U.S. patent application number 10/617157 was filed with the patent office on 2004-08-05 for distributed intelligence, wireless, light-directed pick/put system.
Invention is credited to Peck, John C..
Application Number | 20040153207 10/617157 |
Document ID | / |
Family ID | 32776177 |
Filed Date | 2004-08-05 |
United States Patent
Application |
20040153207 |
Kind Code |
A1 |
Peck, John C. |
August 5, 2004 |
DISTRIBUTED INTELLIGENCE, WIRELESS, LIGHT-DIRECTED PICK/PUT
SYSTEM
Abstract
A system by which a portable computer on a cart translates
warehouse locations to light addresses of locations on storage bays
in a storage facility and communicates instructions by means of a
bi-directional, dual transmitter/receiver element on the cart to a
pick-controller unit positioned on each bay. The pick-controller
unit on the bay is connected with intelligent light assemblies at
each location on the bay that, in response to instructions from the
portable computer, illuminate indicating the need for, and quantity
of a SKU to be retrieved from the illuminated location. In
addition, the portable computer communicates instructions using the
bi-directional, dual transmitter/receiver element to the
put-controller unit positioned on the cart that in turn
communicates these instructions to intelligent light assemblies
adjacent to specific receptacles located on the cart. The
intelligent light assemblies adjacent to the receptacles illuminate
in response to instructions from the portable computer, indicating
the quantity of the retrieved SKU(s) to be deposited into each of
one or more receptacles, thereby facilitating batch picking of
multiple orders by an attendant operating the cart.
Inventors: |
Peck, John C.; (Seneca,
SC) |
Correspondence
Address: |
STEPHEN R. CHAPMAN
P.O. BOX 168
CLEMSON
SC
29633-0168
US
|
Family ID: |
32776177 |
Appl. No.: |
10/617157 |
Filed: |
July 10, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60443584 |
Jan 30, 2003 |
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Current U.S.
Class: |
700/214 |
Current CPC
Class: |
B65G 2209/04 20130101;
B65G 1/1373 20130101; B65G 1/137 20130101; G06Q 10/08 20130101 |
Class at
Publication: |
700/214 |
International
Class: |
G06F 007/00 |
Claims
What is claimed is:
1. A distributed intelligence, wireless, light-directed pick/put
system comprising: a. at least two mobile units comprising, each of
said at least two mobile units comprising: i. a portable computer
comprising data input means, data and instruction presentation
means, and programmed capability to associate input facility
location data with unique light addresses and with specific put
locations; ii. a put-controller unit comprising a bi-directional,
transmitter/receiver component and an intelligent circuit element
capable of controlling intelligent light assemblies, said
put-controller unit having a unique controller address and being in
bi-directional communication with said portable computer through a
bi-directional, dual transmitter/receiver element; iii. a mobile
element capable of being propelled through a storage facility,
wherein said put-controller unit is positioned on said mobile
element, and said portable computer is positioned on said mobile
element, and said bi-directional, dual transmitter/receiver element
is positioned on said mobile element, and further comprising a
power source for said portable computer and said put-controller
unit; iv. one or more storage receptacles positioned on said mobile
element wherein each of said one or more receptacles has associated
with it an intelligent light assembly comprising an intelligent
circuit component, a visual display means, and a momentary contact
switch means, and further wherein each of said intelligent light
assemblies is positioned adjacent to a specific receptacle; and v.
said bi-directional, dual transmitter/receiver element comprising a
wired communication means for connecting to said portable computer
and communication means for connecting to said put-controller unit
and to a pick-controller unit; and b. at least one stationary unit
comprising: said pick-controller unit comprising a
transmitter/receiver component and an intelligent circuitry element
wherein said pick-controller unit has a unique controller address
and is in wireless, bi-directional communication with said
bi-directional, dual transmitter/receiver element, and further
wherein said pick-controller element is in electrical communication
with a plurality of intelligent light assemblies each of which
intelligent light assemblies comprises an intelligent circuit
component, a visual display means, and a momentary contact switch
means, and further wherein each of said intelligent light
assemblies is positioned adjacent to a specific, physical storage
location in a bay of storage locations, such that each of said
intelligent light assemblies contains a specific light address
associated with the physical location at which it is
positioned.
2. The distributed intelligence, wireless, light-directed pick/put
system of claim 1 wherein said data and instruction presentation
means comprise visual display means.
3. The distributed intelligence, wireless, light-directed pick/put
system of claim 1 wherein said data and instruction presentation
means comprise enunciation means.
4. The distributed intelligence, wireless, light-directed pick/put
system of claim 1 wherein said data and instruction presentation
means comprise visual and enunciation means.
5. The distributed intelligence, wireless, light-directed pick/put
system of claim 1 wherein said portable computer receives data and
information via wireless communication from a second computer.
6. The distributed intelligence, wireless, light-directed pick/put
system of claim 1 wherein said portable computer receives data and
information via keypad entry.
7. The distributed intelligence, wireless, light-directed pick/put
system of claim 1 wherein said portable computer receives data and
information via wired communication from a second computer.
8. The distributed intelligence, wireless, light-directed pick/put
system of claim 1 wherein said portable computer and said
bi-directional, dual transmitter/receiver element are removably
positioned on said mobile element and further wherein said
bi-directional, dual transmitter/receiver element is integral to
said portable computer.
9. A method of retrieving items from indicated storage locations
and of placing said retrieved items into designated receptacles
comprising the steps of: a. providing mobile elements; b.
associating a specific, portable computer with each of said mobile
elements; c. programming said specific, portable computer to
translate pick order item locations to specific pick light
addresses and to specific put light addresses; d. entering pick
orders into said at least one portable computer; e. activating a
communication system that allows identification of the location and
quantities of stored items to be retrieved; f. instructing each
operator of each of said mobile elements to travel to a specific
bay of storage locations in response to instructions communicated
by said portable computer; g. identifying both location from which
specified, stored items are to be retrieved and the quantity of
each of said stored items to be retrieved as indicated by
intelligent light assemblies positioned at storage locations; h.
retrieving said designated quantity of an item from the indicated
location and placing indicated quantities of said item into
specific receptacles on said mobile element as indicated by
intelligent light assemblies associated with each of said
receptacles; i. operating a momentary contact switch to indicate
that the pick has been completed; j. repeating the steps of
retrieving designated quantities of items from indicated locations
and placing indicated quantities of said retrieved, designated
items into designated receptacles until at least one order is
filled; and k. unloading said receptacles at a designated station
and returning said mobile element to repeat the entire pick/put
process for a new set of orders.
10. The method of claim 9 wherein the step of retrieving the
desired quantity of an item further comprises the steps of
reporting to the portable computer any insufficiency of items in
the indicated location and thereby reporting an incomplete
pick.
11. A distributed intelligence communication system comprising: a.
means for enabling a pick-controller unit to engage in two-way
communication with a computer by means of a bi-directional, dual
transmitter/receiver element and for enabling said pick-controller
unit to engage in two-way communication with a plurality of first
intelligent light assemblies; b. means for enabling at least one
put-controller unit to engage in two-way communication with a
computer by means of a bi-directional, dual transmitter/receiver
element and for enabling said at least one put-controller unit to
engage in two-way communication with a plurality of second
intelligent light assemblies; c. means for enabling a first
intelligent light assembly to respond to a coded message
transmitted from said computer, through said pick-controller unit
thereby activating a specific light and further activating a
display of unique instructions and related information to an
operator; and d. means for enabling a second intelligent light
assembly to be activated in coordination with the activation of
said first intelligent light assembly in a prescribed, coordinated
manner.
12. The distributed intelligence communication system of claim 11
further comprising programmed means for allowing an operator to
assign a unique light address to each of said plurality of first
intelligent light assemblies and to each of said plurality of
second intelligent light assemblies, and further comprising
programmed means for enabling an operator to indicate that a
designated task has been completed.
13. The distributed intelligence communication system of claim 11
wherein said means for enabling said pick-controller unit comprises
circuitry capable of being programmed to recognize and respond to
coded information and further to transmit programmed instructions
to said first plurality of intelligent light assemblies.
14. The distributed intelligence communication system of claim 11
wherein said means for enabling said at least one put-controller
unit comprises circuitry capable of being programmed to recognize
and respond to coded information and further to transmit programmed
instructions to said plurality of second intelligent light
assemblies.
15. The distributed intelligence communication system of claim 11
comprises programmed means for enabling an operator to assign
unique light addresses to each of said plurality of first
intelligent light assemblies.
16. The distributed intelligence communication system of claim 11
wherein said pick-controller units and each of said at least one
put-controller units and each of said plurality of first
intelligent light assemblies and each of said plurality of second
intelligent light assemblies is capable of being programmed
individually to receive coded instructions to which each
responds.
17. The distributed intelligence communication system of claim 11
comprises programmed means for enabling an operator to assign
unique light addresses to each of said plurality of first
intelligent light assemblies and to each of said plurality of
second intelligent light assemblies, and further wherein said
pick-controller units and said at least one put-controller units
and each of said plurality of first intelligent light assemblies
and each of said plurality of second intelligent light assemblies
is capable of being individually programmed to receive coded
instructions to which each responds.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application 60/443,584 filed Jan. 30, 2003 and which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention is directed to a distributed system of
intelligent automata: it is in part a light-directed, coupled
system to facilitate the retrieval of stock keeping units (SKUs)
stored in uniquely identified locations and subsequent placement of
these same items into uniquely identified receptacles. More
specifically it comprises a system whereby unique location
addresses are translated to specific light addresses in a storage
facility. Even more specifically, it is a system whereby a single
light or lighted character display which is an integral part of an
intelligent light assembly is activated at the exact storage
location of a specific SKU in response to communication by wired
means from a portable computer through a bi-directional, dual
transmitter/receiver element then by wireless means to a
pick-controller unit that is wired to a plurality of intelligent
light assemblies. Each intelligent light assembly represents a
unique light address and is positioned at a corresponding unique
physical location or address in the storage facility. Still more
specifically, it is a system wherein intelligent light assemblies
associated with specific storage receptacles are also activated by
instructions received from the portable computer through a
bi-directional, dual transmitter/receiver element to a
put-controller unit thereby indicating the locations (receptacles)
and quantity of retrieved items to be placed in the designated
receptacles, thereby facilitating batch picking of multiple orders.
And yet more specifically, it is a system wherein the portable
computer, bi-directional, dual transmitter/receiver element,
put-controller unit, and the storage receptacles with associated
intelligent light assemblies are all positioned on a mobile
retrieval element capable of being propelled throughout the storage
facility. A pick-controller unit and intelligent light assemblies
and related hardware are stationary units, with each individual
light assembly mounted and wired on an individual location in a
storage bay.
[0003] The invention anticipates a plurality of mobile retrieval
units and of storage bays.
BACKGROUND OF THE INVENTION
[0004] Filling orders from stored inventory requires at least three
steps: locating the precise item in the storage facility,
retrieving (or picking) the desired quantity of that item, and
storing (or putting) the retrieved items in a designated container
or receptacle. The basic steps may apply to a variety of situations
in which items must be identified, selected, and distributed or
placed in a second location. Frequently this process is generally
described in terms of order fulfillment in a warehouse.
[0005] Storage in a facility may be viewed as a nested or
hierarchical arrangement with bays arranged along aisles and
shelves or storage containers located in or on a bay. Thus, the
location of a specific item, commonly referred to as a Stock
Keeping Unit or SKU, would be an "address" in the storage facility
comprising the aisle, the bay along that aisle, and a shelf, bin or
container located in the bay. So long as a protocol exists to
associate only one SKU with each unique combination of aisle, bay,
and shelf, identification of a particular SKU is unnecessary to
identify or characterize the item to be picked, since the address
of the item is sufficient.
[0006] In an exclusively manual system, an employee receives an
order for a specific item or group of items. Either by memory,
which is subject to error, or by reference to a facility map or
plan, the employee must identify the location of the item, go to
that location, pick the required quantity of items for the order,
and either return to a central shipping point or place them in an
appropriate receptacle. This process is repeated until a given
order is filled. Multiple opportunities for errors exist, from
misreading the storage facility location label, to selecting from
an incorrect, but adjacent shelf or other storage receptacle, to
picking the wrong quantity of the correct item, or to putting the
correct items in an incorrect receptacle for subsequent shipping or
order processing. In addition, many separate orders may require the
same item, but in an exclusively manual system, batch order picking
is most commonly the exception, rather than the rule, resulting in
significant inefficiencies associated with repeated trips to pick
each order individually.
[0007] Technology has advanced beyond the exclusively manual system
of pick and put. The evolution of computer technology and related
electronic systems has played a significant part in this
advancement. U.S. Pat. No. 3,739,339 issued to Hillhouse on Jun.
12, 1973 describes a system that is characteristic of the status of
current pick and put technology for many warehouse-like
situations.
[0008] In the '339 patent, a computer punch-card system is used in
which the row by column punch matrix of the card represents the
storage location of items, and quantities of the item to be picked
may also be encoded. At least one card reader is wired to a
computer. When a card is inserted into a card reader positioned on
a bay or similar group of discrete storage units, the configuration
of punches activates a light system such that the precise location
of the item is indicated by an illuminated element, and the
quantity to be selected is displayed in a centrally located,
lighted display. The system also provides for a put-to-light
process with a separate light system wired to individual containers
or receptacles. Major deficiencies of this system include the
requirement of hard wire communications of the light systems,
communications through the card reader to a central computer, and
the fact that overall efficiency and performance of the system
degrades as the number of lights increases. The system has
virtually no fault tolerance: failure of any central component
causes the entire system to fail.
[0009] Radio communications have been applied to inventory related,
selection applications. U.S. Pat. No. 5,877,698 issued to Kusiner,
eta. on Mar. 2, 1999 describes a system of radio transmitters
positioned throughout a supermarket with mobile receivers
positioned on shopping carts commonly used by customers. When a
receiver is within a limited range of any specific transmitter, an
exclusive link is established whereby the transmitter sends to the
receiver a specific advertising message calling attention to a
"bargain" product at a specific nearby location. The link is broken
as the receiver moves out of range of the local transmitter, but
may establish links with other transmitters throughout the
facility.
[0010] U.S. Pat. No. 6,124,800 issued to Beard and Bunte on Sep.
26, 2000 discloses and claims a route delivery system utilizing
both local area network and wide area network radio frequencies to
communicate inventory data between an end delivery point (such as a
vending machine) and a stocked delivery vehicle, and between the
vehicle and a base office to minimize the number of actual visits a
service person must make to deliver the necessary inventory items
to a specific end point as well as to simplify routing of the
delivery vehicle. U.S. Pat. No. 5,505,473 issued to Radcliffe on
Apr. 9, 1996 and U.S. Pat. No. 5,877,962, a divisionally related
patent issued to Radcliffe on Mar. 2, 1999 describe and claim
respectively a computer-based system to facilitate proper placement
of articles picked by an attendant from inventory storage shelves
and deposited in delivery containers mounted on a cart and a method
for the practical utilization of the system. In addition, the
system and related method include an optional beacon light system
to indicate the location of inventory items to be picked or
recovered.
[0011] The system of the '473 patent and related method of the '962
patent depend on a single intelligent element or computer that must
maintain constant two-way radio communication between a
receiver/central control unit mounted on a cart and between the
optional beacon system located on storage shelves. A scanner
mounted on the cart is used to read codes on either the location or
item to be picked to validate the designated pick.
[0012] Current technology includes warehouse management systems
wherein given a request for any specific item, the system responds
by identifying the specific storage location in the facility.
[0013] There remains opportunity and need for the development of
intelligent automata in which dependency on a single intelligent
unit (computer) is minimized and in which novel, intelligent
technologies and systems are combined to yield a more reliable and
efficient, distributed, generalized, light-directed picking/putting
system as will be fully described in the following specification,
including figures and the appended claims.
SUMMARY OF THE INVENTION
[0014] Accordingly, a goal of this invention is a light directed
picking/putting system utilizing distributed intelligence to
facilitate processing the picking of customer orders such that the
quantity of an item and its specific storage location in a
warehouse are visually displayed to an attendant who retrieves
(picks) the specific quantity of the indicated items and places
(puts) them into one or more designated receptacles for further
delivery processing.
[0015] A further goal of this invention is a system wherein a
portable computer translates pick order information to light
addresses and through a series of circuits activates lighted
character displays indicating the quantity of items and location
from which the items are to be retrieved.
[0016] A still further goal of this invention is an intelligent
light assembly capable of receiving light address and pick order
directions and illuminating a character display indicating the
storage location and quantity of items to be retrieved
therefrom.
[0017] An additional goal of the invention is to utilize
independent portable computers positioned on mobile elements to
each communicate via wireless means with an intelligent
pick-controller unit positioned on storage bays to activate visual
signals indicating the location of an item on a shelf in the
bay.
[0018] A further goal of the invention is a system of distributed
intelligence that reduces the need for repeated visits to the same
storage bay to pick multiple SKUs by directing the attendant to
pick specific quantities of these SKUs from locations designated
with lighted character displays and by directing the attendant to
put these items into a single receptacle identified by a lighted
character display.
[0019] Still another goal of the invention is a system of
distributed intelligence that reduces the need for repeated visits
to the same storage location for an item required in multiple,
independent orders by directing the attendant to pick an aggregate
order quantity from a single storage location, identified by the
aggregate order quantity shown in a lighted character display, and
to put designated quantities of this SKU into multiple receptacles,
each identified by the designated quantity shown in a lighted
character display, thereby facilitating batch putting of multiple,
independent orders.
[0020] And still a further goal of the invention is management
through an interactive system associated with the light-directed
pick/put system that allows the attendant to indicate that the pick
is successfully completed or not.
[0021] Yet an additional goal is a system that indicates
unidentified locations to be assigned a light address that is
unique only to that specific location and independent of any
central computer system.
[0022] Another goal is to provide a system with keyboard or
speech-recognized completion confirmation that tolerates faults in
any put- or pick-controller unit or intelligent light assembly by
directing an attendant through spoken or visual means, independent
of such controller units and intelligent light assemblies, to pick
and put items according to an order.
[0023] These and other goals are achieved by a communication system
having a bi-directional, dual transmitter/receiver element in wired
communication with a portable computer and in wired or wireless
communication with put- and pick-controller units in which the
portable computer translates order location data into light
addresses that are communicated by wireless means to a
pick-controller unit positioned on a storage bay and in electrical
communication with a plurality of intelligent light assemblies each
of which intelligent light assemblies is positioned at a unique
location such that in response to the communicated, translated,
order location data, a specific intelligent light assembly is
activated illuminating a character display thereby indicating the
location and quantity of the SKU to be retrieved from that
location, and further, the portable computer, the bi-directional,
dual transmitter/receiver element, and put-controller unit are
positioned on a mobile element that has a plurality of receptacles
positioned on it, each receptacle having a unique, intelligent
light assembly positioned near it and wired to the put-controller
unit such that in response to translated location data communicated
from the portable computer through the bi-directional, dual
transmitter/receiver element and then through the put-controller
unit a character display is activated indicating the quantities of
any retrieved SKU to be put into each of one or more indicated
receptacles.
[0024] Moreover, these and other goals are achieved by a method
that includes positioning, on a mobile element, a portable computer
that has been programmed to translate pick order locations to
specific pick-location light addresses and to specific put-location
light addresses associated with specific receptacles that are
positioned on the same mobile element on which the portable
computer is positioned, and entering pick orders into the portable
computer after which the mobile unit attendant is instructed to
traverse a predetermined path throughout the storage facility, and
in response to a communication system activated by the attendant,
intelligent light assemblies at specified storage locations
illuminate to indicate the location and quantity of an item to be
picked from that location, and similar intelligent light assemblies
on the mobile unit indicate the quantity of each picked item to be
put into designated receptacles located on the mobile element; the
attendant repeats the intelligent light assembly directed pick and
put process until one or more orders is filled, returns the mobile
unit to a drop-off station for unloading and is then ready to
repeat the entire process when additional orders are entered into
the portable computer.
[0025] These and other goals of the invention are still further
achieved by a distributed intelligence communication system with a
pick-controller unit capable of being engaged in two-way
communication by means of a bi-directional, dual
transmitter/receiver element with a computer and being engaged in
two-way communication with a plurality of first intelligent light
assemblies, and also having a put-controller unit in two-way
communication by means of a bi-directional, dual
transmitter/receiver element with a computer and being engaged in
two-way communication with a plurality of second intelligent light
assemblies, and still further having means that enable a first
intelligent light assembly to respond to coded messages transmitted
through the pick-controller unit by the computer thereby displaying
unique instructions, and still further having means that enable a
second intelligent light assembly to respond to coded messages
transmitted through the put-controller unit by the computer thereby
displaying unique instructions, and finally having means that
enable activation of a second intelligent light assembly in
coordination with activation of a first intelligent light
assembly.
BRIEF DESCRIPTION OF THE FIGURES
[0026] The numerous purposes, applications, and advantages of the
present invention may be better understood by those skilled in the
art by reference to the following figures in which each reference
number, regardless of the figure in which it is used, refers to the
same part with the number as it initially is used and in which:
[0027] FIG. 1 is a schematic, block diagram of the entire wireless,
light-directed, pick/put system with a single mobile unit, a single
stationary unit, and lines of communication and their
inter-relationships;
[0028] FIG. 2A is a detailed schematic diagram of a mobile unit in
accordance with the present invention;
[0029] FIG. 2B is an illustration of a mobile unit illustrating the
relative positions of the components described in FIG. 2A; and
[0030] FIG. 3 is a detailed schematic diagram of a stationary unit
in accordance with the present invention.
DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS
[0031] FIG. 1 presents the major elements and basic organization of
the unique, distributed, wireless, light-directed, pick/put system
1. The system 1 comprises at least one mobile unit 2 and at least
one stationary unit 3.
[0032] Each mobile unit 2 comprises a mobile element 21 on which
are positioned a portable computer 4 and a put-controller unit 5.
The put-controller unit comprises two integrated elements, a
transmitter/receiver component 6 and intelligent circuitry element
7. Preferably, the portable computer 4 is in wired, bi-directional
communication 8 with a bi-directional, dual transmitter/receiver
element 16 that in turn is in wireless, bi-directional
communication 13 with both the put-controller unit 5 and the
pick-controller unit 12. The put-controller unit 5 is wired
directly 9 for bi-directional communication, preferably using an
RS-485 port, to a plurality of intelligent light assemblies 10. The
intelligent light assemblies are positioned on or convenient to
individual, removable receptacles 11 that are positioned on and
transported by the mobile element 21.
[0033] In an alternative mode, the portable computer 4 uses the
bi-directional, dual transmitter/receiver element 16 in a mode
disconnected from the mobile unit 2 to communicate bi-directionally
with put-controller unit 5 and pick-controller unit 12 and
consequently controls the operation of intelligent light assemblies
10 and 15 by wireless means while walking from place to place.
[0034] The portable computer 4 also may include an integrated bar
code reader used in associating light addresses with storage
locations. The bar code reader may be independent of, but capable
of communicating with the portable computer.
[0035] The stationary unit 3 as described in FIG. 1 comprises a
pick-controller unit 12. The pick-controller unit 12 comprises a
bi-directional, dual transmitter/receiver component 6 and an
intelligent circuitry element 7. The put-controller unit 5 and
pick-controller unit 12 are capable of being in bi-directional,
wireless communication 13 with each other. The pick-controller unit
12 is in bi-directional, wired communication 14 with a plurality of
intelligent light assemblies 15, each of which contains a unique
light address and is positioned at a specific location on a storage
bay with multiple locations.
[0036] FIG. 2A provides details of the mobile unit 2. A mobile
element 21 provides the structural frame for the mobile unit 2. In
practice, the mobile element 21 may be any of a variety of custom
or commercially available carts appropriate to move in a specific
facility. Most commonly, the cart is moved by hand; however, the
present invention also anticipates the use of motorized carts or
trays carried on conveyors.
[0037] Receptacles 11 are positioned on shelves 24 of the mobile
element 21. As illustrated in FIG. 2A, the mobile element 21 has
four shelves 24 with four receptacles 11 each positioned on a shelf
24. Various means may be used to secure the receptacles 11 on the
shelves 24. An intelligent light assembly 10 is positioned on or
convenient to each receptacle 11, and each intelligent light
assembly 10 is wired 9 in a daisy-chain arrangement, in
bi-directional communication, to the put-controller unit 5.
Put-controller unit 5, in turn, is in bi-directional, wireless
communication 13 with the bi-directional, dual transmitter/receiver
element 16 that is in wired, bi-directional communication 8 with
the portable computer 4. Each intelligent light assembly 10
includes a visual display means such as an LED or character display
and a momentary contact switch 36 or similar device. Momentary
contact switch 36 is used to set initial light addresses and to
provide the means by which the attendant indicates that the
designated put has been completed.
[0038] FIG. 2B illustrates an upright cart 22 with a base 23
supporting four casters 27 (only three of which are visible) a
vertical frame 25 with a top support 26. As illustrated, the cart
22 has four shelves 24 with three receptacles 11 positioned on
these shelves. A power source 28 is positioned on the back side of
the cart.
[0039] As further illustrated in FIG. 2B, the portable computer 4
is removably positioned on the top support 26. The portable
computer 4 is programmed to translate pick order location data to
specific intelligent light assembly addresses. The portable
computer 4 has visual display means 29, preferably an audio
communications means, a keypad, and a touch screen capable of data
entry with either a finger or stylus. In addition, the portable
computer may receive pick order and other data and instructions by
wireless means, by speech input, by diskette transfer, by network
linkage, by keypad entry, or comparable means. The portable
computer also preferably has audio communication capabilities by
means of an integrated microphone and speaker system.
[0040] In an alternative configuration, the bi-directional, dual
transmitter/receiver element 16 of FIG. 1 may be integral to the
portable computer 4. In this configuration, the portable computer 4
may be operated independently of the cart 22.
[0041] The details of a stationary unit are depicted in FIG. 3. As
illustrated in FIG. 3, the pick-controller unit 12 is positioned on
a bay 31, comprising a group of storage locations 32. An
intelligent light assembly 15 that includes a light display means
such as an LED or character display is positioned near each
location 32 and wired 14 to the pick-controller unit 12. Each
intelligent light assembly 15 includes a momentary contact switch
36, or similar device used to set initial light addresses. As with
the mobile unit described above, the momentary contact switch 36 or
similar device also provides the means by which the attendant
indicates that the designated pick has been completed. Power is
provided through a connection to the entire stationary unit by
means of either a central source of power or a battery.
[0042] The put- and pick-controller units comprise the same basic
components and serve the same basic function. Both include a
transmitter/receiver component and a controller circuitry element.
Communication between both the put- and pick-controller units is by
wireless means such as radio frequency means or infrared means. One
of average skill in the art will realize that the specific
transmitter/receiver component will depend on the wireless means
employed.
[0043] In addition to the transmitter/receiver component, each put-
or pick-controller unit preferably comprises the following:
[0044] LED and circuit protection if necessary;
[0045] power on/off or reset switch;
[0046] power supply; and
[0047] RS-485 bi-directional communication port with RJ-45
connector for connecting assemblies together in a daisy-chain
configuration.
[0048] Each intelligent light assembly preferably comprises the
following:
[0049] LED indicating status of the intelligent light assembly;
[0050] character display (optional);
[0051] momentary contact switch;
[0052] RS-485 bi-directional communication port;
[0053] RJ-45 connectors (2) for connecting assemblies together in a
daisy-chain configuration;
[0054] internal RS-485 terminating resistor, and
[0055] switches for bypassing or activating the internal circuitry
or including or excluding the RS-485 terminating resistor in the
circuitry.
[0056] The system has the capability of assigning a new light
address for any intelligent light assembly positioned at a new
location. After installing a new light intelligent assembly on a
shelf location, the installer holds down the momentary contact
switch on the intelligent light assembly for at least two seconds.
This action results in the temporary resetting of the light address
to zeros. The put- or pick-controller supervising the collection of
intelligent light assemblies polls all known intelligent light
assemblies (using a polling list of light addresses augmented with
light address "zero") and asks if any messages need to be
transmitted. When a newly installed intelligent light assembly
(with light address of "zero") is polled, it transmits a "request
for light address" message to its attached controller. The attached
controller searches for an unassigned light address and assigns
this light address to the requesting intelligent light assembly.
The newly assigned light address will be transmitted in the address
portion of the message header for the intelligent light assembly
for subsequent storage in the intelligent light assembly's
non-volatile (NV) RAM. The attached controller stores newly
assigned light addresses in its poll list and sends a message to
the newly installed intelligent light assembly to initiate a slow
flashing action with its LED.
[0057] Each put- or pick-controller will preferably regulate a
maximum of 255 intelligent light assemblies (each corresponding to
an intelligent light assembly at a storage site or location). Each
time the system is powered-up, it polls all 255 possible
intelligent light assemblies, including unassigned light addresses.
Thereafter, the attached controller only polls light addresses in
the polling list, thereby improving efficiency by bypassing
unattached intelligent light assemblies.
[0058] In practice, when the system of pick-controllers and
intelligent light assemblies is first installed, an operator
traverses the entire storage facility without knowing which
pick-controllers to poll. The portable computer requests a response
from any pick-controller (by polling with a controller address of
zero) within its range (generally less than one meter to avoid
concurrent communication with multiple controllers). As a
pick-controller is contacted, if a new light address has been
assigned, the pick-controller so indicates and communicates that
new light address to the portable computer. The portable computer
in response commands the intelligent light assembly at the new
light address to flash its LED rapidly, instructs the attendant to
scan the barcode on the shelf location adjacent to the flashing LED
with the scanner on the portable computer and to press the
momentary contact switch on the intelligent light assembly. This
procedure enables the portable computer to associate the shelf
location with the newly assigned light address so that attendants
can be directed to pick products at that location by illuminating
the intelligent light assembly.
EXAMPLE 1
[0059] This example of the application of the invention assumes
existence of a warehouse management system in which stock keeping
units are identified with a specific physical location in a
warehouse or storage facility. An order is processed through the
warehouse management system to produce a pick order that indicates
a specific location and quantity of items to be retrieved from that
location.
[0060] The portable computer is preprogrammed to translate
warehouse locations to pick-controller and light addresses of the
desired SKUs and further to allow batch picking of orders by
grouping the picking of SKUs from more than one order and then
designating specific quantities to be placed in individual
receptacles for multiple orders. Generally the light address is
limited to a shelf or single location in a designated bay or group
of shelves. Thus, the portable computer has further been programmed
to, by audio or visual display means, indicate to the
operator/attendant the aisle or comparable location for finding the
SKU. In addition, the program includes the capability to enter
multiple orders for batch putting. The program allows the total
number of items to be picked to be indicated at a single pick
location and the distribution of the retrieved items to multiple,
specific receptacles positioned on the mobile element.
[0061] By way of illustration, but not as a limitation, pick orders
would be loaded into the portable computer by any common means
including a keyboard associated with or remote from the portable
computer, as instructions sent by wireless means to the portable
computer (which assumes the portable computer is capable of
receiving such wireless communications), by network connection, by
telephone, by voice, by scanning or card read devices, or from
another computer using one of the aforementioned means. Input data
include the storage facility location, quantity, SKU number, pick
order number, pick order line and customer number or similar basis
to sort selected items. A variety of locations may be entered, and
the portable computer program will sort picking order lines by
location to minimize travel in the facility.
[0062] When input data exchange is completed, by audio or visual
signal, the portable computer instructs the attendant to travel to
a specific location where the first pick is to be made. After each
pick is made, the portable computer again instructs the attendant
to travel to the next, specific location.
[0063] In practice, a storage facility would have a large number of
bays, each of which would have an independent, intelligent, pick-
controller unit that communicates by wired means with a unique set
of up to 255 intelligent light assemblies, each of which
intelligent light assemblies is positioned adjacent to a specific
storage location. A plurality of mobile elements (carts) each with
an independent portable computer and put-controller unit with
transmitter/receiver capabilities may be distributed throughout the
storage facility and are operated simultaneously. As a means of
avoiding unintended actions by multiple, portable computers that
may receive messages from the same pick-controller unit, each
message transmitted between a portable computer and a
pick-controller unit contains a unique, portable computer address.
Even though multiple portable computers receive the same message,
only the portable computer whose assigned address matches the
portable computer address transmitted by a pick-controller unit
takes an action based upon the message.
[0064] Moreover, the system is designed to confirm successful
communication between a given portable computer and a given put- or
pick-controller unit. ACK/NAK logic is used with timeouts to
confirm success or failure of all communications between the
portable computer and any put- or pick-controller unit. As part of
fail-soft operation, all transmissions between a portable and a
controller unit follow a protocol in which the portable computer
transmits appropriate error messages by audio and visual means in
the event of a failed transmission.
[0065] In a preferred embodiment, an attendant along an aisle
following verbal instructions provided by the portable computer
through audio means, moves an individual mobile unit containing
order location data translated and stored in the portable computer
attached to the mobile unit. The portable computer, through a
bi-directional, dual transmitter/receiver element, constantly
transmits a unique address signal for a specific target
pick-controller unit mounted on a bay (polls for the
pick-controller unit). Any pick-controller unit within the
generally limited range will ignore the poll if the address part of
the message does not match the internal address of the
pick-controller unit. When the correct, bay-mounted, intelligent,
pick-controller unit recognizes its assigned address, a message is
sent from the pick-controller unit to the bi-directional, dual
transmitter/receiver element connected to the portable computer
indicating that the computer has reached the region of the
specific, intelligent pick-controller unit. The portable computer
then sends a message to the pick-controller unit to flash the LED
on an attached, intelligent light assembly at a specific light
address. The portable computer then outputs a spoken message
directing the attendant to stop and "pick" the item(s) at the
location with the flashing LED. If an LED display is part of the
assembly, then the quantity to be picked from the location is
illuminated in the display; otherwise, the portable computer, by
both audio and visual means, instructs the attendant of the
quantity of the item to be picked. Upon completion of the pick, the
momentary contact switch on the intelligent light assembly is
pressed to notify the portable computer of the completed picking.
The attendant can report insufficient quantities of any item at a
location to the portable computer, thereby reporting an incomplete
pick.
[0066] In addition to "pick" capabilities, the system characterized
in FIG. 1 has "put" (or sort) capabilities to direct the attendant
to place various quantities of the picked item from a batch pick
order into specific receptacles on the mobile element. The portable
computer determines the receptacle locations on the mobile element
into which items should be put. Information concerning the
locations on the mobile unit for putting is transmitted from the
portable computer to a put-controller unit, and from the
put-controller unit by wire to the set of intelligent light
assemblies on the mobile element that illuminate an LED and
(optionally) display the quantity to be placed in each intended
receptacle. If a character display is part of the intelligent light
assembly, then the quantity to be put into the receptacle is
illuminated in the display; otherwise, the portable computer, by
either audio or visual means or both, instructs the attendant of
the quantity of the item to be put into each receptacle.
[0067] The portable computer has means of key, stylus, or touch
entry by which the attendant can indicate when the pick/put process
has been completed or can otherwise indicate if an item could not
be completely filled (short picked). If additional items are to be
selected from the same bay, the portable computer activates the
next light address; otherwise, it instructs the attendant, by
either audio or visual means or both, to move the mobile element
(cart) to another area of the storage facility where packing or
subsequent processing of the picked items commences.
EXAMPLE 2
[0068] The technology and procedures described for warehouse
applications find clear application in a variety of other settings.
In a second example, the SKU is an item in a large grocery store.
Grocery carts are equipped with preprogrammed portable computers,
and either an attendant or the customer enters pick instructions
and proceeds as described in Example 1.
[0069] The invention finds application in health care delivery in
at least two settings. Patient rooms, laboratories, and offices all
require certain general supplies and some specialized supplies. The
system is readily adapted for use with in-house inventory
management. In addition, management of the distribution of patient
medications may be improved by application of the system. Pick
orders may be handled in the usual manner as previously described,
but the actual put order (delivery to the patient) can be verified
by a simple RFID chip integrated with the patient's hospital
identification and records.
EXAMPLE 4
[0070] The system finds practical application when operated in
reverse. Distribution of multiple SKUs to different customers can
be accomplished by illuminating intelligent light assemblies
adjacent to receptacles on a cart, where each receptacle contains
multiple instances of a single SKU to be picked, and similarly by
illuminating intelligent light assemblies adjacent to shelves on a
storage bay onto which the items should be put. The illuminated
intelligent light assembly on the cart receptacle would indicate
the quantity of items to be picked while the illuminated
intelligent light assembly (or assemblies) on the bay would
indicate the quantity of the item to be put onto each shelf
location.
[0071] Preferred embodiments of the invention have been described
using specific terms and devices. The words and terms used are for
illustrative purposes only. The words and terms are words and terms
of description, rather than of limitation. It is to be understood
that changes and variations may be made by those of ordinary skill
art without departing from the spirit or scope of the invention,
which is set forth in the following claims. In addition it should
be understood that aspects of the various embodiments may be
interchanged in whole or in part. Therefore, the spirit and scope
of the appended claims should not be limited to descriptions,
figures, and examples herein.
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