U.S. patent application number 11/210014 was filed with the patent office on 2005-12-22 for multiple station inventory control system.
Invention is credited to Ali, Ala.
Application Number | 20050279722 11/210014 |
Document ID | / |
Family ID | 34198289 |
Filed Date | 2005-12-22 |
United States Patent
Application |
20050279722 |
Kind Code |
A1 |
Ali, Ala |
December 22, 2005 |
Multiple station inventory control system
Abstract
An inventory control system may include one or more paddles, a
position of which is changed by adding or removing items to be
inventoried, a plurality of encoder strips, each connected for
motion with a paddle, and a plurality of detectors at least some of
which are each responsive to the motion of an encoder strip to
determine the addition or removal of the items. The encoding strip
may be in the form of a loop mounted for rotation or a linear
member such as self coiling strip. An alternate embodiment may
include an illumination target mounted for motion with each paddle
and a light source and detector for determining motion of the
target.
Inventors: |
Ali, Ala; (Los Angeles,
CA) |
Correspondence
Address: |
IRELL & MANELLA LLP
1800 AVENUE OF THE STARS
SUITE 900
LOS ANGELES
CA
90067
US
|
Family ID: |
34198289 |
Appl. No.: |
11/210014 |
Filed: |
August 23, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11210014 |
Aug 23, 2005 |
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10924665 |
Aug 23, 2004 |
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60497437 |
Aug 22, 2003 |
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Current U.S.
Class: |
211/59.3 |
Current CPC
Class: |
A47F 10/00 20130101;
A47F 2010/025 20130101 |
Class at
Publication: |
211/059.3 |
International
Class: |
A47F 001/04 |
Claims
I claim as my invention:
1. An inventory control system comprising: one or more paddles, a
position of which is changed by adding or removing items to be
inventoried; one or more encoder strips, each connected for motion
with a paddle; and one or more detectors at least one of which is
responsive to the motion of an encoder strip to determine the
addition or removal of the items.
2. The invention of claim 1 wherein the one or more encoder strips
each further comprise: an elongate member having a plurality of
contrasting bars detectable by the detector associated
therewith.
3. The invention of claim 2 wherein each detector further
comprises: an illumination source; and a pair of photo detectors
configured to detect motion and the direction of motion of the
contrasting bars of the encoder strip associated therewith to
determine how many items were added or how many items were
removed.
4. The invention of claim 3 in which the pair of photo detectors
are configured to detect the direction of motion of the encoder
strip associated therewith for determining how many items were
added and how many items were removed from inventory associated
with the encoder strip.
5. The invention of claim 2 wherein at least one of the encoder
strips forms a continuous loop mounted for rotation in response to
motion of the paddle associated therewith.
6. The invention of claim 2 wherein at least one of the encoder
strips forms a linear member mounted for linear motion in response
to motion of the paddle associated therewith.
7. The invention of claim 6 wherein each of the encoder strips
which form a linear member includes a self coiling portion from
which the linear member may automatically be extended or retracted
by motion of the paddle associated therewith.
8. The invention of claim 7 further comprising: a post associated
with each detector for mounting the self coiling portion of an
encoder strip for rotation.
9. The invention of claim 8 further comprising: one or more turning
guides associated with each post to cause the linear portion of the
encoding strip to change direction after being extended or
retracted from the self-coiling portion mounted the post associated
therewith.
10. The invention of claim 9 wherein at least some of the turning
guides further comprise: a housing for an illumination source or
for a pair of photo detectors configured to detect motion of the
contrasting bars of the encoder strip associated therewith to
determine how many items were added or how many items were removed
associated with the encoder strip.
11. The invention of claim 10 in which the pair of photo detectors
are configured to detect the direction of motion of the encoder
strip associated therewith for determining how many items were
added and how many items were removed from inventory associated
with the encoder strip.
12. The invention of claim 2 further comprising: one or more
housings, each including a plurality of monitoring stations, each
monitoring station including a number of the plurality of
detectors, each detector including a source of illumination and one
or more photo detectors configured to detect motion of the
contrasting bars of an encoder strip associated therewith to
determine how many items were removed from inventory associated
therewith, and each detector further including a post on which may
be mounted a self coiling portion of an encoder strip, a linear
member of which is extended or retracted in response to the motion
of one of the paddles; whereby changes in the configuration of the
items to be inventoried may easily be accommodated by changing the
number and position of the paddles, attaching a portion of the
linear member of an encoder strip to each paddle and mounting the
self coiling portion of that encoder strip on a convenient
post.
13. The invention of claim 12 in which the pair of photo detectors
are configured to detect the direction of motion of the encoder
strip associated therewith for determining how many items were
added and how many items were removed from inventory associated
with the encoder strip.
14. An inventory control system comprising: one or more paddles, a
position of which is changed by adding or removing items to be
inventoried, each paddle including an illumination target; one or
more sources of illumination, each illuminating one or more
targets; and one or more detectors, each responsive to light
reflected from the one or more targets for detecting motion of each
paddle to determine how many items to be inventoried were removed
from inventory related to each such paddle.
15. An inventory control system, comprising: a housing including a
plurality of detectors, each detector including a source of
illumination and one or more photo detectors configured to detect
motion of the contrasting bars of an encoder strip which may be
associated therewith to determine how many items were removed from
inventory associated therewith, each detector further including a
post on which may be mounted a self coiling portion of an encoder
strip, a linear member of which may be extended or retracted in
response to the motion of a pusher associated with a subset of the
items, whereby changes in the configuration of the items to be
inventoried may easily be accommodated by changing the number and
position of the pushers, attaching a portion of the linear member
of an encoder strip to each pusher and mounting a self coiling
portion of that encoder strip on a convenient post.
16. The invention of claim 15 wherein each detector further
comprises: one or more turning guides associated with each post to
cause the linear portion of the encoding strip to change direction
after being extended or retracted from the self-coiling portion
mounted on the post associated therewith.
17. A method for inventory control, comprising: providing a
plurality of detectors mounted on a housing; providing a plurality
of encoding strips, one of which may be associated with each of the
detectors and connected for motion with a pusher associated with
items to be inventoried; and detecting motion of the encoder strips
to determine items removed from inventory.
18. The invention of claim 17 wherein detecting motion further
comprises: detecting motion of contrasting bars on the encoder
strip.
19. The invention of claim 17 wherein providing the encoding strips
further comprises: providing encoding strips with self coiling
portions configured for removably mounting in association with each
detector.
20. The invention of claim 19 wherein providing the encoding strips
further comprises: providing turning guides through which the
encoding strips may be threaded to change direction of a linear
portion of each encoding strip to reduce a dimension of the
housing.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation in part of U.S. patent application
Ser. No. 10/924,665, filed Aug. 23, 2004 which claims the priority
of U.S. Provisional Patent Application Ser. No. 60/497,437 filed on
Aug. 22, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to inventory control systems and in
particular to systems which monitor and report on the number of
items stored at a particular location.
[0004] 2. Description of the Prior Art
[0005] Many inventory management systems such as those in grocery
stores and general merchandising stores commonly display products
for sale on a shelf. In an effort to organize products in a more
cost-effective and time-efficient manner, and display them in an
esthetically pleasing way, stores began placing dividers and pusher
paddles on shelves. Dividers may vary in length and height to
facilitate better organization of products on a shelf. They allow a
pusher paddle to be placed in between them to move products forward
as products are retrieved from the front of the shelf.
[0006] Inventory data, that is, data reflecting the number of
items, such as a can, at a particular location on a shelf is
conventionally collected manually although various proposals have
been made to automate the collection of such data.
[0007] Conventional product display systems, such as the
Shelf-facing System, available from FFr Inc. of Cleveland, Ohio
include a spring-powered pusher paddle movable on a track against
the resistance of a flat spring coiled within. In a grocery store
application, a series of cans may be lined up in front of the
paddle to fill the shelf. As one can is removed, the spring causes
the remaining cans to be pushed forward to maintain the appearance
of a full shelf.
[0008] What is needed is an improved technique for automating the
collecting of inventory data.
SUMMARY OF THE DISCLOSURE
[0009] An inventory control system is disclosed in one aspect
having one or more paddles, a position of which is changed by
adding or removing items to be inventoried, one or more encoder
strips, each connected for motion with a paddle and one or
detectors at least one of which is each responsive to the motion of
an encoder strip to determine the addition or removal of the
items.
[0010] An inventory control system is disclosed in one aspect
having one or more paddles, a position of which is changed by
adding or removing items to be inventoried, each paddle including
an illumination target, one or more sources of illumination, each
illuminating one or more targets and one or more detectors, each
responsive to light reflected from the one or more targets for
detecting motion of each paddle to determine how many items to be
inventoried were removed from inventory related to each such
paddle.
[0011] An inventory control system is disclosed in a further aspect
having a housing including a plurality of detectors, each detector
including a source of illumination and one or more photo detectors
configured to detect motion of the contrasting bars of an encoder
strip which may be associated therewith to determine how many items
were removed and/or removed from inventory associated therewith,
each detector further including a post on which may be mounted a
self coiling portion of an encoder strip, a linear member of which
may be extended or retracted in response to the motion of a pusher
associated with a subset of the items, whereby changes in the
configuration of the items to be inventoried may easily be
accommodated by changing the number and position of the pushers,
attaching a portion of the linear member of an encoder strip to
each pusher and mounting a self coiling portion of that encoder
strip on a convenient post.
[0012] A method for inventory control is disclosed by providing a
plurality of detectors mounted on a housing, providing a plurality
of encoding strips, one of which may be associated with each of the
detectors and connected for motion with a pusher associated with
items to be inventoried and detecting motion of the encoder strips
to determine items removed from inventory.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A illustrates an exemplary shelf.
[0014] FIG. 1B illustrates an exemplary shelf with products placed
thereon.
[0015] FIG. 1C illustrates an exemplary shelf with products
organized by dividers.
[0016] FIG. 1D illustrates an exemplary shelf with products
organized by dividers with some products missing from the front of
the shelf.
[0017] FIG. 1E illustrates an exemplary shelf with products
organized by dividers with a push plate pushing the products from
the back of the shelf toward the front of the shelf as products are
retrieved from the front.
[0018] FIG. 1F illustrates an exemplary shelf, wherein a monitoring
device determines the number of products remaining on the shelf and
communicates the information through a computer system.
[0019] FIG. 1G illustrates an exemplary shelf, wherein a monitoring
device determines the number of products remaining on the shelf and
communicates the information through a computer system and also
displays the information in an electronic display located in front
of the products.
[0020] FIG. 2A illustrates an exemplary pushing mechanism having a
push plate.
[0021] FIG. 2B illustrates an exemplary computer mouse.
[0022] FIG. 2C illustrates an exemplary computer mouse attached to
the pushing mechanism behind the push plate.
[0023] FIG. 2D illustrates an exemplary computer mouse according to
FIG. 2C, wherein a movement of the mouse corresponds to the
movement of the push plate.
[0024] FIG. 2E illustrates an exemplary computer mouse according to
FIG. 2C, wherein the mouse moves further backward to correspond to
the movement of the push plate.
[0025] FIG. 2F illustrates an exemplary computer mouse according to
FIG. 2C that has moved backwards to the end of the pushing
mechanism to correspond to the movement of the push plate.
[0026] FIG. 2G illustrates an exemplary computer mouse according to
FIG. 2C with products on the system. The mouse has moved relative
to the push plate.
[0027] FIG. 2H illustrates an exemplary computer mouse according to
FIG. 2C with products on the system that has moved forward the same
distance as the depth of a product as a product has been removed
from the front. The mouse has moved relative to the push plate.
[0028] FIG. 2I illustrates an exemplary computer mouse according to
FIG. 2C with products on the system that has moved forward the same
distance as the depth of a product as another product has been
removed. The mouse has moved relative to the push plate.
[0029] FIG. 2J illustrates an exemplary computer mouse according to
FIG. 2C that has moved forward as all of the products have been
removed from the front of the shelf. The mouse has moved relative
to the push plate.
[0030] FIG. 3A illustrates an exemplary hub that is used to receive
connections from a plurality of the computer mice attached to the
pushing mechanism and communicate the information to a computer
system.
[0031] FIG. 3B illustrates an exemplary computer.
[0032] FIG. 3C illustrates an embodiment of the invention where a
plurality of computer mice attached to the pushing mechanism
transfer information concerning inventory products through a hub to
a computer.
[0033] FIG. 4A illustrates an exemplary electronic tape
measure.
[0034] FIG. 4B illustrates another embodiment of the invention
using an exemplary electronic tape measure (or components from it)
instead of a computer mouse.
[0035] FIG. 4C illustrates an exemplary electronic laser measuring
device.
[0036] FIG. 4D illustrates another embodiment of the invention
using an electronic laser measuring device (or components from it)
instead of a computer mouse.
[0037] FIG. 4E illustrates an example of how the multiple
electronic measuring tape or electronic laser measuring device is
used to detect the number of inventory products on a shelf and
communicate the information through a hub to a computer system.
[0038] FIG. 5A illustrates an exemplary photo cell.
[0039] FIG. 5B illustrates an exemplary light emitting diode
(LED).
[0040] FIG. 5C illustrates an encoder with holes evenly placed.
[0041] FIG. 5D illustrates an encoder with holes evenly placed
moving between a photo cell and a LED.
[0042] FIG. 5E illustrates another embodiment of the invention
where an encoder moves between a LED and a photo cell to determine
the presence or removal of the inventory products remaining on a
display area.
[0043] FIG. 5F illustrates another embodiment of the invention
where an encoder moves between a LED and a photo cell to determine
the presence or removal of the inventory products remaining on each
display area and communicate the information through a hub to a
computer system.
[0044] FIG. 5G illustrates another embodiment of the invention
where an encoder moves between a LED and a photo cell to determine
the presence or removal of the inventory products remaining on each
display area and communicate the information through a hub to a
computer system which is displayed near the corresponding display
area.
[0045] FIG. 5H illustrates another embodiment of the invention as
illustrated in FIG. 5H, except that the invention operates
wireless.
[0046] FIG. 6 is a top view of a multistation inventory control
system illustrating various sensor techniques for determining the
number of items on a shelf.
[0047] FIG. 7 is a front view of a portion of an encoder strip that
may be used in inventory stations in a multistation inventory
control system.
[0048] FIG. 8 is a top view of an inventory station using the
encoder strip of FIG. 7.
[0049] FIG. 9 is a top view of an alternate embodiment of the
inventory station of FIG. 8.
[0050] FIG. 10 is a front view of a rotating target used with
another embodiment of the inventory station of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0051] An improved inventory monitoring system is disclosed that
allows users to keep their existing organization and display
mechanism of products, yet monitors and communicates the most
updated inventory of the products almost at the same time a change
is made to the inventory. At the very moment a customer picks up a
product and removes it from a product display space, the present
inventory monitoring system would determine the number of the
products remaining on the display space and transmits that
information to a computer to be viewed by any user whoever has
access to the computer, e.g., the manager of the store, an employee
of the store, or the supplier of the products. The manager or any
other employee of the store can react to the information by
immediately replenishing the display space with a new set of the
products. The supplier of the products may alert the store to order
more supplies of the products.
[0052] An improved inventory monitoring system is disclosed that
can be used to prevent theft. Knowing the most updated count of
products displayed on the display space alert the store of a
potential shoplifting. Because most shoplifters steal more than one
item at a time, the significant decrease of the number of products
in a short period of time will alert the store whether a potential
shoplifting has taken place. Before the perpetrator leaves the
store, the store security, acting based upon the most updated
information, can locate and capture the perpetrator.
[0053] Such information can also be displayed near the display
space to alert the employees of the number of the products
remaining on the display space along with any other relevant
information about the products, such as the price, the name and the
sale status, the bar code number, etc. The employees walking by the
display space then can react immediately and replenish the display
space with a new set of the products on the display space before
the products completely run out.
[0054] An improved inventory monitoring system is disclosed that
uses an electronic detection system within a product display space
to detect a movement of the inventory products. The product display
space comprises a pusher paddle which indicates the position of the
product placed farthest from the front of the product display
space. By knowing the depth of the product and detecting the
movement of the inventory products displayed on the display space,
the improved inventory monitoring system calculates the number of
products remaining on the display space. FIGS. 1A-2A illustrates an
exemplary inventory display using a shelf 1 upon which products 2
are placed. Using dividers 3, the products 2 can be displayed more
efficiently and consumers can locate products more easily. At the
same time, they are esthetically pleasing to consumers. To further
increase the efficiency of product display, stores typically place
a plurality of the same products 2 together in a row, and thus the
products 2 in a row will share the same depth. To further increase
the efficiency of product display, stores use a pusher paddle 7 to
move the remaining products toward the front of the display space
4. The pusher paddle 7 may be spring-powered. The spring in the
spring-powered pusher paddle 7 may be flat and coiled within the
pusher paddle 7. The pusher paddle 7 determines the position of the
product placed farthest from the front of the display space 4.
[0055] After having determined the depth of the products 2, a user
can use any of the following embodiments to detect the movement of
the pusher paddle 7 and ultimately determine the most updated count
of the products 2 remaining on the display space 4.
[0056] Referring now also to FIGS. 2B through 2J, one embodiment
uses a computer mouse 8 to track the movement of the pusher paddle
7. The computer mouse 8 is configured to detect the movement of the
pusher paddle 7 and travel the identical distance that the pusher
paddle 7 travels.
[0057] The computer mouse 8 will sense any movement of the pusher
paddle 7 and communicate the movement to a computer 10 which is in
communication with the computer mouse 8.
[0058] As shown for example in FIG. 1G, cord 5 may be connected to
the pusher paddle 7 to relay information to the electronic
components to provide information on the movement of pusher paddle
7 and therefore the addition or removal of products.
[0059] Electronic wiring and displays 6 can also be used to display
product information like product name, product description, prices
and inventory levels, etc.
[0060] For example, in FIG. 2G, the pusher paddle 7 is placed
behind three products 2 and the computer mouse 8 is placed behind
the pusher paddle 7. As illustrated in FIG. 2H, after a customer
has removed the product 2 placed closest to the front of the
display space 4, the pusher paddle 7 travels toward the front of
the display space 4 the distance identical to the depth of the
product 2. Behind the pusher paddle 7 is the computer mouse 8 which
has traveled the same distance as the pusher paddle 7. FIG. 2I
further illustrates the further movements of the product 2, the
pusher paddle 7, and the computer mouse 8, leaving only one product
2 on the display space 4. FIG. 2J further illustrates the further
movement of the product 2, the pusher paddle 7, and the computer
mouse 8, leaving the display space 4 empty.
[0061] As Referring now also to FIGS. 3A through 3C, the computer
mouse 8 is in connection with a computer 10 to communicate the
measurement of the distance that the pusher paddle 7 has traveled.
Such communication will translate into a number of the products 2
remaining on the display space 4 using the pre-determined depth of
the products 2. Such communication can take place through a hub 9.
Also, such communication can be done wirelessly. The computer 10
then communicates the resulting number of the products 2 remaining
on the display space 4 to any other computer in connection with the
computer 10. The communication between the computer 10 and another
computer can be wireless. Further, the computer 10 may communicate
the resulting information to an electronic display 6 near the
display space 4, along with other relevant information about the
products, such as the price, the name, the sale status, the bar
code number, etc. The communication between the computer 10 and the
electronic display can be wireless.
[0062] FIGS. 4A through 4E illustrate another embodiment of using
an electronic tape measure 12. The electronic tape measure 12 is
configured to determine the distance that the pusher paddle 7
travels. The electronic tape measure 12 may, for example, be an
electronic laser measuring device 13 such as a laser range finder.
The electronic tape measure 12 is in connection with a computer 10
so that any movement of the pusher paddle 7, once determined, will
be communicated to the computer 10 for users to view. The
communication between the electronic tape measure 12 and the
computer 10 can be wireless. The computer 10 may also be in
connection with an electronic display placed near the display space
so that the most updated count of the products 2 remaining on the
display space 4 can be displayed, along with other relevant
information about the products, such as the price, the name, the
sale status, the bar code number, etc. The communication between
the computer 10 and the electronic display can be wireless. The
computer 10 may also be in connection with another computer so that
the most updated count of the products 2 can be communicated to a
remote user. The communication between the computer 10 and another
computer can be wireless.
[0063] FIGS. 5A through 5I illustrates another embodiment using at
least one light emitting diode (LED) 101 and at least one photocell
102 to detect the movement of an encoder 103 which is configured to
correspond to the movement of the pusher paddle 107. The encoder
103 is further configured to pass between the LED 101 and the
photocell 102 so that a beam of light emitted from the LED 101 can
be received through the encoder 103 by the photocell 102. The
encoder 103 may be made of a strip of various materials, such as
plastic, rubber, metal, etc. having a plurality of holes equally
spaced along the length of the encoder 103. The encoder 103 may be
made into various sizes and assume various shapes, such as
rectangle, square, circle, or disk.
[0064] The encoder 103 may be slideably configured along the length
of the display space to cover at least the combined depths of all
the products displayed on the display space. The encoder 103 may
have one end of the encoder 103 substantially in connection with
the pusher paddle 107 so that the encoder 103 can move as the
pusher paddle 107 moves along the length of the display space.
[0065] In one embodiment, the encoder 103 may have one end of the
encoder 103 substantially in connection with one end of the spring
within the pusher paddle 107 and have the other end of the encoder
103 substantially in connection with the other end of the spring
within the pusher paddle 107 so that the encoder 103 can move as
the pusher paddle 107 moves along the length of the displace
space.
[0066] The encoder 103 that is substantially in connection with the
pusher paddle 107 may loop around the display space. As the pusher
paddle 107 moves towards the back end of the display space, the
encoder 103 moves towards the back end of the display space 104. As
the pusher paddle 107 moves towards the front of the display space,
the encoder 103 moves towards the front of the display space.
[0067] As illustrated in FIG. 5E, the LED 101 emits a beam of light
toward the encoder 103. The holes in the encoder 103 break the beam
of light from the LED 101 so that the photocell 102 sees pulses of
light, instead of a continuous beam of light. With one photocell
102, the system can detect whether the pusher paddle 107 has
traveled. With two photocells 102, the system can detect to which
direction the pusher paddle 107 has traveled.
[0068] The rate of the pulsing is directly related to the speed of
the encoder 103 which is directly related to the speed of the
pusher paddle 107. Similarly, the rate of the pulsing is directly
related to the distance that the encoder 103 has traveled which is
directly related to the distance that the pusher paddle 107 has
traveled. The pulses of light that have been received by the
photocell 102 will be converted to the exact distance that the
pusher paddle 107 has traveled, which will then be converted to the
number of products remaining on the display space 104.
Specifically, the distance that the pusher paddle 107 has traveled
will be calculated by counting the pulses of lights being received
and blocked through the encoder 103. The number of light pulses
being received and blocked correlates to the number of the holes
evenly spaced in the encoder 103 that the light has traveled
through. Thus, using the number of light pulses being received and
blocked can be translated to the distance that the encoder 103 has
traveled, which is the distance that the pusher paddle 107 has
traveled.
[0069] In another embodiment, two photocells 102 are used so that
the system can detect both addition and deletion of a product to
the display space. As illustrated in FIG. 5E, the LED 101 emits a
beam of light toward the encoder 103. The holes in the encoder 103
break the beam of light from the LED 101 so that the photocells
detect that the light has been blocked, instead of a receiving a
continuous beam of light. There are two photocells encased in one
container. The photocells may be arranged vertically or
horizontally. In vertical fashion, one photocell is on top of the
other photocell. In horizontal the two are substantially side by
side. Either arrangement is operable for the present inventory
control system.
[0070] As the encoder 103 moves in one direction the pulses of
light are detected by one photocell before the other photocell. For
example, if on an X-Y axis the encoder 103 moves from 0 to 100
(positive and to the right) and one photocell is at point (1,0) and
the other photocell is at (2,0), a light pulse will be first
detected by the photocell at (1,0) and then by the photocell at
(2,0). If the encoder 103 is moving in the opposite direction, a
light pulse will be first detected by the photocell at (2,0) and
then by the photocell at (1,0).
[0071] When the pusher paddle 107 moves, the encoder 103 moves
along with the pusher paddle 107, changing the light being traveled
though the holes in the encoder 103. Because of their horizontal
alignment along the encoder 103, one photo cell will detect the
change in the light being traveled through the encoder 103 before
the other photocell. If the first photocell has been receiving a
beam of light through one of the holes in the encoder 103, it will
now detect the light being blocked by the filled-in portion of the
encoder 103. If the first photocell has not being receiving light,
it will now detect a beam of light traveling through one of the
holes on the encoder 103, and detect that the light is now being
blocked before the other photocell detects such change. The
distance that the pusher paddle 107 has traveled will be calculated
by counting the number of light pulses being received and blocked
through the encoder 103. The number of light pulses being received
and blocked correlates to the number of the holes evenly spaced in
the encoder 103. Thus, using the number of light pulses being
received and blocked can be translated to the distance that the
encoder 103 has traveled, which is the distance that the pusher
paddle 107 has traveled. The system can detect the change of
direction which translates to either addition or removal of
products from the display space.
[0072] The photocell 102 is in connection with a computer 110 so
that any movement of the pusher paddle 107 is determined and
communicated to the computer 110 for users to view and stored in a
database to be used at a later time. The computer may also be in
connection with an electronic display 112 placed near the display
space so that the most updated count of the products remaining on
the display space can be displayed, along with other relevant
information about the products, such as the price, the name, the
sale status, the bar code number, etc. The computer 110 may also be
in connection with another computer so that the most updated count
of the products can be communicated to a remote user.
[0073] Referring now to FIG. 6, multistation inventory control
system 11 includes one or more multistation units 13 and 14.
Multistation unit 13 may include a plurality of inventory control
stations, such as inventory stations 16, 18, 20 and 22, and
multistation monitor housing 66 which includes at least one monitor
station for each inventory station, such as monitor stations 63,
64, 74 and 80. Each inventory station provides a location at which
data from a particular column of products, such as can goods 24 in
inventory station 16, may be derived by a related monitor station
such as monitor station 63. Multistation unit 13 may combine a
series of separate stations for communication, such as a series of
conventional pushers modified to provide information related the
position of pusher paddle 7 as shown above with regard to FIGS.
1-5, or may be configured as a separate unit with one or more
stations interlocked with monitor housing 66.
[0074] The nature of inventory systems is that the goods may not,
and often are not, the same size at all locations even on the same
shelf. Multistation unit 13, as shown in the figure, has four
separate stations although a smaller or larger number of stations
may be advantageous in particular applications. If inventory goods
substantially larger the diameter of can goods 24 were to be stored
on multistation unit 13 in addition to can goods 24, such larger
can goods could be stored in station 10, while stations 18 and 20
were not used. Multistation monitor 24 may include a large number
of monitor stations which provides the capability of working with a
large number of inventory stations so that maximum shelf space may
be utilized, but multistation monitor is sufficiently flexible so
that the removal or non-installation of one or more of the stations
does not alter the collection of data. Multistation monitor 24
therefore permits the sizes of the goods stored to be changed by
persons stocking the shelves without requiring reprogramming or
adjustment of the data collection system.
[0075] Each of the inventory stations 16, 18, 20 and 22 includes
paddle 26 which pushes the goods stored to the front of the shelf
as goods are purchased. Paddle 26 typically rides along track 28,
on which can goods 24 may be positioned. Paddle 26 and track 28 may
collectively be called pushers. Conventional pushers include a flat
spring, coiled in paddle 26 and fixed at one end to the forward
shelf edge 29 of track 28. Although the pushers may be provided
separately from multistation monitor 24, it may be preferable to
join each track 28 to multistation monitor 24 to improve the
stability of both the inventory stations, that is the pushers and
associated gear, and monitor 24. As discussed above, not all
stations need be populated with pushers.
[0076] A typical multistation unit 13 may typically use the same
type of monitor station mechanism for each inventory station. For
ease of disclosure, four different types of monitor station
mechanisms will be described on a single multistation unit.
[0077] Station 16 utilizes a continuous loop encoder 30 which
rotates freely about forward and rearward rotation wheels 32 and 34
which are mounted for rotation at forward shelf edge 29 of track 28
and on multistation monitor 13 at monitor station 63, respectively.
Wheels 32 and 34 may be positioned within or below track 28 and/or
monitor 13 if convenient. Continuous loop encoder 30 is fixed to
paddle 26 by anchor point 36 so that loop 30 rotates
counterclockwise and clockwise as paddle 26 move forward and back
indicating a decrease or increase in the number of can goods in
inventory on station 16.
[0078] Referring now to FIG. 7, encoder loop 30 may conveniently be
a transparent plastic strip, a portion of which is shown in the
figure as encoder strip 40, on which a series of vertical bars 42
are formed and spaced apart by contrasting bars 44. The contrasting
bars may be transparent and non-transparent, white and black,
reflective or non-reflective or have any other contrasting
relationship which permits the detection of motion of encoder 30 by
photo detectors. The number of vertical bars, per unit of measure
along loop 30, is preferably high enough so that rotation of loop
30 caused by the addition or removal of the smallest product to be
monitored causes more than one vertical bar to pass through
position detector 38 mounted to monitor 24.
[0079] Referring now to FIG. 8, position detector 38 may
conveniently include a pair of photo detectors 46 and 48, such as
those used in a conventional computer mouse, positioned side by
side on one side of encoder strip 40. A source of light, which may
be visible or infrared light such as an LED 47, is positioned on
the other side of loop 38. Bars 42 and 44 are preferably
transparent to the radiation from the LED 47. If the bars are not
contrasting bars based on transmission of light through encoder
strip 40, but are contrasting based on reflection, LED 47 may be
positioned on the same side of encoder strip 30.
[0080] Although shown in the top view as extending through encoder
strip 40, bars 42 and 44 may be formed on one vertical surface
only. For example, black lines printed on one side of a transparent
strip. As encoder strip 40 is caused to move forward or back as a
result of motion of paddle 26, one of the photo detectors will
sense the transition between transparent and non-transparent bars
before the other photo detector. As a result, electronic circuitry,
such as detector circuit 50, may be used to generate pulses as a
result of the movement of encoder strip 30 and also detect whether
the motion is related to the addition or removal of inventory.
[0081] Referring now again to FIG. 6 and also to FIG. 9, inventory
station 18 utilizes a coiled encoder strip 52 which may be attached
at one end to paddle 26 at anchor 36 and the other end is formed in
coil 54 for rotation about pin 56. Movement of paddle 26 is
detected by position detector 39, which may conveniently be a
modified form of detector 38 that causes encoder strip 52 to change
direction by 90.degree.. This may be accomplished by positioning
either or both LED 47 and/or detectors 46 and 48 in or behind a
turning post or guide such as inside guide 60. Optionally, outside
guide 62 may be provided, for example, between strip 52 and photo
detectors 46 and 48.
[0082] Alternately, LED 47 may be positioned adjacent outside guide
62 while photo detectors 46 and 48 are positioned adjacent inside
guide 60. Further, outside guide strip 52 may be guided by other
turning guides and the LED and photo detectors mounted adjacent a
straight section of strip 52 before or after the change in
direction. Turning guides 60 and 62 must be configured to permit
illumination from LED 47 to pass through (or optionally be
reflected by) encoder strip 52 to reach photo detectors 46 and
48.
[0083] Still further, position detector 38 may be used without
turning guides so strip 52 unwinds from coil 54 and travels in a
straight line to anchor 36. This configuration requires that the
width of monitor housing 66 accommodate both position detector 38
and coil 54. It is usually preferable to reduce the width of
monitor housing 66 to maximize the room for inventory on the shelf,
along track 28.
[0084] Encoder strip 52 may conveniently be a self coiling strip,
that is, in an unrestrained state a major portion of encoder strip
52 forms itself into coil 54 which may be easily mounted or
demounted from pin 56. Such strips, currently made without
non-transparent bars, are made of a high quality, coiled roll of
plastic film and are available, for example, from Spring-Roll LLC
in Winder, Ga. Contrasting stripes or bars may be printed directly
on the Spring-Roll coiled roll or added to the coiled roll by
another layer of plastic. When unrolled, at least a substantial
portion encoder strip 52 will return to its original compact coiled
shape, shown as coil 54.
[0085] Forward end 58 of encoder strip 52 is configured to be
anchored to paddle 26 at anchor 36 as shown for example in station
18 of FIG. 1. In a preferred embodiment, forward end 58 may include
a simple thru hole, such as hole 59, which may be fastened over a
protrusion on paddle 26.
[0086] Coil 54 has a central opening permitting it to be easily
slipped onto pin 56 so that coil 54 freely rotates about pin 56
when forward end 58 is not anchored. If preferred, coil 54 may be
fixed to pin 56 so that it cannot slip out of place. Turning guides
60 and 62 permit coiled encoder strip 52 to be easily mounted on
pin 56 and threaded through the guides for attachment to anchor 36.
Monitor station 64 includes a pair of turning guides 60 and 62 and
pin 56.
[0087] Alternately, pairs of inventory and monitor stations may be
configured to detect the position, or changes in position of paddle
26 along track 28 by changes in resistance or capacitance. For
example, a thick film resistor may be positioned along track 28,
along the flat coiled spring in each pusher, or along the shelf on
which the multistation monitor is mounted and changes in the
position of paddle 26 may be detected as a result of changes in the
relationship between the thick film resistor and a fixed or moving
contact. Similarly, the capacitance of the coiled portion of the
flat spring in the pusher, or the capacitance between a fixed
capacitance plate and a moving capacitance plate, one of which have
a varying plate area, may be used to detect the position or changes
of position of the paddle 26 with respect to track 28.
[0088] Multistation unit 13 may include monitor housing 66 being
conveniently molded from a plastic and include a plurality, such as
six, monitor stations molded thereon. Electronic circuitry 50, a
portion of which is shown in FIG. 3, may be formed on a printed
circuit board made to fit inside monitor housing 66. The LEDs and
photo detectors for each monitor station, such as monitor station
64, may be mounted on the printed circuit board so that when
assembled, the LEDs and photo detectors for each station are
properly positioned within the appropriate turning guides 60 and
62.
[0089] In this way, multistation unit 13 will have a plurality of
monitor stations, such as stations 63, 64, 74 and 80 not all of
which are activated. Each monitor station may be activated by
aligning an inventory station, such as station 18, including track
28 and paddle 26, in front of that monitor station, slipping coil
54 of encoder strip 52 over post 56 and attaching forward end 58 to
anchor 36. As a result, once multistation unit 13 is positioned on
an inventory shelf it may be configured, and easily reconfigured,
for a different number of monitor stations up to the maximum number
of stations available on monitor housing 66, depending upon the
sizes of the goods to be stocked or for other reasons.
[0090] Similarly, encoder strip 52, if damaged or to be
reconfigured or updated, may easily be removed by unhooking strip
52 from paddle 26, allowing strip 52 to coil as much as it will
coil and removing coil 54 from pin 56 and turning guides 60 and 62.
Thereafter station 64 may be re-activated by simply installing
another encoder strip 52 as described above. It is important to
note that installation of multistation unit 13, together with one
or more of the stations 16, 18, 20 and 22, is no more complex than
the installation of conventional pushers. The only additional steps
required for the activation of particular monitoring stations is
the insertion of self coiling encoder strip 52, and connection of
leading end 58 to the appropriate pusher and connection of the
appropriate communication systems. These tasks do not require
substantial special training or experience so that they can easily
be handled by the staff normally used to stock and restock
inventory shelves.
[0091] Referring now to FIGS. 6 and 10, inventory station 20
includes light source 72, mounted at monitor station 74 of
multistation unit 13, which is aimed at target 76 at the rear of
paddle 26. Monitor station 74 includes position detector 78 which
receives the light reflected from target 76 and determines the
current distance to paddle 26. Target 76 may include fan shaped
reflector 77 mounted for rotation on paddle 26 by gear and pulley
system 80, also mounted on paddle 26 and in contact with track 28.
Motion of paddle 26 causes the light reflected by fan 77 to
position detector 78 to be interrupted. The output of position
detector 78 will then be a set of pulses which can be processed by
electronic circuitry 50.
[0092] If more than one monitor station uses a target 76 for motion
detection, the light reflected from any such target may be
distinguishable from the light reflected from other pushers by
differently shaped or sized reflecting blades of rotating target
77. For example, the relatively wide pulses from a wide bladed
version of fan 77 may be distinguished from the relatively narrow
pulses of a narrow bladed version of fan 77. The distinguishable
widths of pulses should be greater than the differences in pulse
width resulting from the normal motion of paddle 26. When using
multiple stations with rotation it may be desirable to use a single
light source, such as source 72, to illuminate targets on more than
one station and or a single position detector to detect the
reflected light from more than one station.
[0093] Referring now again to FIG. 6, inventory station 22 includes
conventional laser light distance measuring unit or laser range
finder 82, at monitor station 80 of multistation unit 13. Laser
range finder technology is well known and is available, for
example, from SONIN, Inc., Charlotte N.C. It can be used to detect
movements of 1/4 inch, about 1 cm, or less. The complexity and
resultant costs of such laser range finders may be reduced for use
with multistation monitors. For example, monitor station 74 may be
considered a simplified version of a light based range finder
suitable for use in inventory control management.
[0094] Laser range finder 82 is aimed at target 84 at the rear of
paddle 26. Monitor station 82 may include circuitry to provide
pulses to electrical circuitry 50 for compatibility with other
types of monitor stations or provide a digital or analog output
reflecting the absolute distance to target 84 for use by electronic
circuitry 50.
[0095] Multistation unit 13 includes a pair of communication
connectors 68 which may be connected via cables 70 to other
multistation units, such as unit 14, a portion of which is shown. A
daisy chain of units may be connected in this way. Power may be
provided from a central source to each daisy chain via cables 70 or
individually to each unit. One end of the daisy chain is connected
directly, or wirelessly, to a computer or computer network which
includes software for converting the outputs of all the monitor
stations into useful data related to inventory. For example, the
software may count the pulses, and determine the sense, of the
signals provided by the daisy chain of multistation units.
Alternately, a hardware pulse counter may be provided between the
daisy chain of units and the software to do this task, or circuitry
50 provided in each multistation unit could perform this task.
[0096] In certain applications, such as grocery or other stores
with multiple isles, one or more daisy chained groups of
multistation units, such as those along different shelves of an
isle may be separately connected wirelessly to a main network to
minimize installation costs and complexities. The main network may
provide all processing needed for inventory control purposes using
the signals from all monitor stations or transmit the raw or
partially processed data to a central computer, perhaps via the
Internet, for further processing, display or control.
[0097] The signals for all monitor stations within each
multistation unit may conveniently be assigned to a designated
channel or port so that the inventory data from each monitor
station may be distinguished. In a daisy chained configuration, the
most upstream unit, that is the multistation monitor closest to the
computer collecting the data, may provide a sufficient number of
separate channels or ports to carry data from all downstream units.
Conventional circuitry, based for example on RS 232 standards, may
be used to provide up to 256 separate channels. Conventional
circuitry based on other standards, such as RS 485, may be used to
provide a greater number of channels. Packet addressing may also be
used to distinguish data from different monitor stations by adding
a unique coding as an address header for each group of data
sent.
[0098] The frequency of occurrence of the data is relatively low,
even when shelves are being stocked so that a variety of
conventional techniques may be used to forward, and distinguish,
the relative position changes of each of a large number of pushers.
One further piece of information for each pusher is required and
may be changed whenever the inventory is relocated on the shelves.
Whenever the motion to be detected from a particular pusher for a
single can or other type of goods is changed, this knowledge must
be made available to the system so that the particular number of
pulses representing one can will properly be identified. In some
applications, such as chains of stores where the arrangements of
the goods on the shelves is centrally controlled, the type of goods
on each pusher may be dictated centrally so that the person
stocking the shelf follows a printed list provided by computer. The
number of pulses representing a particular type of goods may be
entered in a large database.
[0099] In other applications, such as those where the inventory
arrangement is not controlled centrally, or changes rapidly,
circuitry 50 may include an operating mode in which the circuitry
or central computer learns the number of pulses related to a single
item. This may be accomplished simply by causing the monitor unit
to enter a learning mode and adding or removing a single item.
Similarly an alarm or notification mode may be automatically
entered whenever an item is added or removed outside of predefined
parameters. That is, once the number of pulses representing a
single item is accurately known by the system, an alarm may be
raised when more than a predetermined number of items is removed
from a shelf. This mode may be particularly useful in identifying
shoplifters who often sweep the shelves by grabbing as many items
at a time as possible. Similarly, the person stocking the shelves
may be notified, perhaps at the end of the day when returned items
are restocked, that an item of a different size than expected was
added to a shelf.
[0100] Although many different embodiments have been described
herein, many additional variations may made without departing from
the spirit or scope of the inventions described herein which are
identified in the appended claims.
* * * * *