GB2541502A

GB2541502A - An inventory system

Info

Publication number: GB2541502A
Application number: GB1610549.6A
Authority: GB
Inventors: Patel Himanshu
Original assignee: Himanshu Rasikbhai Patel
Current assignee: Himanshu Rasikbhai Patel
Priority date: 2015-06-17
Filing date: 2016-06-17
Publication date: 2017-02-22
Also published as: GB201610549D0; GB201510613D0

Abstract

An inventory system comprising a plurality of stations 3 for receiving and temporarily storing items, means associated with each station for sensing delivery of an item to a station or removal therefrom and means for transmitting this information to a remote controller which stores data relating to the time of delivery or removal of the item, wherein the sensing means 2, according to a first aspect of the invention, includes first and second sensors arranged to detect displacement of the item sequentially, the order of detection being indicative of either a delivery of the item to the station or a removal therefrom. The first and second sensors are preferably infrared sensors. According to a second aspect, the sensing means includes a pressure pad arranged to detect placement or removal of an item. The inventory system may further include a recorder with a memory, a counter and a display 4. Thus information which may also be sent to the controller, preferably wirelessly, and stored in a database for subsequent retrieval, analysis and display, includes the location of an item, i.e. the station where the item is/was located, and the number of items at a station.

Description

An inventory system

Field of the Invention

The present invention relates to an inventory system that registers and counts items being placed in and removed from a particular individual location.

Background

There are a number of industries in which it is necessary to sort individual items into different locations depending on their individual classification, and to monitor the items as they are classified, and moved from one location to another.

For example, courier companies or postal companies deal with a high volume of individual and individually classified items, each of which passes through a centralised location (a central hub or a sub-hub) before delivery to an individual address.

Packages may be sorted by a general area location (for example a post code or zip code, group of post codes, town or county, so that an optimal number of items or objects can be shipped together from a central area or hub to a local distribution warehouse or somewhere more convenient.

In a warehouse environment, where stock is removed and replaced by new stock regularly, it is useful for managers to know the location and numbers of individual stock items and the location where they are placed and/or from where they are removed, for example from warehouse shelving. A variety of stock counting systems are well known and commercially available. Generally any counting system provides the number of counts. These systems may be built and configured as data collection transceivers. One example is an infrared beam sensor based system. As people or objects pass an infra-red sensor, the sensor detects the movement and stores this data as a 'counted item or person'. Each individual unit may include a user interface where a user can access, analyse and manipulate counting units

However, counting units such as are known in the art generally do not communicate with one another and exchange data. Therefore, although a warehouse, sorting office or similar system may have a number of individual units in use; these are not connected to a network and cannot communicate with one another, so a user cannot access collected data by any particular individual unit from a central location. Furthermore, counting units such as are known in the art are not usually configured for two-way communication, so it is not possible to send a request from one location in order to enquire if a particular item that is at another location.

Prior Art US7134595 (Clark et al) describes and shows a people counting system including: a first people counting data collection unit configured to store a first set of people count data; and a second people counting data collection unit configured to store a second set of people count data. W02009006306 (American Distributors Inc) describes and shows a networked optoelectronic sensor for detecting and counting objects. The sensor can count objects and/or people passing by the sensor, and can record both the direction of travel of the people and/or objects as well as the distance between the sensor and person and/or object. US5404384 (Medselect Systems Inc) describes and shows an inventory monitoring apparatus capable of real-time counting of objects added to or subtracted from a location whose inventory is to be monitored. The apparatus includes structure for supporting a plurality of objects and a lever adapted to be contacted and displaced by movement of the objects moving to and from a supporting structure. W09622553 (Shelley et al) describes and shows an improved method and apparatus for rapidly, accurately and inexpensively counting stacked objects, preferably by imaging, from below, a stack of flat objects which is standing on its side, preferably on its long side. The objects need not be identical in surface appearance or in configuration. The objects preferably are substantially any size or thickness. GB2307560 (Minibar Production Ltd) discloses an open shelf bar arrangement for a hotel with each shelf for receiving items, weight sensors for detecting items and means for transmitting data from the weight sensors to a central processor. GB2135292 (Minibar Ltd) discloses a dispensing apparatus connected to a computer. W096/31833 (Cowe et al.) discloses a materials monitoring system for automatically sensing the presence and number of items stored in a storage volume.

Summary of the Invention

According to the present invention there is provided an inventory system comprising: a plurality of stations for receiving and temporarily storing an item, the stations are positioned at different locations, associated with each station is a sensing means for sensing delivery and removal of the item, the sensing means includes first and second sensors arranged to detect displacement of the item sequentially, each sensor generating a signal, the order of generation of the signals being indicative of either a delivery status of the item to the station or a removal status of the item from the station; and a transmitter transmits the delivery status and removal status of the item to a remote controller which stores data relating to the time of delivery of the item at the location and the time of removal of the item from the station.

It will be appreciated that the invention aids in locating the items, and displaying resulting data locally. The system can also be connected to a network so that object data can be transmitted to a remote hub.

In this way the location of items can be tracked, for example in a warehouse or shop floor. Additionally it is possible to monitor a user’s activity, for example a user may be assigned to a station and the number of item movements can be tracked. This could aid with performance reviews of users and an indication of efficiency of a company.

In contrast to the prior art systems therefore, the present invention provides an inventory system where the numbers of items entering and leaving a monitored location are counted, and where the count information is both displayed locally and transmitted to other locations in a network where it can be remotely accessed and monitored so enabling real-time tracking to be performed.

The advantage of the inclusion of a display screen is that data relating to a location can be monitored directly locally.

Preferably the remote controller is connected to a central workstation, such as a computer, tablet or smart phone to that collated data from the stations can be managed and analysed.

Preferably the inventory system includes a recorder with a memory means for recording the signals received at the remote controller. In this way data collected can be logged. For example the recorder records the time of receipt and source (location) of the signals received at the remote controller.

Preferably the inventory system includes a counter to count the number of items at each location. In this way the number of items in any location can be recorded and displayed, enabling a real time inventory to be held over multiple locations.

The display may be switched to display a number of menus, one of which displays the number of items at a location. The locations may be indicated on a map or shown as listed items at known locations.

In some preferred embodiments the system includes a means of identifying an item at a location. In this way the system can distinguish items providing an enhanced inventory system. Furthermore the system enables items identified in an incorrect location to be flagged so that corrective steps can be made.

In some embodiments the sensing means includes an infrared sensor.

Typically the infrared sensor includes an infrared source which generates an infrared beam that is detected by an infrared sensor such that a delivery status signal and a removal status signal are generated in dependence of interruption of the infrared beam.

In some embodiments, the sensing means comprises an infrared transmitter and sensor, and a reflector, configured so that in use the infrared transmitter and sensor transmits an infrared beam that is reflected to the sensor, and wherein interruption of the beam indicates that an item has been placed in and/or removed from a location. This provides a simple, readily available and effective sensing means. By inclusion of the reflector this may enable the beam to be deflected and a single transmitter and sensor to be used to detect delivery and removal.

According to another aspect of the invention the inventory system comprises: a plurality of stations for receiving and temporarily storing an item, the stations are positioned at different locations, associated with each station is a sensing means for sensing delivery and removal of the item, the sensing means includes a pressure pad arranged to detect displacement of the item and to generate a signal indicative of either a delivery status of the item to the station or a removal status of the item from the station; and a transmitter transmits the delivery status and removal status of the item to a remote controller which stores data relating to the time of delivery of the item at the location and the time of removal of the item from the station.

In this way presence or absence of an item is detected by the pressure pad.

Optionally the system may be programmed to identify a specific item by its weight. Details of the weights of items are ideally stored on a database.

Preferably distributed stations and the remote controller are in wireless communication. This enables flexibility in location of the stations. In some other embodiments the station and remote controller may be connected with a hard wired copper or optical connection.

In some embodiments the system may include a scanning unit configured to scan items and transmit scanned data relating to the item to the remote controller.

For example a scanning means such as a hand scanning unit configured to scan items within the location and transmit data relating to the scan to the controller may be provided so that an operator can acquire data from a package. This provides a backup and/or an alternative to the main sensing means.

In some embodiments the inventory system may include a means of data entry such as a scanning means and/or a camera and/or a keypad. In this way data can be input to the system, such as item details, for example type of item, number of items, delivery date, originators address as well as other data associated with a package or its contents.

It may also be possible to input user details in order to monitor a user or team of users. For example by inputting a user’s name or user ID on to the system it may be possible to link users or a team of users to selected stations.

Typically the data entry may be enabled via a work station that is connected to the remote controller, thereby permitting interconnection of all stations in the network.

Data may relate to identification of the item, its source location, its destination location and/or a sensor location so as to provide location identification information.

In some preferred embodiments the system includes a database which receives and stores data from at least one remote controller in order to collate and store data for subsequent retrieval and analysis.

In some embodiments the system may also communicate with external databases to enable analysis of data held.

For example the system may be connected to a remote database to enable data collected by the inventory system to be cross referenced with other data. For example data collected relating to an item, such as from a barcode, may be cross referenced with a remote database that holds barcode information so that the type or nature of an item can be identified.

The remote controller may include at least one port configured for hardwire connection for transmitting and receiving data. This allows the remote controller to be connected to a network and/or database for receiving and transmitting data.

The port may be a USB port. The port could be an RS232, RS485, or RJ45 port, or any other suitable port.

In preferred embodiments the display is a liquid crystal display screen (LCD) screen.

In some embodiments the display may be integrated with the remote controller.

In other embodiments the display is separate to the remote controller. This allows the display means to be located remotely from the remote controller.

In some embodiments the system includes at least one indicator to indicate when items are acknowledged as received or removed. For example a brightly coloured light or audible alert may indicate that the item has been detected by the sensing means. This allows a user to quickly and easily note that an item entering or exiting the station has been registered by the system and correctly counted.

The indicator is typically in the form of an alert, such as a light, sound or vibration. For example the system may include a light emitting diode (LED) as an indicator.

In some embodiments two indicators may be provided, one to note if an item is identified by the system and a second indicator to indicate if the item has not been identified by the system.

In this way, if for example the scanner has not identified the type of item as it was received the indicator will be lit and a user will know to re-present the item.

Typically the indicators are associated with the station.

In some embodiments the indicators may be shown on the display, highlighting items that have not been identified but may have been noted as removed or received.

In some cases an intermediary unit or hub may also form part of the system. For example intermediary hubs may be provided for each department of a warehouse and all intermediary hubs feed into a central hub.

In another embodiment a main hub database is configured to relay and receive item location requests, and to transmit data indicative of the presence/absence/location of a particular item. Typically the main hub database may be connected to, or integrated with the work station that is connected to the remote controller. This allows a user to transmit an item location query relating to any point in the network, and to receive an answer.

It is appreciated that in some embodiments the controller could be integrated with the station. However to reduce costs the controller is preferably remote from the stations and capable of receiving inputs from multiple stations as described above.

Preferred embodiments of the inventory system will now be described with reference to the Figures in which.

Brief Description of Figures

Figure 1A shows a perspective view from above and to one side of a station for use with the inventory system.

Figure 1B shows the station of Figure 1 showing the display located remotely, a cable connects the station and the display so that data can be transmitted from the station to the display;

Figure 1C shows a perspective view from below station shown in Figures 1A and 1B and depicts details of a sensor connected to the underside of a controller;

Figure 2 shows a storage rack with multiple shelves divided into discrete locations for receiving items such as parcels, each location is fitted with a station;

Figure 3 shows a schematic view of a number of networked stations connected to a controller and a display;

Figure 4 shows a schematic view of an inventory system;

Figure 5 shows a different embodiment of the station; and Figure 6 shows a third embodiment of an inventory system.

Detailed Description of Figures

Figure 1A shows a station 3 with a display 4. The station 3 has a sensing means 2 that is configured to sense items (not shown) being placed in and removed from the station 3. Groups of stations 3 in use are connected to a remote controller (shown in Figure 3).

In Figures 1B and 1C the stations 3 are shown with the display 4 detached from the station 3 and connected by a wire 7. The display 4 is separate to and separable from the station 3 so that the display 4 can be located remotely from the station 3 and associated sensor 2. The station 3 and display 4 are connected via a cable 7 so that information can be transmitted between the easily and quickly.

This enables the station 3 and display 4 to be provided as a single unit whilst the display and station can be located separately depending on use.

The stations 3 shown in Figures 1A, 1B and 1C have two sensors 2 for detecting items and a display 4 configured to display data relating items to include number of items and location of items.

The stations 3 have infrared sensors 2. In use, an infrared beam is transmitted towards a surface upon which an item (not shown) is added to or from where the item is removed.

The two sensors 2 are located on an underside of the station 3. The sensors 2 are arranged in a line (sequentially) so that an item must pass through both sensors when being received at or removed from the station 3. In this way it is possible to determine if an item is added or removed from the station 3 by the order or sequence in which the sensors 2 detect the items.

In use ideally the sensors 2 are placed in a discrete location and set up so that in normal use the beam generated by the infrared sensor 2 is always interrupted by an item thereby indicating that something has passed through or broken the beam, which is indicative that an item has been placed in, or removed from, the station 3.

When the sensor 2 detects an item the sensor 2 transmits a signal from the station 3 to the controller 1, which is configured to receive the data transmitted by the sensor 2. The signal denotes the delivery status and removal status of the item to the remote controller which stores data relating to the time of delivery of the item at the location and the time of removal of the item from the station 3.

The controller 1 has a memory means (not shown).

The controller 1 typically comprises a computer terminal or dedicated CPU processor configured to monitor and record the item placement and removal data as this is received from the sensor 2.

The display 4 has an LCD screen. The display 4 detachably connects to the front of the station 3. This allows reasonably complex data to be displayed, such as the designation of the particular area being monitored (a name or number), total count data, and potentially a breakdown of same.

In order to assist with preventing miscounting or recoding of items, an indicator LED 5, 6 is provided (see Figure 1).

The station has two indicators 5, 6. Indicator 5 is lit if an item is confirmed as received. Indicator LED 6 is lit if an item is not identified by the sensor when presented. For example if an item was presented too quickly and not detected by the sensor.

The LED indicators are provided outside of or separate to the display screen forming part of the display 4.

The LED indicators illuminate to alert a user quickly and easily as to whether an item entering or exiting the monitored area of the station has or has not been registered and if the action should be repeated.

In some embodiments the indicator may be accompanied by a buzzer or similar audio indicator if required.

Figure 3 shows a number of stations 1 connected one each to a number of discrete areas on a shelving unit. The displays 4 are mounted to the front of the shelves, with the stations 3 and sensors 2 on the undersides of the shelves.

Reflecting strips 10 are provided on the shelf below.

The stations 3 are networked either wirelessly or via a hardline connection, as shown schematically in Figure 3 to form the inventory system 100.

Each station 3 and its associated shelf space forms a node within the network.

All stations 3 are connected to the controller 1. A main hub database 8 in the form of a workstation is connected to the controller 1 so that data collected from all stations is collated. A user can interrogate the hub database 8 to track items moving on and off the shelves. The hub database 8 is further configured to relay and receive item location requests, and to transmit data indicative of the presence or absence of a particular item. A user can interrogate the network via the hub 8 to track a particular item and to see where it is within the network (i.e. what particular shelf it might be on). This allows multiple stations 1 to be networked, and for item location requests to be sent and received at each system so that the location of individual items can be more easily monitored.

In alternative forms, the stations form a distributed control system for the network. A user can use any of the stations 3 as an interface, viewing data via the display 4, and plugging in wirelessly or via the port to transmit commands and data, or to receive further information to a remote viewer.

As an addition to the system described above, a hand scanning unit (not shown) can also be used, configured to scan items within the location and transmit data relating to the scan to the controller 1. This provides a backup and/or alternative to the main sensors 2.

Figure 4 shows a second embodiment of the inventory system 200. The system 200 includes a multiplexer 11 for selecting input signals and forwarding the selected input into a single line. For example this enables inputs from multiple controllers to be received and data signals passed to the database/workstation 8.

Figure 5 shows an alternative embodiment of a station 3. The station 3 includes a sensor 2, a screen 4 integrate with the station and two ports 12. This embodiment of the station has an inbuilt controller. Therefore the station transmits directly to the main database.

Figure 6A shows a network of stations 3, each station associated with a desk to provide an inventory system 300. Each station can receive items 13 or have items 13 removed from the station. Data collected from each station relating to the delivery status or the removal status is transmitted to a first controller 1A. Data collected from other stations 3A is fed back to a second controller 1B.

It is appreciated that all controllers 1A, 1B may feed into a central workstation (not shown).

Figure 6B shows a station connected to a data inputting device 9, such as a handheld scanning unit or smart phone. In this way the identification details of the item that are detected by the scanner can be input to the inventory system. The inputting device may be wired or wirelessly connected.

The invention has been described by way of examples only and it will be appreciated that variation may be made to the above-mentioned embodiments without departing from the scope of invention with reference to the claims.

Claims

1. An inventory system comprises: a plurality of stations for receiving and temporarily storing an item, the stations are positioned at different locations, associated with each station is a sensing means for sensing delivery and removal of the item, the sensing means includes first and second sensors arranged to detect displacement of the item sequentially, each sensor generating a signal, the order of generation of the signals being indicative of either a delivery status of the item to the station or a removal status of the item from the station; and a transmitter transmits the delivery status and removal status of the item to a remote controller which stores data relating to the time of delivery of the item at the location and the time of removal of the item from the station.

2. An inventory system according to claim 1 includes a recorder with a memory means for recording the signals received at the remote controller.

3. An inventory system according to claim 2 wherein the recorder records the time of receipt and source of the signals received at the remote controller.

4. An inventory system according to any preceding claim includes a counter to count the number of items at each location.

5. An inventory system according to any preceding claim includes a display that displays number of items at a location.

6. An inventory system according to any preceding claim wherein the system includes a means of identifying an item at a location.

7. An inventory system according to any preceding claim wherein the sensing means is an infrared sensor.

8. An inventory system according to claim 7 wherein the infrared sensor includes an infrared source which generates an infrared beam that is detected by an infrared sensor such that a delivery status signal and a removal status signal are generated in dependence of interruption of the beam.

9. An inventory system comprises: a plurality of stations for receiving and temporarily storing an item, the stations are positioned at different locations, associated with each station is a sensing means for sensing delivery and removal of the item, the sensing means includes a pressure pad arranged to detect displacement of the item and to generate a signal indicative of either a delivery status of the item to the station or a removal status of the item from the station; and a transmitter transmits the delivery status and removal status of the item to a remote controller which stores data relating to the time of delivery of the item at the location and the time of removal of the item from the station.

10. An inventory system according to claim 9 includes a recorder with a memory means for recording the signals received at the remote controller.

11. An inventory system according to claim 10 wherein the recorder records the time of receipt and source of the signals received at the remote controller.

12. An inventory system according to any of claims 9 to 11 includes a counter to count the number of items at each location.

13. An inventory system according to any of claims 9 to 12 includes a display that displays number of items at a location.

14. An inventory system according to any of claims 9 to 13 wherein the system includes a means of identifying an item at a location.

15. An inventory system according to any preceding claim wherein the stations and remote controller are in wireless communication.

16. An inventory system according to any preceding claim includes a database which receives and stores data from at least one remote controller in order to collate and store data for subsequent retrieval and analysis.

17. An inventory system according to any preceding claim includes a scanning unit configured to scan items and transmit scanned data relating to the item to the remote controller.

18. An inventory system substantially as herein described with reference to the figures.