的方法，其中在恰当的地方标号被重复使用，以指示所引用的项目间的对应关系，并且其中：
图1是在其中可以使用本发明的移动盘存机器人系统的示例性的工作环境的示意性图示；
图2是图1中的所述移动盘存机器人系统的盘存控制系统的高级体系结构的方框图；
图3是图1和图2中的所述移动盘存机器人系统的示例性移动盘存机器人的图，其中所述移动盘存机器人包括供用于在零售商店或仓库中对货架进行照相的一个或多个成像照相机的固定长度的支撑；
图4是图1和图2中的所述移动盘存机器人系统的示例性移动盘存机器人的图，其中所述移动盘存机器人包括供用于在零售商店或仓库中对货架进行照相的一个或多个成像照相机的可伸展的支撑；
图5包括图5A和图5B，并表示过程流程图，所述过程流程图图示了在零售商店或仓库中安装图1和图2中的所述移动盘存机器人系统的示例性的方法；
图6是图示了在针对脱销物品对零售商店或仓库进行盘存时图1和图2中的所述移动盘存机器人系统的操作的示例性方法的过程流程图；
图7包括图7A和图7B，并表示零售商店或仓库中的示例性的货架的图，所述货架由图1和图2中的移动盘存机器人系统进行照相和盘存，其中在所述货架中没有检测出任何脱销物品；
图8包括图8A和图8B，并表示零售商店或仓库中的示例性的货架的图，所述货架由图1和图2中的移动盘存机器人系统进行照相和盘存，其中在所述货架中检测出脱销物品；
图9包括图9A和图9B，并表示图1和图2中的移动盘存机器人系统的一个实施例的高级层级结构的方框图，其中音频和视像通信系统被用于与零售商店中的顾客或仓库中的雇员进行通信；以及
图10是图示了使用图1和图2中的移动盘存机器人系统来生成产品数据库用于对零售商店或仓库进行盘存的示例性的方法的过程流程图。
具体实施方式
以下定义和解释提供从属于本发明的技术领域的背景信息，并且旨在在不限制本发明的范围的条件下促进对本发明的理解。
循环盘点(cycle count)：仓库或零售商店里的库存盘点，其被用于保持“可供出售”的库存余额的准确度。有效的循环盘点系统包括：每晚对仓库或零售商店里的部分库存进行实物盘存(physical inventory)。实地位于仓库内或位于零售商店的货架上的每个物品的数量应该对应于存储在系统里的现有库存减除交付的库存。任何差异都被记录并调整。
脱销(out of stock)：在仓库或零售商店里没有物品的存货。
过剩(overage)：从永久存货纪录所确定的存货与实际现有的存货量之间的超出量。
库存过多(overstock)：具有比在合理的时间量内能售出的量更高量的物品。
实物盘点(physical count)：实物盘点是对零售商店或仓库里的库存的年度、定期、周期或紧急盘点，以核实纪录、确定财务值、或帮助确定可疑存货问题的原因。典型地，在每个财政年度结束时，审计员要求对整个仓库或整个公司进行的实物盘存。
重新订购点(re-order point)：算术上理想的点，在该点重新定购物品以使占用或存货成本最小，同时防止所述物品变成脱销。
缩减(shrinkage)：从永久存货纪录所确定的存货与实际现有的存货量之间的短缺。导致缩减的原因包括：雇员偷窃、顾客偷窃、卖主偷窃、毁坏、破损、腐坏、记账和纪录错误、在标记零售价格时的错误、收银机错误、已经减价但没有做纪录、考虑顾客退货时的错误、以及考虑卖主接收和退货时的错误。典型的缩减占所有存货的1％到3％。
图1图示了其中可以使用移动盘存机器人系统10(系统10)的示例性的盘存系统100。系统10包括盘存控制系统15和移动盘存机器人20。所述盘存控制系统15和所述移动盘存机器人20经由网络25进行通信。网络25可包括例如：局域网、广域网、因特网等等。所述盘存控制系统15可与所述移动盘存机器人20位于相同的建筑内、可位于诸如地区或公司总部之类的远程位置、或位于诸如在海外运作的支持位置之类的任何其他位置处。
系统10可以采取以下形式：整个是硬件的实施例或者包含硬件和软件单元二者的实施例。在一个实施例中，所述盘存控制系统15用软件来实现，其包括但是不限于固件、驻留软件、微码等等。
此外，所述盘存控制系统15可以采取可从计算机可用或计算机可读的介质中进行访问的计算机程序产品的形式，所述介质提供由计算机或者任何指令执行系统使用或结合计算机或者任何指令执行系统来使用的程序代码。出于这种描述的目的，计算机可用或计算机可读的介质可以是任何装置，其可包含、存储、传递、传播、或传送所述程序以由计算机执行系统、装置或设备使用或结合计算机执行系统、装置或设备来使用。
所述介质可以是电的、磁的、光的、电磁的、红外、或半导体系统(或者装置或设备)或传播介质。计算机可读的介质的例子包括半导体或固态存储器、磁带、可移除的计算机磁盘、随机存取存储器(RAM)、只读存储器(ROM)、硬磁盘和光盘。光盘的当前例子包括只读存储器致密盘(CD-ROM)、读/写致密盘(CD-RW)和DVD。
适于存储和/或执行程序代码的数据处理系统包括至少一个通过系统总线直接或间接耦合到存储器单元的处理器。所述存储器单元可以包括在所述程序代码的实际执行期间所使用的局部存储器、海量存储装置、以及高速缓冲存储器，所述高速缓冲存储器给至少某种程序代码提供临时存储，以减少在执行期间从海量存储装置检索代码的次数。
输入/输出或者I/O设备(包括但不限于键盘、显示器、定点设备等等)可直接或者通过中间I/O控制器耦合到所述系统。
网络适配器也可以耦合到所述系统以使所述数据处理系统能通过中间私有或公共网络耦合到其他数据处理系统或者远程打印机或存储设备。调制解调器、电缆调制解调器以及以太网卡仅仅是网络适配器的当前可用类型中的少数几种。
所述移动盘存机器人20包括一个或多个成像设备30。所述成像设备30包括用于对商店中的货架、货架上的条形码标签、货架上的物品以及物品上的条形码进行照相的数字照相机。所述成像设备30还包括可选的光源，用于照亮货架上的物品以进一步增强所述成像设备30的成像能力。在一个实施例中，所述成像设备30包括高分辨率、低帧率的数字照相机，诸如例如具有规格为大约3兆像素和大约1Hz帧率带有自动聚焦和曝光以及可远程控制的可变焦镜头的数字照相机，以提供足够用于读取货架标签上和产品上的条形码、以及拍摄货架上的多个物品的图像分辨率。
所述移动盘存机器人20包括成像设备安置和支撑系统35。所述成像设备30被附着到所述成像设备安置和支撑系统35。在一个实施例中，所述成像设备安置和支撑系统35在高度上被固定而且所述成像设备30被安置为对应着移动盘存机器人20所察看的货架的高度。在另一个实施例中，所述成像设备安置和支撑系统在高度上可调，以使所述成像设备30垂直地运动以察看货架里的物品，诸如察看在具有可上升超过18英尺的货架的仓储式商店或库房里的货架里的物品。
所述移动盘存机器人40还包括控制系统40、发射模块45、接收器模块50、跟踪系统55、障碍物避让系统60、地图绘制系统65、移动平台模块70、RFID读取器73、以及供电系统75。所述供电系统75包括可充电电池，其给所述移动盘存机器人20供电并且通过将盘存机器人与固定的电源对接站(未示出)对接(dock)来进行充电。
发射模块45将货架的图像发射到盘存控制系统15。在一个实施例中，发射模块45发射由控制系统40执行的处理所生成的关于货架上的物品的附加信息。这种附加信息包括例如从图像所确定的条形码、从图像所确定的脱销物品、在错误位置(例如不在它们的货架条形码上方)的物品。接收器模块50从盘存控制系统15接收信息和指令，以由控制系统40在例如安置成像设备30、控制所述移动盘存机器人20的运动以及执行其他功能时使用。在另一个实施例中，RFID读取器73被用于在库房中读取货盘和货柜上的RFID标志以提供对已接收和存储的物品的盘存。RFID标志还可被用作用于导航的路线点(waypoint)。
控制系统40控制移动盘存机器人20的运动和任何对由成像设备30拍摄的图像执行的图像预处理。控制系统40通过使用跟踪系统55所提供的反馈，使得移动盘存机器人20沿着被存储在所述地图绘制系统65中的盘存地图运动。跟踪系统55通过使用来自跟踪标志的反馈在诸如零售商店之类的建筑内跟踪移动盘存机器人20的位置，所述标志诸如在建筑物的天花板上的回射标志和被放置在建筑物的地板中的红外路线点。控制系统40还通过使用障碍物避让系统60来控制移动盘存机器人20的运动，障碍物避让系统60探测移动盘存机器人20的路径中的障碍物，包括：人、购物车、待堆到货架上的成箱物品，以及落地式展示。
存储在地图绘制系统65中的盘存地图还包括盘存计划，其定义了对货架和货架中的物品进行照相的顺序。随着所述移动盘存机器人20遍历所述盘存地图，按预定的顺序拍摄下述图像：货架、货架上的条形码、货架上的物品以及物品上的条形码；这个预定的顺序就是所述盘存计划。
图2图示了盘存控制系统15的高级层次结构。盘存控制系统15包括产品图像分段模块205、产品条形码解码器210、脱销检测器215、产品计数器220、产品数据库225、盘存控制模块230、以及可选的手工控制系统235。盘存控制系统15还包括用于从移动盘存机器人20接收图像和其他信息的接收器240以及用于发射指令、命令和程序代码给所述移动盘存机器人20的发射器245。
所述产品图像分段模块205对由成像设备30拍摄的图像进行分段以隔离出各个产品的图像。产品条形码解码器210从被放置在货架上位于物品下面的以及在物品上的条形码上的条形码标志的图像(当对于成像设备是可见的时候)中提取条形码。所提取的货架条形码指示哪一个物品被期望处于条形码上方的货架里。所提取的物品条形码识别所述物品。在一个实施例中，盘存控制系统15使用对应着所提取的条形码的物品的图像作为所述产品视像描述符(被存储在所述产品数据库225里)，并将所述图像与货架上的物品的图像进行比较以确定货架上的物品是否与所提取的条形码相匹配。如果不相匹配，则生成一个指示货架上的物品处于错误的地点的标记。
脱销检测器215检测何时物品在货架上缺失。如果一个或多个物品出现在货架上则脱销检测器215返回0。如果物品在货架上缺失则脱销检测器215返回1。
在一个实施例中，货架由诸如例如反射从成像设备30发出的光的回射材料之类的材料形成背部。在图像中所拍摄的这种反射光指示在反射光的位置处的所成像的货架上没有任何物品。脱销检测器215检测缺失的物品，并且生成指示在货架上所期望的物品正缺失的标记，同时还生成所述缺失的物品的描述和条形码。
产品计数器220对货架上的物品的数量进行计数并且确定现存于货架里的物品的数量是否低于盘存阈值，由此要求在物品脱销之前对货架进行重新进货。移动盘存机器人20是移动的，其允许拍摄相同物品的另外的察看点以确定在货架上是否有另外的物品。另外的成像设备提供货架的垂直透视图，这允许从上面拍摄货架图像并使所述控制盘存系统能够确定货架上的物品的足够精确的数量。
产品数据库225包括产品视像描述符(例如从多个角度所获得的物品的图像、大小、颜色、物品的质地、产品上的条形码)、物品的条形码、以及被产品条形码解码器210、脱销检测器215、以及产品计数器220用于进行比较和分析的物品在商店中的位置。盘存控制模块230接收缺失物品标记和误放的物品标记，由此为商店的雇员生成盘存控制报告。通过使用所述盘存控制报告，雇员可以从位于商店中的其他位置处的库存或者从商店仓库中重新放置缺失的产品。雇员还可以基于所述盘存控制报告来订购重新放置产品。雇员可以基于所述盘存控制报告来重新定位被误放的物品。在一个实施例中，盘存控制报告包括对处于混乱的货架的指示，在所述货架中大量的物品处于货架上但是这些物品未被恰当地堆放或安排。
在一个实施例中，移动盘存机器人20是自动化的，其在没有人的干预下导航于零售商店或仓库并且订购物品。在另一个实施例中，移动盘存机器人20被手工地控制，当移动盘存机器人20正拍摄货架上的物品的图像时，其需要由在所述盘存控制系统15处的操作员来导航。操作员可以使移动盘存机器人20从一侧运动到另一侧以获得不同视角，等等。在另一个实施例中，移动盘存机器人20包括自动化控制和手工控制的混合，其中移动盘存机器人20自主地和自动地导航于商店并检测脱销物品，并且当注意到异常或遇到机器人不能导航绕过的障碍物(诸如箱子、新的落地式展示、购物车和人)时请求远程操作员的协助。操作员可以输入障碍物的位置，于是下次当盘存机器人遇到所述障碍物时盘存机器人可以避让所述障碍物，以减少请求操作员协助的次数。
图3图示了示例性的移动盘存机器人20A的一个实施例的图。移动盘存机器人20A包括成像设备30。示例性的成像设备是例如数字照相机。移动盘存机器人20A还包括固定长度的成像设备安置和支撑系统35。在允许每个成像设备30拍摄商店里的货架的图像的高度处，成像设备30被附着到成像设备安置和支撑系统35。针对每个货架高度使用一组诸如成像设备组305之类的成像设备30，以致在一个通道里所述移动盘存机器人20A拍摄移动盘存机器人20A两侧的每个货架的图像。在一个实施例中，成像设备安置和支撑系统35包括被诸如泡沫橡胶之类的柔软材料覆盖的可伸缩的杆，以防止在发生碰撞的情况下对移动盘存机器人20A或对其他对象或人员的损伤。
障碍物避让系统60和控制系统40利用成像设备310、315和320(统称为导航成像设备325)来避让或导航绕过障碍物并提供图像反馈给操作手工控制系统235的雇员以导航移动盘存机器人20A。跟踪图像设备330经由安装在商店的天花板上的跟踪标志的图像来提供跟踪反馈给控制系统40。在一个实施例中，每个导航成像设备325包括带有广角镜头的低分辨率、高帧率的数字照相机。这种低分辨率、高帧率的数字照相机所具有的分辨率和帧率规格例如大约640×480VGA分辨率以及大约10Hz帧率。
移动平台模块70包括电动机和供电系统75。移动平台模块70的组件的重量造成了低重心，由此给移动盘存机器人20A提供了稳定性。移动平台模块70还包括缓冲器335，轮子340、用于给供电系统70的电池充电的对接端口345、以及用于障碍物避让的检测器350、360(统称为检测器365)。在一个实施例中，检测器365包括发射并接收超声信号的超声范围探测器，由此允许移动盘存机器人20A检测并避让障碍物。检测器355检测红外路线点(未示出)并且帮助控制系统40将对接端口345导航到固定的电源对接站(未示出)。
移动盘存机器人20A通过导航成像设备325、跟踪成像设备330、安装在商店的天花板上的跟踪标志、内嵌于移动盘存机器人20内的检测器365以及推算定位法的结合进行导航。在以下参考文献中讲授了被安装在天花板上的跟踪标志：T.Zimmerman的“Tracking Shopping Carts UsingMobile Cameras Viewing Ceiling-Mounted Retro-reflective Bar Codes”，Proceedings of the Fourth IEEE International Conference on ComputerVision Systems 2006，以及在2006年1月5号提出申请的、申请号为11/325952、标题为“Mobile Device Tracking”的申请未决的美国专利申请。移动盘存机器人20还使用安装在零售商店或仓库里的架子上的条形码标志，用于在盘存路径的盘存地图中进行定向以及用于产品识别。
图4图示了包括可伸缩成像设备和安置支撑系统70的示例性的移动盘存机器人20B的另一个实施例的图。所述可伸缩的成像设备和安置支撑系统70包括支撑杆405和可伸缩部件410。成像设备30和RFID读取器73被附着到支撑杆405。可伸缩部件410升起或降低支撑杆405，从而允许成像设备30对货架条形码、货架物品以及货架物品上的条形码进行拍照；并且允许RFID读取器73读取在货架、地板、地面上的或相互堆积的货盘(pallet)、硬纸盒(carton)以及物品的RFID标志。在一个实施例中，可伸缩部件410包括展开和压缩的波纹管，由此使支撑杆405垂直地运动。在另一个实施例中，可伸缩的部件410包括套接伸缩式支撑。
图5(图5A、5B)图示了在零售商店里安装系统10的方法500。安装者在商店里安装网络25的无线接入点，以创建无线网络，由此在商店里为移动盘存机器人20提供全网络通信覆盖(步骤505)。安装者将诸如例如回射标志之类的跟踪标志附着到天花板(步骤510)。跟踪系统55使用所述跟踪标志来确定位置。安装者安装用于给供电系统75的电池充电的对接站(未示出)并且将移动盘存机器人20插入所述对接站(步骤515)。在最开始的充电之后，盘存机器人20从那时起可以进行自对接以在需要时自动给自己充电。
安装者经由网络25建立与移动盘存机器人20的通信并且核实系统10(步骤520)。安装者在靠近商店的地板的地方放置路线点，供跟踪系统55用于导航穿过商店(步骤525)。在一个实施例中，所述路线点包括红外发射器。所述路线点提供导航矢量；进行检测以给盘存机器人提供它在商店中的位置的绝对位置方位。安装者在地图绘制系统65中生成包括所述红外路线点的位置的商店地图；所述移动盘存机器人在导航时使用所述地图(步骤530)。安装者通过手工驱动移动盘存机器人20穿过商店的过道、发现跟踪标志和路线点，在地图绘制系统65里建立精确的商店的盘存地图(步骤535)。安装者通过拍摄产品和条形码的图像以及通过检测脱销物品的一个或多个案例来测试成像设备30(步骤540)。
远程操作员经由盘存控制系统15和网络25建立与移动盘存机器人20的通信，其从移动盘存机器人20接收已生成的商店的盘存地图以及附加文件(步骤545)。远程操作员指挥移动盘存机器人20(步骤550)。远程操作员手工地导航所述移动盘存机器人20穿过商店、定义盘存路径、以及生成盘存计划和产品数据库225(步骤555)。
图6图示在针对脱销物品对商店进行盘存时系统10的操作的方法600。系统10开始对零售商店的脱销搜索(步骤605)。成像设备30拍摄货架图像(步骤610)。产品条形码解码器210从已拍摄的图像中解码产品条形码(步骤615)。产品条形码解码器210确定已拍摄的图像是否包括条形码(判决步骤620)。如果不包括，则移动盘存机器人20就将成像设备的帧移动一个宽度(步骤625)。处理返回到步骤610。
如果在判决步骤620处在图像中发现了条形码，则产品图像分段模块205就将已拍摄的图像分段以识别产品的货架图像(步骤630)。盘存控制模块230从产品数据库225中检索产品的视像描述符，所述视像描述符通过所发现的条形码来进行索引(步骤635)。脱销检测器215确定产品数据库225里的产品视像描述符是否与成像设备30所拍摄的货架图像充分匹配(判决步骤640)。如果充分匹配，则盘存控制模块230将所发现的条形码标记为旧的，并且处理返回步骤610(步骤645)。否则，所述产品视像描述符未充分匹配货架图像(判决步骤630)，并且盘存控制模块230针对在所述产品位置所期望的产品设置脱销标记(步骤650)。在一个实施例中，盘存控制模块230发送脱销消息给商店产品订购系统(未示出)。盘存控制模块230将所述条形码标记为旧的(步骤645)并且处理返回到步骤615。将条形码标记成旧的(步骤645)防止在给定的图像中相同的条形码被处理超过一次。相同的条形码可能在另一个图像中出现，当产品被库存在商店的多个位置中时这将会发生。对于那些产品，盘存控制模块230利用地图绘制系统65所提供的位置信息(数据路径未示出)来消除被库存在多个位置处的一种产品间的歧义。在另一个实施例中，通过检测并解码物品上的条形码，识别物品，以及将识别包括形状和颜色的特性的物品放置在产品图像数据库里。
图7(图7A、7B)图示了零售商店里的示例性的货架的图，所述货架在实物盘点期间由系统10进行照相。货架结构705包括货架1：710、货架2：715、以及货架3：720，统称为货架725。货架725中的每个货架包括在其上可以放置条形码标志的前边缘。例如，货架2：715包括前边缘730。前边缘730包括条形码标志，诸如条形码标志735、条形码标志740、条形码标志745以及条形码标志750(统称为条形码标志755)。条形码标志755中的每个都包括条形码、物品名称、以及关于被放置在货架2：715上在对应的条形码标志上面的物品的附加信息。例如，条形码标志735、条形码标志740、条形码标志745以及条形码标志750中的每个分别包括针对物品组760、物品组765、物品组770以及物品组775的条形码。
图7B图示了拍摄物品组770以及条形码标志745的图像的成像设备30。通过使用这个已拍摄的图像，系统10可以对已拍摄的图像分段以检测哪一个产品位于该物品组770里，对在条形码标志745里的条形码进行解码，将在已拍摄的图像里所检测的产品与所述产品的已存储的图像进行匹配，以及核实货架2：715上的该物品组770是否匹配条形码标志745里的条形码。
图8(图8A、8B)图示零售商店里的示例性的货架的图，所述货架在实物盘点期间由系统10进行照相。货架2：715缺失了图7(图7A、7B)中示出的物品组770。图8B图示拍摄在条形码标志745上面的货架2：715的图像的成像设备30。通过使用这个已拍摄的图像，系统10可以确定货架2：715空无物品，对条形码标志740中的条形码进行解码；以及将对应着所述条形码的物品标记为在货架2：715上的该位置处脱销。此外，系统10可以确定条形码标志755之一缺失，并且标记所述缺失的条形码标志的位置，供雇员进行纠正。在一个实施例中，回射810被贴于货架的后墙，并且光源820被安装得充分靠近成像设备30。当在货架上没有任何物品时，来自光源820的光被所述回射材料810朝着成像设备30充分反射，由此提供了指示着脱销状态的明亮的易检测的光信号。
系统10提供了一种用于在仓库或商店里执行物品的实物盘点或循环盘点的方法，该方法比使用雇员、外部审计员等等的传统方法廉价。系统10提供货架上物品的盘点，其可被用于获得货架上的每个物品的重新订购点，而不会引起物品的库存过多的状态。系统10还可以通过提供商店内的所有物品的存货的准确状态来减少缩减，而不会引入人为错误，所述人为错误在使用人作为盘存主体的盘存控制的传统解决方法中是固有的。
图9(图9A、9B)图示了一个实施例，其中移动盘存机器人20C被用于从操作盘存控制系统15C的远程雇员到靠近移动盘存机器人20C的雇员或顾客进行通信。盘存控制系统15C包括控制音频和视像通信系统905，用于发射音频和视像给移动盘存机器人20C以及从移动盘存机器人20C接收音频和视像。移动盘存机器人20C包括机器人音频通信系统910，所述音频通信系统包括音频输入和音频输出(未示出)，用于发射音频给盘存控制系统15C以及从盘存控制系统15C处接收音频。在一个实施例中，使用基于因特网协议的语音传送经由网络25发射音频信号。
在另一个实施例中，控制音频通信系统905包括语音识别系统，其将语音转换成文本、将来自盘存控制系统15C处的雇员的语音音频转换成文本用于发射给移动盘存机器人20C。机器人音频通信系统910使用语音合成将所发射的文本转换成音频。所合成的语音可以为移动盘存机器人20C保持人物角色，并且去掉盘存控制系统15C处的雇员的语音中的任何口音。
盘存机器人20C还可包括可选的触摸屏监视器系统915。触摸屏监视器系统915允许移动盘存机器人20C充当移动顾客信息站，由此向顾客提供诸如产品位置、顾客的当前位置、产品是否被商店库存之类的信息，定位商店雇员，以及其他顾客和雇员服务和职责。成像设备30可提供控制音频和视像通信系统905的视像拍摄功能。触摸屏监视器系统915可提供控制音频和视像通信系统905的视像输出功能。
系统10可以拍摄并发送货架物品布局的图像给不能每日走过整个商店区域的远程商店管理员。系统10还可提供货架物品布局的图像给消费品公司，以确保消费品公司的产品在货架上并且确认产品的放置。确认产品的放置对于验证消费品公司与零售商之间的合约而言特别有用，其中消费品公司为产品放置和促销支付额外费用。
系统10通过检测空货架来识别并消除脱销物品、通过记录货架上所触摸的物品来跟踪顾客的触摸和购买模式、以及提供精确的盘存可见性。系统10针对商店开发了哪些产品位于哪一个货架上的盘存地图，并且使所述地图能够被远程监视。系统10使能了基于真实货架盘存数据和购买有效性的按业绩付费的合同的使用。RFID读取器73使得盘存机器人能够检测并跟踪库房或仓库里的货盘和硬纸盒的位置，由此提供商品在供应链中的更大可视度。RFID读取器73和成像设备30的组合提供了下述方法，供盘存机器人跟踪物品，从它们到达商店或仓库的装卸台到它们储放在货架上以及从货架消失。
从消费品公司或制造商(被称为公司)的观点来看，系统10使公司能够核实已付费货架空间的使用、对销售规划设置的坚持、理想的存货水平、以及在其中产品可以买到的许多商店和商店的位置。系统10允许公司核实在过道中或过道顶端的促销展示，以了解产品最初何时可以买到以及促销持续多久。
对于总额折扣，由系统10生成的统计允许公司基于货架上摆放的物品以及已出售的物品而不是基于运送到配送中心的容器的数目来提供付款。这确保了交易资金被用于在零售链里在公司指定的位置处将产品摆放在顾客面前。
在一个实施例中，系统10可以提供货架上的物品的精确计数。这允许零售商店在货架计数改变没有在销售点交易日志中得到反映时检测偷窃。货架上的物品的精确计数还使能了零售商店的个体级(unit level)的自动盘存。在另一个实施例中，系统10被用于对超市的库房或仓库里的箱子进行盘存，其中所述箱子被标注以条形码、RFID标志、文字打印、或标签的组合。
系统10要求：除了将跟踪标志附着到天花板、地板上的路线点、以及安装用于给移动盘存机器人20充电的对接站之外对商店几乎不产生物理的和美感的影响。系统10使每个商店所需要的初始安装和校准的成本以及工作量最小化。在一个实施例中，校准和维护被远程地执行。通过远程调整，系统10适合于商店的布局的改变而无需在每个商店处的专家支持。
图10图示了生成产品数据库225的方法1000，所述方法开始于步骤1010。成像设备30拍摄货架图像(步骤610)。产品条形码解码器210从已拍摄的图像解码产品条形码(步骤615)。产品图像分段模块205将已拍摄的图像分段以识别所述产品的货架图像(步骤630)。一个或多个产品视像描述符被从产品的已分段的图像中提取(步骤1020)。所述产品视像描述符被放置在产品数据库225里(步骤1030)。如果还有任何未处理的货架条形码(步骤1040)，则所述未处理的货架条形码被解码(步骤615)。如果商店里的所有货架已经都被处理(步骤1050)，则完成产品数据库225的生成(步骤1060)，否则拍摄新的货架图像(步骤610)。
应当理解，已经描述的本发明的各具体实施例仅仅是本发明的原理的某些应用的图解说明。在不偏离本发明的实质和范围的条件下，可以对此处所描述的用于使用移动盘存机器人来执行盘存的系统和方法做许多修改。而且，尽管出于说明的目的仅针对零售商店和仓库里的产品来描述本发明，但是应当清楚，本发明也可应用于例如在其中对物品进行计数或盘存的任何应用中，诸如图书馆、医院、学校或大学、大型宾馆等等。此外，尽管出于说明的目的仅针对货架上存储的产品描述本发明，但是应当清楚，本发明也可应用到以被存储在任意类型的展示里的产品，诸如例如存储在箱柜里、堆里、库棚上、搁物架上、钩子上、笼子里、军事基地、货栈、装卸台、或其他室内或室外环境(包括黑暗的、远程的、荒凉的或危险的环境)等等里的物品。
Claims (24)
1.一种用于通过使用移动盘存机器人对被布置在商店里的众多货架上的带有标识符的产品执行盘存的用处理器实现的方法，所述方法包括：
将所述移动盘存机器人导航穿过所述商店到一货架；
拍摄所述货架的图像；
从已拍摄的货架图像解码产品条形码；
对已拍摄的货架图像分段以检测所述货架上的至少一个产品的图像；
用已解码的产品条形码检索产品视像描述符；
确定所述至少一个产品中的检测图像是否与已检索的产品视像描述符相匹配；以及
当确定所述至少一个产品的检测图像与已检索的产品视像描述符不匹配时，针对对应着已解码的产品条形码的产品设置脱销标记。
2.根据权利要求1所述的方法，其中将所述移动盘存机器人导航穿过所述商店包括定位众多跟踪标志中的至少一个。
3.根据权利要求2所述的方法，其中所述跟踪标志被紧固到所述商店的固定结构以协助所述移动盘存机器人确定所述移动盘存机器人在所述商店内的位置。
4.根据权利要求1所述的方法，其中导航穿过所述商店进一步包括使用所述商店的盘存地图。
5.根据权利要求4所述的方法，进一步包括通过手工地导航所述移动盘存机器人穿过所述商店来生成所述商店的盘存地图，目的是识别所述货架上的产品的标识符和位置。
6.根据权利要求1所述的方法，其中用已解码的产品条形码检索产品视像描述符包括生成产品数据库，所述产品数据库包含以下列表：产品、产品的位置、以及产品的标识符。
7.根据权利要求6所述的方法，其中生成所述产品数据库包括：
拍摄货架的图像；
从已拍摄的货架图像中解码产品条形码；
对已拍摄的货架图像分段以检测所述货架上的至少一个产品的图像；
提取产品图像的产品视像描述符，其中从下面中的任何一个或多个中选择所述产品视像描述符：产品的一列图像、产品的大小、产品的形状、产品的颜色、产品的条形码和产品的质地；以及
将所述产品视像描述符放置进产品数据库里。
8.根据权利要求1所述的方法，其中拍摄所述货架的图像由成像设备来执行。
9.根据权利要求8所述的方法，进一步包括利用位于所述成像设备附近的光源以及位于紧靠所述货架的后墙的回射材料指示脱销状态，其中当没有任何产品位于所述货架上时产生被反射的光信号，以指示脱销状态。
10.根据权利要求8所述的方法，其中所述成像设备被安装在能够使所述成像设备垂直运动的可伸缩的部分上，目的是在不同高度处给所述货架上的产品照相。
11.根据权利要求1所述的方法，其中所述移动盘存机器人由远程操作员来控制。
12.根据权利要求11所述的方法，其中所述移动盘存机器人包括音频输入和音频输出以使所述远程操作员能够与靠近所述移动盘存机器人的人员交谈。
13.根据权利要求1所述的方法，其中从产品的一列图像、产品的大小、产品的颜色、和产品的质地中的任何一个或多个中选择所述产品视像描述符。
14.一种用于通过使用移动盘存机器人对被布置在商店里的众多货架上的带有标识符的产品执行盘存的用处理器实现的系统，所述系统包括：
用于将所述移动盘存机器人导航穿过所述商店到一货架的跟踪系统；
用于拍摄所述货架的图像的成像设备；
用于从已拍摄的货架图像解码产品条形码的解码器；
用于对已拍摄的货架图像分段以检测所述货架上的至少一个产品的图像的产品图像分段模块；
用于用已解码的产品条形码检索产品视像描述符的盘存控制模块；
用于确定所述至少一个产品中的检测图像是否与已检索的产品视像描述符相匹配的脱销检测器；以及
当确定所述至少一个产品的检测图像与已检索的产品视像描述符不匹配时，所述盘存控制模块针对对应着已解码的产品条形码的产品设置脱销标记。
15.根据权利要求14所述的系统，其中所述跟踪系统通过定位众多跟踪标志中的至少一个来将所述移动盘存机器人导航穿过所述商店。
16.根据权利要求15所述的系统，其中所述跟踪标志被紧固到所述商店的固定结构以协助所述移动盘存机器人确定所述移动盘存机器人在所述商店内的位置。
17.根据权利要求14所述的系统，其中所述跟踪系统使用所述商店的盘存地图来导航穿过所述商店。
18.根据权利要求17所述的系统，进一步包括地图绘制系统，用于通过使用手工控制系统来手工地导航所述移动盘存机器人穿过所述商店来生成所述商店的盘存地图，目的是识别所述货架上的产品的标识符和位置。
19.根据权利要求14所述的系统，其中所述盘存控制模块通过生成包括产品、产品的位置、以及产品的标识符的列表的产品数据库来用已解码的产品条形码检索产品视像描述符。
20.根据权利要求19所述的系统，其中生成所述产品数据库包括：
所述成像设备拍摄货架的图像；
所述解码器从已拍摄的货架图像中解码产品条形码；
所述产品图像分段模块对已拍摄的货架图像分段以检测所述货架上的至少一个产品的图像；
提取产品图像的产品视像描述符，其中从下面中的任何一个或多个中选择所述产品视像描述符：产品的一列图像、产品的大小、产品的形状、产品的颜色、产品的条形码和产品的质地；以及
将所述产品视像描述符放置进产品数据库里。
21.根据权利要求14所述的系统，进一步包括位于所述成像设备附近的光源；以及
位于紧靠所述货架的后墙的回射材料，由此当没有任何产品位于所述货架上时产生被反射的光信号，以指示脱销状态。
22.根据权利要求14所述的系统，其中所述成像设备被安装在能够使所述成像设备垂直运动的可伸缩的部分上，目的是在不同高度处给所述货架上的产品照相。
23.根据权利要求14所述的系统，其中所述移动盘存机器人由远程操作员来控制。
24.根据权利要求23所述的系统，其中所述移动盘存机器人包括音频输入和音频输出以使所述远程操作员能够与靠近所述移动盘存机器人的人员交谈；以及
其中从产品的一列图像、产品的大小、产品的颜色、和产品的质地中的任何一个或多个中选择所述产品视像描述符。
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| US11/534,162 | 2006-09-21 | ||
| US11/534,162 US7693757B2 (en) | 2006-09-21 | 2006-09-21 | System and method for performing inventory using a mobile inventory robot |
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| CN101149792B true CN101149792B (zh) | 2010-06-23 |
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Also Published As
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| US20080077511A1 (en) | 2008-03-27 |
| US7693757B2 (en) | 2010-04-06 |
| CN101149792A (zh) | 2008-03-26 |
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