WO2008061253A2 - Système et procédé de stockage, de gestion des stocks et de sécurité - Google Patents

Système et procédé de stockage, de gestion des stocks et de sécurité Download PDF

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Publication number
WO2008061253A2
WO2008061253A2 PCT/US2007/085032 US2007085032W WO2008061253A2 WO 2008061253 A2 WO2008061253 A2 WO 2008061253A2 US 2007085032 W US2007085032 W US 2007085032W WO 2008061253 A2 WO2008061253 A2 WO 2008061253A2
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WIPO (PCT)
Prior art keywords
compartment
compartments
loading
movement
frame
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Application number
PCT/US2007/085032
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English (en)
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WO2008061253A3 (fr
Inventor
Rogers F. Brackmann
Dennis J. Kossnar
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Private Pallet Security Systems, Llc
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Application filed by Private Pallet Security Systems, Llc filed Critical Private Pallet Security Systems, Llc
Publication of WO2008061253A2 publication Critical patent/WO2008061253A2/fr
Publication of WO2008061253A3 publication Critical patent/WO2008061253A3/fr

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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Definitions

  • the invention relates to the field of warehouse and retail back room storage, inventory control and security systems, and more particularly to an apparatus system comprising a motorized, automated, multi-level, multi-row and multi-column array of storage compartments, typically platforms, cages and shelves, which system includes computerized access, retrieval and inventory tracking and security systems.
  • the inventive storage system comprises a 3 -dimensional array of the storage compartments mounted on special, motorized storage rack structures, which permit sequential, floor-level, standing level or wheel chair level access for loading/unloading of the compartments, which are then elevated to raised storage levels and moved back into one or more vertical rows.
  • Retail store back rooms are used for inventory storage until space is available on the selling floor shelving.
  • Most retail stores employ heavy steel rack storage shelving in their back rooms which provide from 2 - 6 levels of storage, typically within in a 12 - 24' ceiling height.
  • the goods come in by distribution truck on pallets, and the boxes are often stretch-wrapped with plastic to maintain the integrity of the stack.
  • pallets are often stacked one on top of another when the pallets are well wrapped and the goods are not fragile.
  • the retail "stackers" continuously move, rearrange and break down the pallets and distribute the goods to the selling floor.
  • the invention comprises a motorized, automated, multi-level storage compartment storage and retrieval system which includes computerized access, retrieval, security and inventory tracking systems.
  • the inventive storage systems include vertically oriented columns of storage compartment units mounted on special, motorized storage rack structures, which permit floor-level, standing level or wheel chair level access for loading/unloading of specially designed storage bins, cages, pallets, or shelves, which are then sequentially elevated to raised storage levels and moved back to multiple vertical rows behind the front face row of the storage bins.
  • the storage compartments herein called "bins" in a genetic sense, range in size from pallet sized cages or platforms on which pallets can be rolled, to shelving.
  • the motorized bin moving system mounted in the storage rack structures can include chain drive carousels, guide tracks for powered wheels on the bins, or bins configured with grooved wheels to roll laterally on other bin structures on which they rest, with screw drive lifters to raise and lower the bins from one level to the next.
  • the pallets or bins include an identifier device or indicia that is trackable from the rack or from the individual cages, so that the pallets are automatically inventoried remotely from an administrative office in real time.
  • each pallet includes a unique bar code identifier that is manually scanned, or preferably automatically scanned as the pallet is being loaded into the cage.
  • each cage includes a bar code scanner that reads the pallet identifier, and communicates the scanned information to a central computer, by hard wire, RF (WiFi or Bluetooth), IR, fiber optic or other transmission links.
  • the pallets include RFID transducers, or other electronically detectable identification elements, that are proximity scanned as the pallet is loaded into the cages. In these cases, the tracking of when and where the pallets are loaded into the inventive storage assembly is accomplished.
  • the inventive storage system is addressable, in that the computer database includes the pallet inventory cross-referenced to the unique address array of row and cage numbers.
  • the drive motors of the carousel can be initialized (started) and controlled to bring any chosen cage in any chosen row to the #1 position for unloading.
  • the pallet bar code or RFID includes data on what is on the pallet, e.g., 1 gross of men's jeans of selected sizes (per a known PO number or packing slip), 2 gross of women's: skirts, 10 CD players, etc.
  • the manager or inventory clerk can select the item, and the computer system locates the pallet, identifies the row, and brings the cage to the #1 position for the stocker.
  • the inventive storage system can use dedicated sealed pallet boxes fitted with receiver elements. The receivers click into hangar systems on the carousel chain drive, (which correspond to hanging hardware fitted underneath delivery semi-trailers). This type of sealed boxes also can be stacked like pallets inside trucks.
  • the array of frames is placed against a warehouse wall, and access to the cages is always via Position 1, at the "front" of the frame, away from the wall.
  • Each cage has a front, lower wall, at least one angled side wall side (as seen in the side view), and a high back wall, designed to fit within the frame and prevent goods from being pushed or fall out the back of the cage.
  • the cages may be a simple U-shaped bin which include a floor, two spaced side walls, and a top bar or top cage structure that joins and supports the side walls (or is supported by them). This permits access to the cages from either Position 1 or 8 as the cages are lowered to floor level on either side of the framework.
  • the front and back of the cage may have a wall that is hinged at the top so the access is provided by raising the screen wall facing outwardly - the front of the cage in the #1 position, the rear of the #8 cage.
  • the storage container units comprise shelving, where sections of shelving move to create alternate aisles for storing and retrieving goods from shelves, which are approximately 13" deep by 13" high (distance between adjacent shelves) by 4' long.
  • the currently available shelf systems are 6 or 8 shelves high and require storing or retrieving products by bending or stooping, or from stools/ladders. This is questionable ergonomically and certainly not ADA compliant, hi the inventive system move vertically as in the bin/cage system embodiments above. They also move horizontally employing the multiple Row and Level aspect of the inventive system. This allows shelves to be moved to any selected height (Level) to better accommodate any user thereby overcoming a need to stoop, climb, or go through other gyrations to assist retrieval and storage functions.
  • the system is accompanied by a wheeled retrieval "cart” that is height adjustable to accommodate standing or wheel-chair bound system users.
  • Fig. IA is a schematic isometric view of the nomenclature for identifying cages and array location addresses.
  • Fig. IB is a side view of the motorized track and cages showing an alternate position nomenclature.
  • Figs. 2a through 2g are schematic progression of the shuttle movement of the cages in calling a particular one from the position AII-2 to the on-load/off-load position AII-I.
  • Figs. 3a through 3c are illustrations of a gear train embodiment of the cage drive system.
  • Figs. 4a through 4d are a related series of front and side elevations of a cage configuration having top rails and grooved wheels so that the cages roll horizontally on cages beneath them on which they rest, or on floor level rails.
  • Figs. 5 and 6 are an isometric view and a side view schematic, respectively of an alternate embodiment employing a carousel drive.
  • Figs. 7a -7c are a series sowing the cage for the carousel system of Figs. 5 and 6.
  • Fig. 8 is an isometric of an alternative configuration of the cage for the carousel system of Figs. 5 and 6, that permits both front and back access.
  • Fig. 9 is a system diagram of one embodiment of the present invention.
  • Fig. 10 is a functional diagram of one embodiment of the present invention.
  • Fig. 11 is a perspective drawing of one embodiment of an adjustable height cart which can be used as a part of the system and method of the present invention.
  • Fig. 12 is a flow chart of one embodiment of the process of storing and retrieving a plurality of compartments for holding items of the present invention.
  • Fig. 13 is a flow chart of another embodiment of the process of storing and retrieving a plurality of compartments for holding items of the present invention.
  • Fig. 14 is a flow chart of another embodiment of the process of storing and retrieving a plurality of compartments for holding items of the present invention.
  • FIG. Ia illustrates the nomenclature for the addressable array of bins.
  • each frame is identified with a Column letter, and in this example, is two Rows deep and is four Levels high.
  • Each cage of each column and row has a cage number.
  • each unique numbered bin or stored pallet will have at a given time a unique Storage Location defined by the Column, Row and Level numbers, thus; AI-3, Dl 1-4, etc.
  • Bin 2345 is at CIII-5. hi operation, an empty cage is rotated to the lowest, forward position, called the #1 position.
  • the cage is then loaded with a low-rise forklift, a pallet jack of other transfer device, hi one alternate embodiment, the cages can include screen doors front or/and back to close the cage.
  • Figure Ia applies a second identification system, an alpha-numeric system for a shelf-type storage system, considering a single Column, front to back from right to left in the figure.
  • the spaces with the large X in them are the empty spaces for each pair of Rows.
  • there are 6 levels, and the useful storage bins are numbered 1 - 11 in Rows I and 11, 1 A and 1 IA in Rows III and IV, and IB - IIB in Rows V and VI.
  • a plurality of vertical, columns of modular storage rack frames e.g., 5' wide x 8-10'deep x 15-25' high are arrayed side- by-side the width of the storage area to be served.
  • the height is selected in increments of 4-5' to fit the available ceiling height of the back room storage area.
  • a drive system is secured to the rack structure to move the cages, each large enough to carry a pallet load, so that the cage interior dimension is on the order of 48" wide, by 5' deep by 4-5' high.
  • a typical system storage configuration is:
  • a double 5' x 5' front to back foot print (that is Rows I and II). Cubes/bins/cages of 4' x 4' x4' interior space.
  • Cubes 4 high on the adjacent 5' space all 4 Levels filled in Row II). Cubes rotate in either direction upon demand.
  • the drive system comprises a vertical up/down elevator system, with the horizontal top and bottom movement being accomplished by moving the bins or cages on rails.
  • the rails are formed, for example, by L-shaped brackets secured to the sides of the cages, so that the cage below the top level supports the moving cage on the top level in its horizontal movement.
  • the cages roll on rails embedded in the floor, or spanning the front to back of the lowest rack plate.
  • An alternate rail system is inverted angle iron, which form an inverted V-track, on which grooved wheels attached to the carts can roll.
  • the cages/bins can be moved horizontally by any number of motive system, such as powered rollers on or engaging the carts, chain drive, hydraulic pushers, or the like.
  • the vertical elevator system in one embodiment comprises a screw drive comprising a powered, grooved vertical shaft that engages pins on the sides of the compartments, such as cages/bins. When the cage is in position, the pins engage the grooves, and the shaft, when turning in one direction lifts the cages, and when reversed lowers them. [0027] In all cases, in this embodiment, there is a single empty address location in the array of the column. Thus, in a column with 6 levels high, the AI-6 location has no cage or bin.
  • the elevator To retrieve the cage/bin at location AII-3, the elevator lifts the bins in the A Column, Row 1, Levels 1-5 up one space so that the empty position is now at the AI-I position.
  • the rear bottom cage at AII-I moves horizontally forward to the AI-I position, then the elevator moves all the Row II column AII-2 through 6 bins down one space. Then the AI-6 cage can be moved horizontally back to the II Row.
  • This shuttle movement continues step-wise until the original AII-3 position cage arrives at AI-I . If it is desired to load or unload that cage or bin at it higher than floor level position, the shuttle motion is continued until the selected cage is at the desired level, say AI-2 or 3.
  • Fig 2a through 2g is a side elevation view of the A Column, of a structure that has two Rows and four Levels.
  • the horizontal and vertical motions are gear driven.
  • the yellow bin needs to be moved from AII-2 to AI-I for unloading, that is clockwise.
  • the empty cell is at AII-3.
  • the yellow bin and the one just below it move upward one level so the empty cell is now at AII-I, as seen in Fig 2c.
  • the AI-I bin moves into the empty space, the three bins above it move down in the I Row, and the bin above the yellow one moves horizontally from AII-4 to Al -4.
  • the yellow bin has transited up to the AII-4 level, then horizontally to the AI-4 level and the space is at AII-4, as seen in Fig. 2d.
  • the yellow bin is starting its descent, and the bin at the AI-I level is moving horizontally on the horizontal gear drive, shown in red.
  • the vertical elevator drive is shown in green, and the structural framework is in black.
  • the yellow bin is descending to the AI-I level, and in Fig. 2g, the bin (here a pallet) is off-loaded and the cycle is complete.
  • Figs 3a - 3e illustrate additional features of this gear-train drive embodiment.
  • the structure is designed for warehouse type stores, such as Costco, Home Depot or Lowes, and is 21' 6' tall. It is powered by 2 electric motors riding on a side track to control different gear trains at different times.
  • the bins are sized to allow loading of product 52" wide, 48" high and 48" deep.
  • Fig 3a shows a 3D layout of a two Row structure, in which each shelf or bin is able to support 2000 lbs. Since the drive is bi-directional, the product can be recalled from any location. The user selects the desired product, typically on a screen display mounted in association with the rack system array.
  • Fig 3 a identifies the upper and lower horizontal gear trains and the vertical elevator gear trains.
  • Fig 3b is an enlargement showing gear tracks on the sides and bottom of the product cage, and a gondola upper support cradle, best seen in Fig 3d.
  • Fig 3b shows how the side gear tracks mesh with the vertical gear trains mounted to the main frame.
  • Fig 3 c shows a single cage rotated so that the top cross-bar supports are visible.
  • the cage grab assembly cradle or gondola of Fig 3d mounts to the cross-bars of Fig 3c.
  • Fig 3e shows the gear track along the bottom side edges of the cage engaging the bottom gear train for horizontal motion of the cages, hi addition, the side gear tracks can be seen engaging the vertical elevator gear trains.
  • Figs 4a - 4d illustrate the cage embodiment in which the cages have structural skeletons and includes wheels 38 along the lower sides and tracks 40 on the upper longitudinal edges on which the cages above rest and can move in going horizontally at the top from Row I to II, to III, to IV etc.
  • Fig. 4a is a front elevation of a cage cube, the upper edge of which includes L-shaped tracks 40 welded to the upper side structural rail. The gap between the rail and the edge of the cage is on the order of 2", and the track top may extend from slightly below to somewhat above the rail height.
  • a plurality of wheels 38 is mounted to the lower edge structural rail.
  • Fig. 4b illustrates the cage from a side elevation view, and shows an example where the cage is fitted with 6 wheels, three on each side, Fig 4c shows the cage in isometric with the wheels at the bottom and the track along the upper edge.
  • Fig 4d is a front elevation of a Column of 3 cages high, showing how each cage rests on the cage below.
  • the floor of the cage may be solid sheet steel and the sides of wire mesh, or the bottom may also be mesh. Heavy gauge wire or expanded metal may be used as the mesh.
  • a second drive system embodiment employs a motorized, vertical carousel drive system mounted inside each frame with corresponding drive and driven elements on the opposite interior sides. Suspended from the drive system are a set of cages, each large enough to carry a pallet load, so that the cage interior dimension is on the order of 48" wide, by 5' deep by 4-5' high. In this embodiment, the front of the cages is truncated so that the cages do not interfere with each other when going around the top and bottom corners. [0032] The carousel rotates the cages either clockwise or counter-clockwise (as seen from the side), so that there is a capacity for 8 cages in the rack footprint defined above.
  • Chain drive (driven on one side, jack shaft across the top, and second chain down the other side).
  • the cages move either by being hung by center of gravity-located horizontal bars secured to the chains, or by wheels moving in tracks on the side walls of the frames.
  • a single chain drive can be provided in the vertical center between the side walls, and the cages hung from their backs by cantilever brackets.
  • the inventive storage system 10 comprises an array of vertically oriented frames 12, designed to hold pallets 14 two-deep and as high as the warehouse ceiling will allow, in increments of approximately 5'.
  • Fig. 5 shows an array (Columns A, B, C, D%) of 4-high cages (4 Levels), each of which holds seven or eight cages, 16, to receive pallets or loose cartons of inventory.
  • FIG. 1 Visible on the left side of the frame of Column A is one side of the generally rectangular or oval motorized track 18 on which the cages rotate clockwise or counterclockwise. They are attached to the track by pivoting links so that they can pivot in order to stay oriented horizontally. Bumpers and tethers can be provided to prevent the cages from oscillating and bumping each other.
  • Each cage position is associated with a number, the floor-level front position being Level #1, and numbering continuing upward (2,3,4) and thence down the back, so that the highest number corresponds to the floor level position located behind the #1 pallet position.
  • Position #1 in Fig. 5 shows a cage 16 loaded with cartons of merchandise inventory 22 which can be accessed from the floor level.
  • Fig. 6 shows an 8-cage frame 12, the cages 16, numbered 1-8, located around the motorized track 18.
  • the operator 20 advances the cages 16 via the motor control mechanism 24.
  • Each of the frameworks is modular, here three columns in each module. In a presently preferred embodiment, each modular frame unit has its own motor(s) and control panel(s) 25 that are accessible from floor level.
  • the cages can be callable by entering the product or cage number and the software initiates the motor to rotate the cage carousel either clockwise or counterclockwise. The user then accesses the inventory from the cage 16-1 which has rotated into position #1. The cages 16 can then be indexed upward to gain access to inventory 22 in a different cage 16-2 in the same or another frame module 12 or another Column of the same module.
  • Fig. 7a, b and c are three views of a first exemplary embodiment of cage 16.
  • Fig. 7a shows a wire grid cage 16 with side walls 26, angled at the front and a high back 28, intended for front-loading access only.
  • the cage bottom 30 is fitted optimally with hold-down slots 32 which engage the clip or hook a portion of strapping and buckling hardware for lashing pallets 14 or carton inventory 22 into the cage 16.
  • the slots are optional where the sides of the cage are wire or X-metal which provides convenient hook catches.
  • Fig. 7b shows the sides 26 of cage 16 in side view with the front top corner removed to form an angle for easier access.
  • Fig. 7c shows a rear view of the high back 28 of cage 16.
  • Fig. 8 shows, in perspective, an alternate cage design, which, with high sides 36 and no front or back walls, offers access to inventory 22 from front or back, that is, from the front side of the #1 position or the back side of the #8 position.
  • the front access can be identified differently than the back.
  • the front side, accessible at the #1 position is the storage array address AF-I and the back side #8 position is address AB-8 (or AB-I, if desired).
  • the PIC controller for the drive can permit access for positions 1-4 on aisle side AF and for position 5-8 from aisle side AB.
  • the code AF means frame A aisle side front
  • AB means frame A aisle side back.
  • all aisle and cage positions can be assigned numbers so all addresses are totally numeric, and unique, for ease in digital tracking.
  • the truncated front and back edges of the side walls insure that the cages do not interfere with each other when navigating both the bottom and top turns of the carousel.
  • the item storage and retrieval system 900 includes a frame 902 having a plurality of support members 904 defining a plurality of vertical compartment position columns, as understood from the above description.
  • the vertical compartment position columns have a plurality of compartment positions 906.
  • Each of the plurality of compartments (not shown in Figures 9 and 10) are configured, as provided herein, to be positioned in a respective compartment position 906. At least one of the compartment positions define a loading/unloading position 908.
  • the system/method 900, 1000 also includes a storage / inventory / security controller 920 having a processor, a memory and a movement control software module or application 1010 therein.
  • the movement control software module or application 1010 is provided for moving and controlling the movement of each of the plurality of compartments from position to position within the frame 902, such as from a respective current compartment position to a next compartment position.
  • the system/method 900, 1000 also has a central storage / inventory / security server or central computer 930 having a processor, a memory, and an inventory tracking / security software module or application 1020, such as an inventory management module or application for at least tracking the inventory of the items in each of the plurality of compartments.
  • the system also has storage / inventory / security client computers 940, 942 from which various interface screens can be utilized by facility managers and/or inventory personnel 950.
  • the storage / inventory / security client computers 940, 942 can include bar code readers, RFID tag sensing devices, and access control or security information readers, as described here.
  • the access control readers are configured to receive one or more access control identifiers, such as a key, a numerical code, a password, and/or a biometric identifier.
  • the inventory tracking / security software module or application 1020 can be configured to generate various interface screens to interact with the facility managers and/or inventory personnel 950 to perform the inventory, security, tracking and other functionality within the system/method 900, 1000.
  • the system/method 900, 1000 also has one or more sensors 960 positioned within the frame 902 adjacent each of the positions 906/908, or adjacent the frame 902. The sensors 960 are in communication with the controller 920 and/or the server 930 via a wired and/or wireless communication path 964.
  • each compartment can have an identification device, such as an RFID tag, for use in tracking which position 906 each the compartments is located at within the system.
  • Each item within each compartment can also have an identification device, such as an RPID tag for tracking which compartment each item is located within the system/method 900, 1000.
  • the system/method 900, 1000 also has one or more positioning motors 970 in communication with the controller 920 for moving the compartments from position to position within the frame 902, as described herein.
  • the system 900 can also have one or more digital cameras or other digital image taking devices 980 positioned adjacent at least the loading/unloading position 908, or other positions 906.
  • the digital cameras or other digital image taking devices 980 are in communication with at least one of the controller 920 and/or the central computer and the applications 1010, 1020 therein for taking a digital photograph each time a compartment is loaded into or unloaded from the loading/unloading position 908 or other positions 906 within the frame 902.
  • the item storage and retrieval system and method 900, 1000 and the applications therein can be implemented in software, firmware, hardware, or a combination thereof.
  • the item storage and retrieval system and method 900 is implemented in software, as one or more executable programs or applications, and is executed by one or more special or general purpose digital computer(s), such as a personal computer (PC; IBM-compatible, APPLE-compatible, or otherwise), personal digital assistant, workstation, minicomputer, server, and/or mainframe computer. Therefore, the computers 920, 930, 940, and 942 may be representative of any computers in which the applications of the item storage and retrieval system and method 900, 1000 resides or partially resides.
  • the computers 920, 930, 940, and 942 of the system 900 include a processor, memory, and one or more input and/or output (I/O) devices (or peripherals) that are communicatively coupled via a local interface.
  • the local interface can be, for example, but not limited to, one or more buses or other wired or wireless connections, as is known in the art.
  • the local interface may have additional elements, such as controllers, buffers (caches), drivers, repeaters, and receivers, to enable communications. Further, the local interface may include address, control, and/or data connections to enable appropriate communications among the other computer components.
  • the processors are hardware devices for executing software, particularly software stored in memory.
  • the processors can be any custom made or commercially available processor, a central processing unit (CPU), an auxiliary processor among several processors associated with the computers 920, 930, 940, and 942 of the system 900, a semiconductor based microprocessor (in the form of a microchip or chip set), a macroprocessor, or generally any device for executing software instructions.
  • CPU central processing unit
  • auxiliary processor among several processors associated with the computers 920, 930, 940, and 942 of the system 900
  • a semiconductor based microprocessor in the form of a microchip or chip set
  • macroprocessor or generally any device for executing software instructions.
  • Suitable commercially available microprocessors are as follows: a PA- RISC series microprocessor from Hewlett-Packard Company, an 80x86 or Pentium series microprocessor from Intel Corporation, a PowerPC microprocessor from IBM, a Sparc microprocessor from Sun Microsystems, Inc., or a 68xxx series microprocessor from Motorola Corporation.
  • the processors may also represent a distributed processing architecture such as, but not limited to, EJB, CORBA, and DCOM.
  • the storage / inventory / security server computer 930 is a WINDOWS based server or series of servers.
  • Each memory of each computer 920, 930, 940, and 942 of the system 900 can include any one or a combination of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, etc.)) and nonvolatile memory elements (e.g., ROM, hard drive, tape, CDROM, etc.). Moreover, these memories may incorporate electronic, magnetic, optical, and/or other types of storage media. The memories can have a distributed architecture where various components are situated remote from one another, but are still accessed by the processors of the computers 920, 930, 940, and 942 of the system 900.
  • volatile memory elements e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, etc.
  • nonvolatile memory elements e.g., ROM, hard drive, tape, CDROM, etc.
  • the memories can have a distributed architecture where various components are situated remote from one another, but are still accessed by the processors of the computers 920, 930, 9
  • the software within one or more of the above referenced memories may include one or more separate programs.
  • the separate programs comprise ordered listings of executable instructions for implementing logical functions.
  • the software in the memories includes suitable operating systems (O/S).
  • a non-exhaustive list of examples of suitable commercially available operating systems is as follows: (a) a WINDOWS operating system available from Microsoft Corporation; (b) a NETWARE operating system available from Novell, Inc.; (c) a MACINTOSH operating system available from Apple Computer, Inc.; (d) a UNIX operating system, which is available for purchase from many vendors, such as the Hewlett-Packard Company, Sun Microsystems, Inc., and AT&T Corporation; (e) a LINUX operating system, which is freeware that is readily available on the Internet; (f) a run time VXWORKS operating system from WindRiver Systems, Inc.; or (g) an appliance-based operating system, such as that implemented in handheld computers or personal digital assistants (PDAs) (e.g., PalmOSTM available from Palm Computing, Inc., and WINDOWS CE available from Microsoft Corporation).
  • PDAs personal digital assistants
  • the operating systems essentially control the execution of other computer programs, such as the movement control application 1010 and/or the inventory tracking/security application 1020, in accordance with the present invention, and provide scheduling, input-output control, file and data management, memory management, and communication control and related services.
  • the movement control application 1010 and/or the inventory tracking/security application 1020, and other source programs within the system 900 may be a source program, executable program (object code), script, or any other entity comprising a set of instructions to be performed.
  • a source program the program needs to be translated via a compiler, assembler, interpreter, or the like, which may or may not be included within the memories, so as to operate properly in connection with the O/S.
  • these applications can be written as (a) an object oriented programming language, which has classes of data and methods, or (b) a procedural programming language, which has routines, subroutines, and/or functions, for example but not limited to, VB .Net, C#, C, C++, Pascal, Basic, Fortran, Cobol, Perl, Java, and Ada.
  • the movement control application 1010 and the inventory tracking/security application 1020 are written in the micro-controller language of the selected micro-controller and in C++, respectively.
  • the I/O devices referred to above may include input devices, for example input modules for PLCs, a keyboard, mouse, scanner, microphone, touch screens, interfaces for various medical devices, bar code readers, stylus, laser readers, radio- frequency device readers, etc. Furthermore, the I/O devices may also include output devices, for example but not limited to, output modules for PLCs, a printer, bar code printers, displays, etc. Finally, the I/O devices may further include devices that communicate both inputs and outputs, for instance but not limited to, a modulator/demodulator (modem; for accessing another device, system, or network), a radio frequency (RF) or other transceiver, a telephonic interface, a bridge, and a router.
  • modem for accessing another device, system, or network
  • RF radio frequency
  • the software in the respective memories may further include a basic input output system (BIOS) (not shown in Figs. 9 and 10).
  • BIOS is a set of essential software routines that initialize and test hardware at startup, start the O/S, and support the transfer of data among the hardware devices.
  • the BIOS is stored in ROM so that the BIOS can be executed when computers 920, 930, 940, and 942 of the system 900 are activated.
  • the processors therein are configured to execute software stored within respective memories, to communicate data to and from memories, and to generally control operations of the computers 920, 930, 940, and 942 of the system 900, pursuant to the software.
  • the movement control application 1010 and/or the inventory tracking/security application 1020, and other source programs within the system 900, and the O/S, in whole or in part, but typically the latter, are read by respective processors, perhaps buffered within the processors, and then executed.
  • the item storage and retrieval system and method 900, 1000 are implemented in software, as is shown in Figs.
  • a computer readable medium is an electronic, magnetic, optical, or other physical device or means that can contain or store a computer program for use by or in connection with a computer related system or method.
  • the application programs can be embodied in any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions, hi the context of this document, a "computer-readable medium" can be any means that can store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
  • the computer readable medium can be for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium.
  • the computer-readable medium would include the following: an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic), a random access memory (RAM) (electronic), a read-only memory (ROM) (electronic), an erasable programmable read-only memory (EPROM, EEPROM, or Flash memory) (electronic), an optical fiber (optical), and a portable compact disc read-only memory (CDROM) (optical).
  • an electrical connection having one or more wires
  • a portable computer diskette magnetic
  • RAM random access memory
  • ROM read-only memory
  • EPROM erasable programmable read-only memory
  • Flash memory erasable programmable read-only memory
  • CDROM portable compact disc read-only memory
  • the computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted or otherwise processed in a suitable manner if necessary, and then stored in a computer memory.
  • Fig. 12 shows a first step 1202 wherein the movement control application 1020 is configured to determine and track the current position of each of the compartments.
  • the controller 920 and movement control application 1020 therein receives signals from one or more of the sensors 960 from, including position information and the controller 920 and movement control application 1020 therein determine the current position of each of the compartments using this position information.
  • the controller 920 and movement control application 1020 therein then stores the position information and/or determined positions of each of the compartments within a position data repository or memory 1030 within the controller 920 or other memory.
  • this interface screen can receive a request to move a particular item, set of items, and/or compartment from its current position to the load/unload position 908. This request is communicated to and is received by the inventory tracking/security application 1020. If an item, set of items or compartment is requested to be moved to the load/unload position 908, the inventory tracking/security application 1020 can be configured to look up which compartment holds such item(s) and/or the position of such item(s) / compartment within an inventory / position / compartment / security / digital photograph data repository or memory 1040.
  • the inventory tracking/security application 1020 can then communicate this position information to the movement control application 1010 either in the same form or in a translated form, communicated to the movement control application 1010.
  • the movement control application 1010 can use this received position information and/or position information within the position data repository 1030 to determine the optimal movements of the compartments necessary to cause the identified compartment to move to the load/unload position 908.
  • the movement control application 1010 will then send one or more control or movement signals to the motors 970 position each of the plurality of compartments in a respective compartment position, and move each of the plurality of compartments from a respective current compartment position to a next compartment position.
  • the positions of each of the compartments are stored within the position data repository and/or within the inventory / position / compartment / security / digital photograph data repository 1040. This process of positioning and moving compartments within the system is continuously performed, as shown by line 1208 in Fig. 12.
  • the movement control application 1010 sends movement signals to the motors 970 which ultimately place the identified compartment in the load/unload position 908.
  • the inventory personnel 950 can then remove the identified compartment from the load/unload position 908, and place the identified compartment on an adjustable cart 1100, shown in Fig. 11.
  • the cart 1100 can have adjustable legs 1102 to raise or lower the height of the cart, to align the table surface 1104 with the height of the load/unload position 908.
  • the inventory personnel 950 through use of the client computer 942, 940, can enter an unload command and the movement control application 1010 will send an unload movement signal to the motors 970 to automatically move the identified compartment onto the cart 1100.
  • Sensors communicating with the movement control application 1010 can also be used to automatically sense the existence of the cart 1100 adjacent the load/unload position, and can automatically move the identified compartment onto the cart 1100 without receiving a separate unload command from the inventory personnel 950 through a client computer 942, 940.
  • each of the sensors 960 is an RFID sensor and each of the compartments have attached thereto an RFID tag. Each time an RFID tag nears an RFID 960 sensor, the sensor 960 communicated this position information to movement control application 1010 for tracking which position each the compartments is in within the system.
  • FIG. 13 shows a first step 1302 wherein the movement control application 1020 in conjunction with other components of the system 900 is configured to track the positions of the compartments as the compartments move from position to position within the frame, as at least described in relation Fig. 12 and steps within blocks 1202, 1206, and 1212.
  • a sensor 960 transmits a signal to the movement control application 1020 indicating which compartment is being unloaded and whether the identified compartment has been fully unloaded from the load/unload position 908.
  • the movement control application 1020 is configured to determine which compartment is in the loading/unloading position and whether such compartment has been fully unloaded. If the compartment has not been fully unloaded, the movement control application 1020 is configured to continuously make this determination until the compartment is fully unloaded.
  • the movement control application 1020 and/or the inventory tracking / security application 1020 are configured to transmit a take picture signal to the digital camera 980 for commanding the digital camera to take a digital photograph as the compartment is being unloaded from the loading/unloading position 908.
  • the digital camera 980 then transmits the digital photograph to the inventory tracking / security application 1020 for tracking unloading actions of inventory personnel as well as the condition of the items within the compartment at the time of unloading.
  • the inventory tracking / security application 1020 stores this information within the inventory / position / compartment / security / digital photograph data repository 1040, _along with other inventory tracking information, as described in relation to Fig. 12 in at least blocks 1202 and 1212.
  • a similar set of actions can be implemented in relation to loading a compartment into the load/unload position 908.
  • the inventory personnel 950 can load the identified compartment into the load/unload position 908, or the movement control application 1010 can send an load movement signal to the motors 970 to automatically move and load the identified compartment into the load/unload position 908.
  • a sensor 960 transmits a signal to the movement control application 1020 indicating which compartment is being loaded and whether the identified compartment has been fully loaded into the load/unload position 908.
  • the movement control application 1020 is configured to determine which compartment is in the loading/unloading position 908 and whether such compartment has been fully loaded. If the compartment has not been fully loaded, the movement control application 1020 is configured to continuously make this determination until the compartment is fully loaded.
  • the movement control application 1020 and/or the inventory tracking / security application 1020 are configured to transmit a take picture signal to the digital camera 980 for commanding the digital camera to take a digital photograph as the compartment is being loaded into the loading/unloading position 908.
  • the digital camera 980 then transmits the digital photograph to the inventory tracking / security application 1020 for tracking loading actions of inventory personnel as well as the condition of the items within the compartment at the time of loading.
  • the inventory tracking / security application 1020 stores this information within the inventory / position / compartment / security / digital photograph data repository 1040, along with other inventory tracking information, as described in relation to Fig. 12 in at least blocks 1202 and 1212.
  • FIG. 14 shows a first step 1402 wherein the inventory access / security application 1020 is configured to generate a security interface screen to receive an access control identifier through one of the client computers 940, 942.
  • This access control identifier representing the identification of a particular person, can alternatively be received through and from an access control device, such as a biometric reader associated with the client computer and/or the storage/inventory/security server computer 930 and/or the controller 920. Either way, the inventory access / security application 1020 receiving one or more the access control identifiers and security information is generally within Fig. 10, by way of at least block 942.
  • an access control device such as a biometric reader associated with the client computer and/or the storage/inventory/security server computer 930 and/or the controller 920.
  • the inventory access / security application 1020 is configured to track and store each attempt at gaining access to the interface screens and functionality of the inventory access / security application 1020 and/or movement control application 1010, within the inventory / position / compartment / security / digital photograph data repository 1040, including when such attempt was made, a digital picture of the person attempting to gain access from digital camera 980, the identifier used to attempt to gain access, among other information.
  • the inventory access / security application 1020 is configured to store and track each attempt at gaining access to the system 900.
  • the inventory access / security application 1020 is configured to determine whether access should be granted to the personnel, for example to control the movement of the plurality of compartments, hi one embodiment, the inventory access / security application 1020 compares the received access control identifier to stored access control identifiers stored within the inventory / position / compartment / security / digital photograph data repository 1040. If the received access control identifier does not match the stored access control identifiers, at a fourth step 1408, the inventory access / security application 1020 is configured to transmit a negative access response to the interface shown on the client computer 940, 942 for providing the determination that access shall not be granted.
  • the inventory access / security application 1020 is also configured to electronically communicate an alarm message to security personnel when access is denied.
  • the inventory access / security application 1020 and central computer 930 can be in communication with an email software application, such as MICROSOFT OUTLOOK, and can be configured to send an email with a "alarm message" that unauthorized access is being attempted to the system 900 to OUTLOOK for forwarding to one or more predetermined security personnel (previously identified in an email list within OUTLOOK). OUTLOOK would then automatically forward the alarm message to the security personnel.
  • an email software application such as MICROSOFT OUTLOOK
  • the inventory access / security application 1020 can be configured transmit a positive access response to the interface shown on the client computer 940, 942 for providing the determination that access has been granted. In a sixth step 1412, the inventory access / security application 1020 can be configured to then grant access to all of the functionality of the system. [0067] In one further embodiment, the inventory access / security application 1020 is configured to generate a scan items/ compartment interface screen on the client computer 940, 942, for presenting selections that inventory personnel can use to check in items and/or compartments into the load/unload position 908.
  • the inventory personnel can be provided an option to "scan items" to place into a particular compartment. Once selected, the inventory personnel would be directed to then use a scanner, such as a bar code scanner, to scan an identifier on the compartment, and then scan an identifier on each item as each item is placed in the particular compartment.
  • a scanner such as a bar code scanner
  • the scanner could be built into the client computer 940, 942, such as a bar code scanner built into a PDA 942, or can be attached to the client computer as a wand or other scanning device.
  • the inventory access / security application 1020 could also be configured to provide the inventory personnel with functions to direct the inventory personnel to scan the identifier on the compartment as the compartment is being loaded and/or unloaded from the load/unload position.
  • Each of these scanning actions by the inventory personnel using a scanner generate inventory and/or position information signals, generally referred to in box 942 in Fig. 10, which are communicated to the inventory access / security application 1020 and which are stored and tracked within the inventory / position / compartment / security / digital photograph data repository 1040.
  • inventive storage system has wide applicability to the inventory storage and transfer industry, namely to provide efficient storage and easy floor-level access to back room, warehouse and retail warehouse racking, as well as computerized inventory control and tracking from the warehouse floor or by remote control from corresponding administrative office.

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Abstract

L'invention concerne un système et un procédé de stockage et de récupération d'articles dans une pluralité de compartiments. Le système et le procédé respectif utilisent une structure de cadre ayant une pluralité d'éléments de support qui définissent des colonnes de position de compartiment verticales. Les colonnes de position de compartiment verticales sont adjacentes les unes aux autres. Chaque colonne de position de compartiment verticale possède une pluralité de positions de compartiment. La pluralité de compartiments adaptés pour être placés dans une position de compartiment respective, et au moins une des positions de compartiment est une position de chargement/déchargement. Le système et le procédé utilisent également un moyen pour déplacer et contrôler le déplacement de chacun de la pluralité de compartiments à partir d'une position de compartiment actuelle respective à une position de compartiment suivante. Chacun de la pluralité de compartiments est attaché de manière amovible à au moins une partie du moyen de déplacement. Le système et le procédé utilisent également une application de gestion de stocks qui est configurée pour suivre la gestion des articles dans chacun de la pluralité des compartiments.
PCT/US2007/085032 2006-11-16 2007-11-16 Système et procédé de stockage, de gestion des stocks et de sécurité WO2008061253A2 (fr)

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US8374926B2 (en) 2005-08-01 2013-02-12 Worthwhile Products Inventory control system
US8577759B2 (en) 2005-08-01 2013-11-05 Worthwhile Products Inventory control system process
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