WO2009053703A2

WO2009053703A2 - Inventory control system

Info

Publication number: WO2009053703A2
Application number: PCT/GB2008/003598
Authority: WO
Inventors: William Wesley Martin
Original assignee: Zeroshift Limited
Priority date: 2007-10-24
Filing date: 2008-10-22
Publication date: 2009-04-30
Also published as: GB0720871D0; GB2453977A; WO2009053703A3

Abstract

An inventory control system for monitoring the removal and replacement of inventory items. The inventory control system includes a container (2) for storing the inventory items and means for monitoring (12) the removal and replacement of inventory items from the container, wherein the container (2) includes at least one electronic system (12, 30), a docking bay (107), a cartridge (100) including an electronics module, said electronics module including a processor device and circuitry associated (14, 16, 28, 31) with the electronic system, and a connector device arranged to communicate electrical signals between the electronic system and the electronic module, said connector device having a first part that is electrically connected to the electronic system and a second part that is electrically connected to the electronics module (106), the first and second parts of the connector including complementary connector formations that are releaseably attachable to each other, wherein the docking bay (107) is arranged to receive and house the cartridge (100) and the cartridge is removable therefrom. A storage container (2) for storing inventory items and a process for repairing an inventory item container is also disclosed.

Description

INVENTORY CONTROL SYSTEM

The present invention relates to an inventory control system and in particular, but not exclusively, to an inventory control system for monitoring the use of hand tools or surgical instruments. The invention also relates to an inventory item storage container for use with the inventory control system, and a process for repairing the inventory item storage container.

An inventory control system may be useful when it is important to monitor the usage of inventory items, such as hand tools, and to ensure that they are returned to storage after use. This can help to ensure that inventory items are not lost or stolen. Such a system is particularly important when inventory items are used for repairing or maintaining aircraft engines, as any inventory items left inside the engine after completion of the job could cause catastrophic damage. Similarly, in the case of surgical implements, it is essential to ensure that no implements are left inside a patient after an operation.

An inventory control system can also be useful by helping to ensure that only the correct inventory items are used for a particular task. Such a system may also be helpful to track the identity of the person using the inventory items, so that if an inventory item goes missing or if a inventory item is taken that is inappropriate for the task in hand, appropriate remedial action can be taken.

A known inventory control process and container therefor is disclosed in WO 2005/028165. That system uses a series of sensors located in recesses formed in a foam liner to detect the presence of tools in the recesses. Each recess is individually shaped to receive a specific tool, the shape of the recess being matched to the shape of the tool. Each recess includes a sensor to detect whether or not the tool is present. However, the inventors have found that the electronics used to control the inventory system that are located within the container can fail due to operational factors. For example, it has been found that the electronics may fail due to damage caused to a container during transit from the point of manufacture to the site where the container is used. Problems can also occur with the electronics when a heavy load is dropped on a container or liquids, such as oil or cleaning fluids, are spilt onto the electrical components. Such incidents can cause the inventory control system to fail.

The current practice to address the above-mentioned problems is to send an engineer to the place where the container is located and to fix the container on site. This can take a significant period of time since inventory control containers are specialist items requiring specialist knowledge and skills to repair them. Thus there are few engineers who have the necessary skills to repair the containers, there are limitations as to their availability and they may have to travel a considerable distance in order to diagnose and fix the problem. This can lead to significant tool downtime for the users, which is unacceptable. The only alternative available to the user is to return the container to the manufacturer for repair. Both methods are very costly, time consuming and inconvenient for users and may significantly affect operational matters.

Therefore the present invention seeks to provide an inventory control system, container and repair process, which mitigates at least some of the aforesaid problems.

According to the present invention there is provided an inventory control system for monitoring the removal and replacement of inventory items, said system including a container for storing the inventory items and means for monitoring the removal and replacement of inventory items from the container, wherein the container includes at least one electronic system, a docking bay, a cartridge including an electronics module, said electronics module including a data processing device and circuitry associated with the electronic system, and a connector device arranged to communicate electrical signals between the electronic system and the electronic module, said connector device having a first part that is electrically connected to the electronic system and a second part that is electrically connected to the electronics module, the first and second parts of the connector including complementary connector formations that are releaseably attachable to each other, wherein the docking bay is arranged to receive and house the cartridge and the cartridge is removable therefrom. Thus at least some of the core electronic control systems can be easily removed from the container and replaced quickly in the event of a system failure, for example due to accidental damage. This enables users to keep spare electronics modules on site or alternatively for replacement modules to be couriered to user over night. This significantly reduces the down time for the inventory control system.

Advantageously the connector device is arranged such that when the cartridge is inserted into the docking bay the first and second parts of the connector device engage thereby electrically connecting the electronic system to the electronic module via the connector device. This provides an automatic push fit arrangement. Advantageously the arrangement is such that when the connection is made the cartridge is substantially fully housed within the docking bay. The docking bay houses the cartridge and is arranged to protect the cartridge from being interfered with by unauthorised persons. The electrical connection can be broken by pulling the cartridge from the docking bay. Preferably one of the first and second parts of the connector device includes at least one male connector element and the other part includes at least one female connector element.

The cartridge is arranged for insertion into the docking bay via a port in a first face of the container. Advantageously the first face can be a front face of the container, that is, a face from which inventory items are accessible such as a face from which a door or drawer can be opened. Advantageously the cartridge is accessible when located in the docking bay from a second face of the container. For example, the docking bay can be accessible from a second face of the container that is opposite to the first face. For example, the docking bay can be accessible via a rear face of the container. The docking bay and cartridge can be arranged such that the cartridge can only be inserted into, and removed from, one of the ends of the tubular docking bay. For example, the docking bay can include a blocking member to prevent the cartridge from being removed from one end of the docking bay.

Advantageously the docking bay can include a lockable access member. Advantageously the lockable access member is located on a container face opposite to that were the cartridge is inserted into the container, for example it is located on a rear face of the container. Preferably the access member comprises a lockable flap. The access member can include at least one access port for receiving at least one additional electrical connector. Preferably the access member includes a plurality of access ports. In this arrangement the cartridge also includes at least one additional connector device for receiving at least one additional connector via the access member. Advantageously the arrangement is such that each connector device is axially aligned with one of the access ports formed in the access member.

Advantageously the cartridge can include an outer panel with at least one of the following located thereon: a locking device, a data entry device, a transceiver device, a data card reader, and a logout button. Advantageously the cartridge includes a substantially cuboid hollow body and the outer panel can be arranged such that it provides a flanged region for the hollow body. The arrangement is such that the or each item located on the outer panel is accessible to a user of the system when the cartridge is located in the docking bay.

Advantageously the electronics module can include electronic devices and/or circuitry associated with at least one of a data transmission system, a control system arranged to receive signals from the means for monitoring the removal and replacement of inventory items, and an access control system for controlling access to the container.

Advantageously the cartridge can include a transceiver device located therein. For example, the cartridge can include an aerial for receiving and sending data wirelessly. The advantage of having it stored in the cartridge is that it is inaccessible to ordinary users of the system, that is, it requires supervisory access to remove the aerial. It has been found on earlier systems that some ordinary users have damaged or removed the aerial to inhibit the transmission of data, thereby providing an opportunity to steal inventory items.

Advantageously the container can include locking means for locking the cartridge in the docking bay. Preferably a mechanical lock is used, such as a conventional key lock or clamping device, so that the lock is operable when there is a loss of power and that access is restricted to those users, typically supervisors or technical specialists, who are issued keys. The locking means can include a screw element for securing the cartridge in place. Advantageously the screw element can be inserted into a threaded hole in the cartridge. Preferably the locking means is located such that it is accessible via the lockable access member. This ensures that users of the system cannot remove the cartridge from the container without supervisory permission. It also requires the container to be turned to remove the cartridge, which draws attention to the persons doing so.

Advantageously the container includes a plurality of inventory item storage locations. The system monitors which inventory items have been removed from and replaced in the container, and indicates the presence and/or absence of the inventory items. This makes it easy to assess whether all the inventory items taken from the container have been returned after use, thus reducing the risk of any inventory items being inadvertently left behind. Safety in critical situations such as aircraft engine maintenance is thus significantly improved. The invention also reduces the risk of inventory items being lost or stolen, since the fact that a inventory item has gone missing can be indicated immediately. The system also makes it possible to monitor which inventory items are being taken for any specified task, thereby helping to ensure best practice in maintenance operations.

Each inventory item storage location can comprise an individually-shaped recess for receiving a specific inventory item, the shape of the recess being matched to the shape of the inventory item. This ensures that inventory items are always returned to the correct storage locations, which makes it possible for the system to identify which inventory items have been removed, without requiring the use of sophisticated sensors and tagging devices on the inventory items. It also allows a visual check of the inventory items to be completed very easily, by looking for any empty recesses. This provides a manual backup to the automatic system, allowing the full complement of inventory items to be confirmed easily, even in the event of a power failure or other fault. Preferably, the recesses are colour-coded, to simplify further the visual checking process.

Advantageously the means for monitoring the removal and replacement of inventory items includes at least one of sensing means and a camera system together with image recognition means for detecting the presence and/or absence of inventory items in the container. Advantageously the electronic system can include the means for monitoring the removal and replacement of inventory items. Advantageously the sensing means can include a plurality of sensors for sensing the presence of inventory items in the recesses, each sensor being associated with a recess and arranged to generate a signal representing the presence or absence of a inventory item in the associated recess. The sensors are located in or adjacent the recesses. At least some of the sensors may consist for example of magnetic sensors, for sensing the presence of ferromagnetic materials. Such sensors have the advantage of being cheap, robust and simple.

Advantageously the data processor device can be constructed and arranged to receive signals from the sensor means or the image recognition means, to identify the inventory items from the received signals and to record the removal and replacement of inventory items according to the received signals.

Advantageously the container can comprise a cabinet having one or more inventory item storage drawers.

Advantageously the container can include a locking mechanism for controlling access to the inventory items. Preferably the locking mechanism includes a locking bar that is driven by a motor. Advantageously the electronics for controlling the locking mechanism can be included in the removable electronics module.

Advantageously the inventory control system can include an input device for entering the identity of a user. Advantageously the input device is arranged to operate the locking mechanism and can be included in the removable electronics module. Preferably the input device includes at least one of a keyboard and a data card system reader. Advantageously the input device is accessible by users and is preferably located on an outer face of the electronics module. There is a significant advantage in having the input device as part of the removable electronics module and that is because it is particularly prone to damage during transit and use since it has to be located in an easily accessible position for users, thus it is likely to get damaged more frequently. Advantageously the inventory control system can include means for recording the identity of a user. This makes it possible to monitor the inventory item usage of individual workers and ensure best working practices. Also, if an inventory item goes missing, it is possible to identify who last had possession of that inventory item. Preferably the data processing device performs this function.

Advantageously the inventory control system can include means for recording the time of removal and replacement of inventory items. Preferably the data processing device performs this function.

Advantageously the data processing device can be a computer.

Advantageously the system can include a second data processing device that is located remotely from the container and is connected to the container by a data transmission system. Advantageously the data transmission system can be included in the removable electronics module. For example, the data transmission system can include a wireless modem that is included in the removable electronics module. Alternatively a data link such as a cable can be used, which may be more appropriate if the data processing device is positioned locally, for use in the workplace.

The container can include a local indicator device for indicating the presence and/or absence of inventory items in the container. Advantageously the local indicator device can be included in the removable electronics module.

According to another aspect of the invention there is provided a storage container for storing inventory items, said container including means for monitoring the removal and replacement of inventory items from the container, at least one electronic system, a docking bay, a cartridge including an electronics module, said electronics module including a data processing device and circuitry associated with the electronic system, and a connector device arranged to communicate electrical signals between the electronic system and the electronic module, said connector device having a first part that is electrically connected to the electronic system and a second part that is electrically connected to the electronics module, the first and second parts of the connector including complementary connector formations that are releaseably attachable to each other, wherein the docking bay is arranged to receive and house the cartridge and the cartridge is removable therefrom.

Advantageously the container can be arranged according to any configuration described herein, in particular to any configuration of container described above in relation to the inventory control system.

Advantageously the container can be arranged according to any of the configurations described herein.

According to another aspect of the invention there is provided a process for repairing and/or updating an inventory item container that is part of an inventory control system, said container including means for monitoring the removal and replacement of inventory items from the container, at least one electronic system, a docking bay, a cartridge including an electronics module, said electronics module including a data processing device and circuitry associated with the electronic system, and a connector device arranged to communicate electrical signals between the electronic system and the electronic module, said connector device having a first part that is electrically connected to the electronic system and a second part that is electrically connected to the electronics module, the first and second parts of the connector including complementary connector formations that are releaseably attachable to each other, wherein the docking bay is arranged to receive and house the cartridge and the cartridge is removable therefrom, and the method includes removing the existing cartridge from the docking bay and replacing it with an equivalent cartridge.

Advantageously the new cartridge can be similar to the existing cartridge that it replaces or alternatively can include improvements or updates, for example in software or electronic components to improve the functionality and/or reliability of the inventory control system.

Advantageously the container in the process can be configured according to any of the configurations described herein. The method may include unlocking a locking device in order to remove the removable electronics module.

Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a first embodiment of the invention that includes a tool cabinet with a removable electronics cartridge in-situ;

Figure 2 is a perspective view from above of an open drawer of the container shown in Figure 1;

Figure 3 is a plan view showing the layout of another tool drawer;

Figure 4 is a view from below, showing the layout of tool sensors in the drawer shown in Figure 3;

Figure 5 is a perspective view of the tool cabinet of Figure 1 with the electronics cartridge having been removed;

Figure 6 is a perspective view of the removable electronics cartridge with a lid in place;

Figure 7 is a perspective view from above of the removable electronics cartridge with the lid removed;

Figure 8 is a schematic diagram illustrating the main components of an inventory control system;

Figure 9 is a flow diagram showing the main steps of an inventory control process;

Figure 10 is a perspective view of a second embodiment of the invention that includes a tool cabinet with a removable electronics cartridge in-situ; Figure 11 is a perspective view of the tool cabinet of Figure 10 from the rear;

Figure 12 is a perspective view of a lockable flap for gaining access to the removable electronics cartridge from the rear of the cabinet; and

Figure 13 is a schematic plan view of the removable electronics cartridge.

The tool cabinet 2 shown in Figures 1-8 includes a steel cabinet housing 4, which may be static or mobile (for example, it may be mounted on castors 5). The cabinet includes six tool drawers 6a-6f, the top drawer 6a being shown pulled out in Figure 2. Each drawer includes a liner 8, for example of a rigid foam material, having a number of cut-out compartments (or recesses) 10a- 1Of, which are shaped to receive specific tools. The recesses are preferably colour-coded, to provide a simple visual indication that a tool has been removed. For example, the recesses may have a bright colour (e.g. yellow), while the top surface of the drawer liner has a contrasting colour (e.g. black).

Within or adjacent to each compartment 10, a sensor 12 is provided (for example, 12a-f in Figure 2), which senses the presence in the compartment of a tool. The sensors 12 may for example be Hall effect sensors, to detect the ferromagnetic materials such as iron or steel, from which most tools are made. Alternatively, other types of sensor can be used, including for example optical sensors, mechanical contact switches and so on.

The sensors 12 are connected to an input/output unit 14, which may optionally include a visual display to show which tools are present. The input/output unit 14 is in turn connected to a control unit 16. The control unit 16 is connected to receive signals from the sensors 12 via the input/output unit 14, and has an output for transmitting signals to a computer 24 having database software for maintaining an inventory of the tools in the cabinet. Preferably data is transmitted via a wireless device 18, having an antenna 18b, for example via an infrared, radio or GSM link. The computer 24 may be kept locally or at a remote location.

The tool cabinet 2 also includes a motor driven electrically operated lock 30 for the drawers, which can be actuated by an access control system 28, which may include using a key, a personal identification number (PIN) via a chip and pin card or keypad 19, and/or a swipe card reader 29. The swipe cards and chip and pin cards may contain data identifying the user. This allows the identity of the user to be monitored.

Figure 3 shows an alternative drawer 6 layout, with a number of tool compartments 10 and sensors 12. Each of the compartments also includes a finger recess 20, allowing the tool to be easily removed from or replaced in the appropriate recess 10. The sensors 12 are interconnected by means of a printed circuit 22, as shown in Figure 4.

The main components of an inventory control system are shown schematically in Figure 8. The system includes the tool cabinet 2 and the computer 24. The cabinet 2 includes the sensors 12, the input/output unit 14, control unit 16, the access control system 28 including the keypad 19 and swipe card reader 29, the motor driven locking mechanism 30 for operating electrical locks on the tool drawers 6a-f, the wireless modem 18 and antenna 18b. The cabinet 2 also includes a power supply 26, a motor control unit 31 for controlling operation of the motor and a backup power supply (not shown) in the form of one or more rechargeable cells. The computer 24 includes a central processing unit 32, a wireless modem 33, a power supply 34 and a visual display unit 36. Data can be transmitted between the cabinet 2 and the computer 24 via the wireless modems 18,33.

Of the above-mentioned components, the following are located in or on a removable electronics cartridge 100: the input/output unit 14, the control unit 16, the modem 18 and its antenna 18b, the keypad 19, swipe card reader 29, and the motor control unit 31. The cartridge 100 additionally includes a log-out button 102, a key operated lock 104 for securing the cartridge 100 to the cabinet 2 and a male connector 106 (see Figures 6 and 7). It will be appreciated by the skilled person that other electrical or electronic systems additionally, or alternatively, can be located within the cartridge 100 and that the benefit of the invention can be obtained by including one or more systems in the electronics cartridge 100. The cartridge 100 fits into a housing 107 within the cabinet via an aperture 108 formed in the front panel of the cabinet 2 (see Figure 5). The housing 107 substantially encloses the cartridge.

The cabinet 2 includes a female connector (not shown) located in the housing 107 that is complimentary to the connector 106, the arrangement being such that sliding the cartridge 100 into the aperture 108 allows the complimentary connectors to engage in a detachable manner, thereby connecting the electrical/electronic systems in the cartridge 100 with the associated electrical/electronic systems located in the cabinet 2. Each of the electrical/electrical systems located in the cartridge 100 are electrically connected, either directly or indirectly, with the connector 106 (the electrical connections are not shown in Figure 7 for clarity).

The following components are mounted in or on the front panel 110 of the cartridge for ease of access by users: the mechanical lock 104, the log-out button 102, the swipe card reader 28, the input/output device 14, the modem antenna 18b and the keypad 19. The input/output device 14 includes a series of LED indicators which can indicate that tools are missing, one or more drawers are open, the operability of the radio link, battery status, system status and that a user is logged-in. The log-out button 102 provides a quick and easy way for a logged in user to end his log-in session with the cabinet 2. Pressing the log-out button 102 also has the effect of operating the cabinet locking mechanism 30.

In the event of an electronics failure, the cartridge 100 can be replaced with an equivalent cartridge 100, or an updated cartridge if available. The supervisor having a key for locking mechanism 104, opens the lock 104 (and any additional temporary locking features such as screws) and withdraws the cartridge 100 from the aperture 108 thereby disconnecting the male connector 106 from its complementary connector within the cabinet 2 body. The new cartridge 100 is then inserted into the same aperture 108 until the connector 106 is firmly located in its complementary socket and the locking mechanism 104 is activated to lock the cartridge 100 in place. The cabinet 2 is then ready to resume operation. An inventory control process carried out using the system described above will now be described with reference to Figure 7, which shows the steps of a typical control process. First, a user (for example a technician or mechanic) identifies him or herself 40 by entering a PIN or using a swipe card. The identity of the user is checked against a list of authorised users held on the computer 24 and, if the authorisation of the user is valid, the locks of the tool box are unlocked, allowing the user to gain access to the tools. At the same time, the identity of the user and the time are recorded 42 in a database on the computer. If the identity of the user is not validated as that of an authorised user, the tool box remains locked, preventing access to the tools. Optionally, a warning may be sent to the computer, to indicate that an unauthorised person has attempted to gain access.

Assuming that the identity of the user has been validated, the user then removes the required tools from the cabinet and the sensors automatically detect 44 which tools have been removed. This information is transmitted to the computer, where it is recorded 46, together with the time of removal. The user then closes the cabinet and, after a short delay, the box then re-locks automatically 50, and the registered user is signed off.

After completing the assigned task, the user re-enters his or her ID 40, and once this has been verified the box unlocks 42 and the identity of the user is registered on the computer. The user then replaces the tools 52 in the appropriate recesses: this is sensed by the sensors and the identity of the tools that have been replaced is recorded on the computer 54, together with the time of replacement. If the tool is not replaced, an alert can be issued. The user then closes the cabinet and, after a short delay, the box re-locks and the user is logged off 58.

The computer therefore records which tools are in use, who has taken them and the time at which the tools are removed and returned. Using this information, it is a simple matter for a supervisor to check whether all the tools are present in the cabinet and, if any are missing, who has taken them and when. The supervisor can also check that the tools taken for a particular task are appropriate for that task. Checks can be carried out by the supervisor whenever required, or they can be instigated automatically, for example whenever the cabinet is opened or at predetermined intervals. In addition, the tool cabinet can be checked visually at regular intervals, to ensure that the full complement of tools is present and that the automatic system is operating correctly.

The computer can also keep a continuous log of how long each tool has been in use, which may be useful for tools and measuring instruments such as torque wrenches that have to be recalibrated at preset intervals. It can also be programmed to disregard the absence of tools that have been removed deliberately for repair or replacement.

It may be noted that although the system checks for the presence of a tool in each of the sensed recesses, it does not check that the correct tool has been placed in each recess. In fact, since in the embodiment described above the detectors are simple magnetic detectors, it would be relatively easy to mislead the detection system, for example by placing a steel bolt in one of the recesses instead of the correct tool. This is not considered to be a serious disadvantage, since the main aim of the system is to ensure that trusted personnel do not accidentally forget to return tools to the container after use, rather than preventing deliberate theft. However, it is worth noting that since the system also records who has taken each tool from the container, this will deter deliberate theft, particularly if regular visual inspections of the cabinet are also carried out.

If necessary, the system can be adapted to include more sophisticated sensors that are capable of detecting the presence of individual tools, for example by detecting identification tags attached to the tools. However, this is generally less preferred, since it increases the cost and complexity of the system and gives rise to other disadvantages, such as the difficulty of attaching tags to the tools and the risk of the tags becoming detached during use. The simple system described first is likely therefore to be preferred in many situations.

A second embodiment of the invention is shown in Figures 10 to 13. The second embodiment includes an inventory control system that is similar to the first embodiment and operates in a similar manner. It differs in how access is gained to the housing 207 that stores the cartridge 200, how the cartridge 200 is locked in place and the arrangement of the electronics cartridge 200. The following systems and devices are located in or on the removable electronics cartridge

200: an input/output unit 214, a control unit 216, which includes a data processor for receiving signals from the tool monitoring system, a data connection 218 such as a modem and/or LAN connection and its antenna 218b, the keypad 219, swipe card reader 229, the motor control unit 231 , and a multi-connector 248. The cartridge 200 can optionally include additional devices and systems such as a VGA output port 250, a low voltage fuse array 252, a radio communications port 256, a kettle plug 258, one or more rechargeable cells 260 and a charger unit 262 for the cells (electrical connections have not been shown in Figure 13 for clarity). These additional devices include connectors located towards the rear of the cartridge and are arranged to receive the appropriate cable connections. It will be appreciated that other systems can be placed in or on the cartridge 200.

The aerial 218b is located with the cartridge 200, towards the rear end. The aerial can be arranged to protrude through an opening in the cartridge to ensure that a good signal is achieved. It has been found by the inventors that locating the aerial substantially within the cartridge provides a more secure position since it prevents users from having an opportunity to remove or damage the aerial.

The rear of the tool cabinet 202 includes a lockable flap 264 and a locking device 268 for locking the cartridge 200 into place in its housing 207. The locking device includes a bolt 270 that is arranged to screw into a threaded hole in the rear of the cartridge 200, and a support plate 272. The locking device 268 is only accessible via the rear of the container when the lockable flap 264 is open. This ensures that only supervisors that have access to the key to the flap can remove the cartridge from the cabinet 202. Thus in order to remove the cartridge 200, the flap 264 is first opened, the bolt 270 is removed and the cartridge 200 is pulled out of the housing 207 from the front of the container. The support plate 272 prevents removal from the rear of the cabinet. The inventors have found that this is a secure arrangement since a user would be required to turn the cabinet 202 around in order to release the cartridge 200 and therefore would draw attention to himself/herself.

The flap 264 includes apertures formed through its body to allow cables to be connected with the additional devices and systems located in the cartridge. Thus additional connections can be made with the additional devices and systems without having to open the flap 264. This enables users to use the additional devices and systems without compromising the security of the removable cartridge 200.

Various other modifications of the invention are of course possible. For example, instead of using magnetic sensors to detect the presence of tools in each of the recesses, other types of sensor such as optical sensors or mechanical switches may be used. Alternatively, instead of providing a separate sensor for each recess, the cabinet may include an array of optical sensors mounted above each drawer, which scan the drawer as it is opened, in a manner similar to a conventional optical scanner. An image of the drawer can then be generated, which can be compared with previous images to sense the removal of tools from the recesses or their replacement in the recesses. Alternatively, instead of optical sensors, an array of magnetic sensors can be used to scan the drawer as it is opened.

The tool container may also take different forms: for example it may consist of a box with a single layer of tools, or with tools in removable trays, or it may take the form of a cupboard or a board on or within which the tools are hung, or any other suitable form. The tools may also of course be of any kind, including engineering tools, surgical tools and so on. The invention may also be adapted to other non-tool applications where an inventory control system is required, and references within this specification to tools should be construed accordingly to include equivalent items in suitable non-tool applications. The invention may for example be used for inventory taking or stock taking/control purposes.

The idea of having a removable electronics module can be used in conjunction with the inventory control system and container described in PCT/GB2007/003387, which uses a camera system and image recognition software to detect the presence/absence of tools instead of the sensor system described above. This system is able to determine whether the correct tool has been replaced, unlike the embodiment described above. At least some of the electronics required to implement the system can be located in a removable cartridge similar to the cartridge 100 for quick and easy replacement. This can include electronics associated with the camera system, and where applicable, the image recognition processing means, in addition to those described above.

Claims

1. An inventory control system for monitoring the removal and replacement of inventory items, including a container for storing the inventory items and means for monitoring the removal and replacement of inventory items from the container, wherein the container includes at least one electronic system, a docking bay, a cartridge including an electronics module, said electronics module including a data processing device and circuitry associated with the electronic system, and a connector device arranged to communicate electrical signals between the electronic system and the electronic module, said connector device having a first part that is electrically connected to the electronic system and a second part that is electrically connected to the electronics module, the first and second parts of the connector including complementary connector formations that are releaseably attachable to each other, wherein the docking bay is arranged to receive and house the cartridge and the cartridge is removable therefrom.

2. An inventory control system according to claim 1 , wherein the connector device is arranged such that when the cartridge is inserted into the docking bay the first and second parts of the connector device automatically engage thereby electrically connecting the electronic system to the electronic module via the connector device.

3. An inventory control system according to claim 1 or 2, wherein the cartridge is arranged for insertion into the docking bay via a port in a first face of the container.

4. An inventory control system according to any one of the preceding claims, wherein the docking bay includes a lockable access member.

5. An inventory control system according to claim 4, wherein the access member includes at least one access port for receiving at least one additional connector.

6. An inventory control system according to any one of the preceding claims, wherein the cartridge includes at least one additional connector device for receiving at least one additional connector.

7. An inventory control system according to any one of the preceding claims, wherein the cartridge includes an outer panel with at least one of the following located thereon: a locking device, a data entry device, a transceiver device, a data card reader, and a logout button.

8. An inventory control system according to any one of the preceding claims, wherein the electronics module includes electronic devices and/or circuitry associated with at least one of a data transmission system, a control system arranged to receive signals from the means for monitoring the removal and replacement of inventory items, and an access control system for controlling access to the container.

9. An inventory control system according to any one of the preceding claims, wherein the cartridge includes a transceiver device located therein.

10. An inventory control system according to any one of the preceding claims, including locking means for locking the cartridge in the docking bay.

11. An inventory control system according to claim 10, wherein the locking means includes a screw element for securing the cartridge in place.

12. An inventory control system according to claim 10 or 11 when dependent on claim 4, wherein the locking means is located such that it is accessible via the lockable access member.

13. An inventory control system according to any one of the preceding claims, wherein the container includes a plurality of inventory item storage locations.

14. An inventory control system according to claim 14, wherein each inventory item storage location comprises an individually-shaped recess for receiving a specific inventory item, the shape of the recess being matched to the shape of the inventory item.

15. An inventory control system according to any one of the preceding claims, wherein the means for monitoring the removal and replacement of inventory items includes at least one of sensing means and a camera system together with image recognition means for detecting the presence and/or absence of inventory items in the container.

16. An inventory control system according to claim 14 when dependent on claim 15, wherein in the sensing means includes a plurality of sensors for sensing the presence of inventory items in the recesses, each sensor being associated with a recess and arranged to generate a signal representing the presence or absence of a inventory item in the associated recess.

17. An inventory control system according to claim 16 or 17, wherein the processor device is constructed and arranged to receive signals from the sensor means or the image recognition means, to identify the inventory items from the received signals and to record the removal and replacement of inventory items according to the received signals.

18. An inventory control system according to any one of the preceding claims, wherein the container comprises a cabinet having one or more inventory item storage drawers.

19. An inventory control system according to any one of the preceding claims, wherein the container includes a locking mechanism for controlling access to the inventory items.

20. An inventory control system according to claim 19, wherein the locking mechanism includes an input device for entering the identity of a user.

21. An inventory control system according to any one of the preceding claims, including means for recording the identity of a user.

22. An inventory control system according to any one of the preceding claims, including means for recording the time of removal and replacement of inventory items.

23. An inventory control system according to any one the preceding claims, including a second data processing device located remotely from the container that is connected to the container by a data transmission system.

24. An inventory control system according to any one of the preceding claims, wherein the container includes a local indicator device for indicating the presence and/or absence of inventory items in the container.

25. A storage container for storing inventory items, including means for monitoring the removal and replacement of inventory items from the container, at least one electronic system, a docking bay, a cartridge including an electronics module, said electronics module including a data processing device and circuitry associated with the electronic system, and a connector device arranged to communicate electrical signals between the electronic system and the electronic module, said connector device having a first part that is electrically connected to the electronic system and a second part that is electrically connected to the electronics module, the first and second parts of the connector including complementary connector formations that are releaseably attachable to each other, wherein the docking bay is arranged to receive and house the cartridge and the cartridge is removable therefrom.

26. A storage container according to claim 25, wherein the connector device is arranged such that when the cartridge is inserted into the docking bay the first and second parts of the connector device engage thereby electrically connecting the electronic system to the electronic module via the connector device.

27. A storage container according to claim 25 or 26, wherein the cartridge is arranged for insertion into the docking bay via a port in a front face of the container.

28. A container according to claim 27, wherein the container includes a plurality of inventory item storage locations.

29. A container according to claim 28, wherein each inventory item storage location comprises an individually-shaped recess for receiving a specific inventory item, the shape of the recess being matched to the shape of the inventory item.

30. A container according to any one of claims 25 to 29, wherein the means for monitoring the removal and replacement of inventory items includes at least one of sensing means and a camera system together with image recognition means for detecting the presence and/or absence of inventory items in the container.

31. A container according to claim 30 when dependent on claim 29 wherein the sensing means includes a plurality of sensors for sensing the presence of inventory items in the recesses, each sensor being associated with a recess and arranged to generate a signal representing the presence or absence of a inventory item in the associated recess.

32. A container according to claim 30 or 31, wherein the processor device is constructed and arranged to receive signals from the sensor means, or the image recognition means, to identify the inventory items from the received signals and to record the removal and replacement of inventory items according to the received signals.

33. A container according to claim 32, including a data transmission system constructed and arranged to transmit signals to a remote data processing device.

34. A process for repairing and/or updating an inventory item container that is part of an inventory control system, said container including means for monitoring the removal and replacement of inventory items from the container, at least one electronic system, a docking bay, a cartridge including an electronics module, said electronics module including a data processing device and circuitry associated with the electronic system, and a connector device arranged to communicate electrical signals between the electronic system and the electronic module, said connector device having a first part that is electrically connected to the electronic system and a second part that is electrically connected to the electronics module, the first and second parts of the connector including complementary connector formations that are releaseably attachable to each other, wherein the docking bay is arranged to receive and house the cartridge and the cartridge is removable therefrom, and the method includes removing the existing cartridge from the docking bay and replacing it with a new cartridge.

35. A process according to claim 34, including unlocking a locking device to release the existing cartridge.