U.S. patent application number 11/155054 was filed with the patent office on 2006-12-21 for rf identification apparatus for pallet conveyances.
Invention is credited to Harold Charych.
Application Number | 20060287760 11/155054 |
Document ID | / |
Family ID | 37569555 |
Filed Date | 2006-12-21 |
United States Patent
Application |
20060287760 |
Kind Code |
A1 |
Charych; Harold |
December 21, 2006 |
RF IDENTIFICATION APPARATUS FOR PALLET CONVEYANCES
Abstract
Apparatus for reading RFID tags of picked goods as they are
loaded onto a picked pallet, and a method of picking and tracking
goods using the device. The invention is mounted on a pallet
support on a pallet conveyance, and has an RFID interrogator
connected to at least one antenna mounted on a vertically movable
antenna mount. The interrogator triggers the transponders in the
goods and sends the decoded replies to the control unit. An object
sensor adjacent to the antenna senses the presence of goods, and a
control unit controls the movable antenna mount to raise the
antenna mount above the goods. A computer having a display visible
to an operator loading the pallet conveyance is used to communicate
with the operator, confirming the loaded goods are the correct
ones, and tracking inventory loaded on the conveyance. A barcode
reader may be located on the antenna mount.
Inventors: |
Charych; Harold; (Poquott,
NY) |
Correspondence
Address: |
BROWN & MICHAELS, PC;400 M & T BANK BUILDING
118 NORTH TIOGA ST
ITHACA
NY
14850
US
|
Family ID: |
37569555 |
Appl. No.: |
11/155054 |
Filed: |
June 17, 2005 |
Current U.S.
Class: |
700/214 |
Current CPC
Class: |
H01Q 1/2216 20130101;
G06K 7/10336 20130101; B66F 9/0755 20130101 |
Class at
Publication: |
700/214 |
International
Class: |
G06F 7/00 20060101
G06F007/00 |
Claims
1. An apparatus for reading RF identification transponders in
picked goods loaded on a pallet conveyance having a pallet support
for conveying the picked goods, comprising: a) an RFID interrogator
for triggering the transponders and receiving and decoding replies;
b) at least one vertically movable antenna mount, mounted to the
pallet support for movement therewith, the mount being moveable
from a base level adjacent to a pallet supported by the pallet
support to a level at least even with the top of a load of picked
goods on the pallet support; c) at least one antenna mounted to the
antenna mount and coupled to the interrogator; d) at least one
object sensor adjacent to at least one antenna; e) a control unit
coupled to the interrogator for initiating interrogation of
transponders and accepting decoded replies, to the antenna mount
for controlling the level of the antenna mounted on the mount, and
to the object sensor for detecting the presence of goods adjacent
to the object sensor, such that when picked goods are loaded on the
pallet support, the interrogator triggers the transponders in the
goods and sends decoded replies to the control unit, and if the
object sensor senses the presence of the goods blocking the
antenna, the control unit controls the movable antenna mount to
raise the antenna mount above the goods.
2. The apparatus of claim 1, in which there are four antennas.
3. The apparatus of claim 1, in which there are at least two
antenna mounts, mounted on at least a right side and a left side of
the pallet support.
4. The apparatus of claim 3, in which each antenna mount has an
object sensor mounted adjacent to its antenna, and the level of
each pair of antennas is adjustable independently.
5. The apparatus of claim 3, in which there are two antennas on
each mount.
6. The apparatus of claim 1, further comprising a fixed antenna
mounted adjacent to the pallet support and coupled to the
interrogator.
7. The apparatus of claim 1, further comprising a computer having a
user input, a visual display and control input and output coupled
to the control unit.
8. The apparatus of claim 7, in which the computer is programmed to
display a total of items and transponders read since a pallet
picking operation was initiated.
9. The apparatus of claim 7, in which the computer is programmed to
display a number of items and transponders read since the pallet
conveyance stopped.
10. The apparatus of claim 7, in which the computer is programmed
to display at least one pick location.
11. The apparatus of claim 7, in which the computer has an audio
output, and the computer is programmed to provide audio feedback
when an RF transponder is read.
12. The apparatus of claim 7, in which the keypad and display are
visible and available to a user during a pallet loading
process.
13. The apparatus of claim 1, in which the computer is coupled to
the control unit using wireless communications.
14. The apparatus of claim 1, further comprising a motion sensor
for determining when the conveyance is moving.
15. The apparatus of claim 1 further comprising a wireless
communication transceiver for communicating with a warehouse
infrastructure system.
16. The apparatus of claim 1, in which the interrogator, antenna
mounts, antennas and control unit are mounted to a frame which is
removably mounted to the pallet support.
17. The apparatus of claim 16, in which the frame further comprises
a plurality of wheels on a bottom of the frame, for moving the
frame across a surface.
18. The apparatus of claim 1, further comprising a barcode reader
mounted on the antenna mount adjacent to, and aligned with, the
object sensor, and coupled to the controller.
19. A method of identifying picked goods having RF identification
transponders while the goods are loaded on a picked pallet
conveyance having a pallet support for conveying the picked goods,
and a reading apparatus comprising an RFID interrogator for
triggering the transponders and receiving and decoding replies; at
least one vertically movable antenna mount, mounted to the pallet
support for movement therewith, the mount being moveable from a
base level adjacent to a pallet supported by the pallet support to
a level at least even with the top of a load of picked goods on the
pallet support; at least one antenna mounted to the antenna mount
and coupled to the interrogator; at least one object sensor
adjacent to at least one antenna; a controller coupled to the
interrogator for initiating interrogation of transponders and
accepting decoded replies, to the antenna mount for controlling the
level of the antenna mounted on the mount, and to the object sensor
for detecting the presence of goods adjacent to the object sensor,
the method comprising the steps of: a) loading a case onto the
picked pallet with the RF identification transponder facing the
antenna; b) interrogating the transponder in the case, and sending
information from the transponder to the controller; c) decoding the
information from the transponder; d) displaying on a user interface
identification of items loaded; e) using the object sensor,
detecting if the case is blocking the antenna, and if the case is
blocking the antenna, raising the antenna mount until the antenna
is positioned to read the transponder on a next case to be loaded;
f) if there are more cases to be picked, repeating the method from
step (a).
20. The method of claim 19, in which the method starts, before step
(a), with the antenna mount at the base level and the pallet
empty.
21. The method of claim 19, in which step (f) further comprises the
steps of locating the next item on the pick list and driving the
conveyance to a location of the next item.
22. The method of claim 19, in which step (d) further comprises the
steps of comparing the case picked with a pick list, and displaying
a message if there has been an error.
23. The method of claim 19, in which step (d) further comprises the
steps of comparing the case picked with a pick list, and displaying
a confirmation if the case is on the pick list.
24. The method of claim 19, in which the apparatus further
comprises a barcode reader aligned with the object sensor, and the
method further comprises the step, after step (b), of reading
barcode information from the case, and step (c) further comprises
decoding the barcode information.
25. The method of claim 24, in which the apparatus further
comprises a motion sensor adjacent to the barcode reader, and the
step of claim 24 is initiated when the motion sensor detects
motion.
26. The method of claim 19, further comprising the step, after step
(c) of communicating through a wireless link with a warehouse
computer.
27. The method of claim 19, in which the displaying step (d)
further comprises displaying information selected from a group
comprising, a total number of items read since a picking operation
was started, transponders read since a picking operation was
started, a total number of items read since the conveyance last
stopped, and transponders read since the conveyance last
stopped.
28. The method of claim 19 in which the apparatus further comprises
a fixed antenna mounted adjacent to the pallet support and coupled
to the interrogator, and the method further comprises: before step
(a), the steps of: loading a pallet on the pallet support; reading
a pallet transponder on the pallet with the fixed antenna;
communicating with a warehouse computer to determine contents of
the pallet; if the warehouse computer indicates that there are
cases already expected to be on the pallet; downloading
identification of the cases expected to be on the pallet; in step
(d): displaying the cases expected to be on the pallet; and
displaying any discrepancies between the cases found to be actually
on the pallet in steps (a) through (d) and the cases expected to be
on the pallet downloaded from the warehouse computer.
29. The method of claim 19 further comprising: before step (a), the
steps of: loading a pallet on the pallet support; interrogating a
transponder from at least one case on the pallet and decoding an
identity of at least one case; communicating with a warehouse
computer to determine contents of the pallet associated with the at
least one case; if the warehouse computer indicates that there are
cases already expected to be on the pallet with the at least one
case; downloading identification of the cases expected to be on the
pallet; in step (d): displaying the cases expected to be on the
pallet; and displaying any discrepancies between the cases found to
be actually on the pallet in steps (a) through (d) and the cases
expected to be on the pallet downloaded from the warehouse
computer.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention pertains to the field of registers for reading
and displaying data pertaining to goods. More particularly, the
invention pertains to apparatus and methods for identifying and
tracking picked goods on a pallet conveyance using RF
identification transponders (RFID tags) associated with the
goods.
[0003] 2. Description of Related Art
[0004] Pallets are a cost effective means used to ship products
from the point of manufacture to distribution centers and finally
to retailers where the merchandise is sold to the general public.
Retailers need to know what goods are in the supply chain in order
to make better business decisions and to make sure that goods are
on the store shelves when consumers want to purchase them. Mandates
from major retailers such as Wal-Mart, Target, Best Buy, Metro, and
others are requiring that cases, cartons, and shipping totes,
primarily shipped on pallets (hereinafter, simply "cases"), have
Radio Frequency Identification transponders, commonly called "RFID
tags" attached to identify the product content.
[0005] Manufacturers and distribution centers receive orders from
stores for a variety of merchandise. The order is typically
"picked" which means that a manufacturer or distribution center
uses a pallet that is carried on the forks of a pallet conveyance,
which may be a forklift truck, motorized pallet jack, manual pallet
jack, or other such vehicle, onto which goods from a "pick list"
are loaded for delivery to a given location. The operator will move
the pallet via the conveyance to an area of the warehouse where
merchandise listed on the pick list is stored. The operator will
then add the number of cases listed on the pick list to the pallet.
This pallet will now be called the "picked pallet", and the goods
"picked goods".
[0006] The manufacturer or the distribution center would like to
know that the right merchandise was loaded onto the picked pallet.
Prior art used barcodes read with a handheld barcode scanner as a
way to insure accuracy. As each item is added to the picked pallet,
the barcode printed on the case is scanned with a hand held
scanner. A computer system is used to check that the right
merchandise was picked. This process is time consuming and depends
on the operator to manually scan each case.
[0007] Prior art, such as U.S. Pat. No. 6,669,089, describes
methods of reading an RFID tag on one or more pallets loaded on the
forks of the forklifts. The patent does not address a method of
reading RFID tags on individual cases loaded onto pallets. The
antennas in this patent are fixed to the forklift structure (either
to the moving fork structure, or the fixed vertical support), and
are not independently movable apart from the normal raising and
lowering of the forks.
[0008] Reading the RFID tags attached to cases as they are loaded
onto a picked pallet has proven to be difficult using prior art.
The operator can park the forklift or other pallet conveyance
vehicle with the picked pallet anywhere in the warehouse. Because
the RF field generated by the RFID reader and antenna is imprecise
and may bounce off metallic objects in the warehouse, such as the
metal shelves, it is difficult to know if the item is on the picked
pallet or near it. As goods are loaded onto the picked pallet,
antennas that were visible before are now covered with merchandise.
Depending on the type of merchandise, the RF signal from the reader
will become blocked and no additional RFID tag reading will take
place.
[0009] Published Patent Application no. 2005/0071234 describes a
pallet picking operation in detail. The application makes the
assumption that if there is an RFID reader it will read the tag of
items placed on the pallet, but does not discuss the placement of
the RFID reader antennas with respect to the RFID tags on the
cases. This location and proximity between the tags and the
antennas is critical if the tags are going to be read correctly--or
at all. As an example, paragraph 0016 states "Once on the pallet
the RF reader for the pallet identifies the item and logs the item
into the pallet's inventory. At the same time the forklift's RF
reader reads the RF tag of the item and identifies the item in the
pick list". This requires knowing the location of the antennas of
the forklift RF reader, and the location of the antennas of the
pallet RF reader. The forklift is a metallic structure and RF waves
from the forklift may be blocked in many cases. The pallet and
forklift RF readers and antennas are not described at all.
SUMMARY OF THE INVENTION
[0010] The invention is an apparatus that will read the RF
identification transponders (RFID tags) of picked goods as they are
loaded onto the picked pallet, and a method of picking and tracking
goods using the device. Human error is reduced and the picking
process can be accomplished much faster.
[0011] The invention is mounted on a pallet support of a pallet
conveyance such as a forklift, pallet jack, or the like, having
pallet supports (such as the "forks" of a forklift) which engage
the pallet. The apparatus has an RFID interrogator for triggering
the RFID transponders on picked goods and receiving and decoding
replies.
[0012] The interrogator is connected to at least one antenna
mounted on a vertically movable antenna mount, which is moveable
from a base level to a level at least even with the top of a load
of picked goods on the pallet support. The base level is
approximately even with the pallet on the conveyance.
[0013] As goods are loaded onto the picked pallet an interrogator
triggers the transponder in the goods and sends the decoded replies
to the control unit. If the goods are placed onto the picked pallet
blocking the antenna, an object sensor adjacent to the antenna
senses the presence of goods, and a control unit controls the
movable antenna mount to raise the antenna mount above the
goods.
[0014] A computer having a display which is visible to a user
loading the pallet conveyance is used to communicate with the user,
confirming that the goods the user has loaded are the correct ones,
and tracking the inventory loaded on the conveyance.
[0015] Another aspect of the invention is a semi-automatic method
of reading barcode labels. The bar coded labels and the RFID tags
are usually on the same face of the case. Because the vertical
movement of the antenna attempts to maintain a line of sight from
the antennas to the newly loaded cases, bar code reading is
possible. A bar code reader device can be either a laser scanner or
digital camera imager. It will be optionally mounted next to the
antenna section. Preferably, a motion sensor next to the bar code
scanner will trigger scanning when a new case is loaded onto the
picked pallet, but other triggering methods are also possible
within the teachings of the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0016] FIG. 1 shows a forklift having the apparatus of the
invention mounted on its forks.
[0017] FIG. 2 shows a pallet jack having the apparatus of the
invention mounted on its forks.
[0018] FIG. 3 shows a front-view diagram of the invention.
[0019] FIG. 4 shows a side-view diagram of the invention.
[0020] FIG. 5 shows a block diagram of the interconnection of the
parts of the invention.
[0021] FIG. 6 shows a diagram of a cable management arrangement for
use with the invention.
[0022] FIG. 7 shows a flowchart of the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The forklift RFID reading apparatus of the invention is self
contained and may be used on any number of pallet conveyances
including, forklifts, stock pickers, motorized pallet jacks, manual
pallet jacks, and other conveyances that have forks that engage the
pallet. In the description below these pallet conveyances may be
referred to as "forklifts", but it will be understood that any such
conveyance is possible.
[0024] FIG. 1 shows how the invention might be mounted upon a
forklift truck (1), which has a vertically movable set of pallet
forks (2) mounted on its front end. The forks (2) are slipped
underneath a pallet, which is a flat support for goods having space
underneath for the forks. Such forklifts (1) are typically driven
by an operator seated (7) on the vehicle, although some, often
referred to as "stock pickers," have the driver's position on the
fork portion, so that the operator can ride up with the forks to
move goods from the upper levels of a warehouse.
[0025] FIG. 2 shows the invention as it might be mounted on a
motorized pallet jack (10). The jack has forks (11) to slip under
pallets, and is moved by motors controlled by an operator walking
with the truck, operating and steering with controls on a handle
(12).
[0026] Both figures show the vertically movable antenna mounts (6),
sliding on their risers (5), each with two antennas (4) for
interrogating the RFID tags on goods on pallets on the forks.
[0027] The apparatus is mounted on its own pallet guard frame (3)
and rests on the forks (2) or (11) of the pallet conveyance vehicle
(1) or (10). The apparatus may be secured to the pallet guard (44)
of the forklift (1), or it may be secured to the battery
compartment (13) of the motorized pallet jack (10), or to any
structure located at the base of the forks. Any type of mechanical
arrangement may be used to hold the apparatus in place, with the
weight of the apparatus carried by the forks (2)(11) of the
conveyance.
[0028] FIGS. 3 and 4 show a simplified drawing of an embodiment of
the apparatus of the invention.
[0029] The pallet (42) is lifted by the forks (2) of the pallet
conveyance (1) or (10). A pallet guard (44) is a part of the pallet
conveyance, attached to and moving with the forks (2). The pallet
guard (44) prevents the pallet (42) and any goods stacked on the
pallet from moving into the lift rails (46) and lifting mechanism
of the conveyance.
[0030] Frame (3) provides a structure on which the apparatus of the
invention is constructed, with the guide rails (5) running between
a top rail (30) and a middle rail (31). Pulleys (23) can be mounted
on the top rail (30), for cables (22a)(22b) controlling the height
of the antenna mounts (6a)(6b). Middle rail (31) and bottom rail
(32) form a compartment for mounting the operational components of
the invention, such as control unit (26), RFID interrogator (24),
pallet antenna (27), motors (25a) and (25b), and possibly batteries
or power supplies or other components, as needed. Wheels (28) may
be mounted on the bottom rail (32) to allow the frame to be moved
easily from conveyance to conveyance, or to be removed for service
or storage.
[0031] The preferred embodiment shown in these figures has two
antenna mounts (6a) and (6b), aligned with the left and right sides
of the pallet (42) on the forks (2), although it will be understood
that one or more antenna mount assemblies could be provided within
the teaching of the invention. The antenna mounts (6) are
independently movable on risers (5) from a lower base level at or
near the level of the pallet (42), up to a top level which is at
least even with the highest (40e) of the goods (40a)-(40g) which
are piled on the pallet (42). Preferably, the top level is about 80
inches (203 cm) above the base (pallet) level.
[0032] Each antenna mount (5) has one or more antennas (4) for
interrogating RFID tags (41a)-(41g) in the goods (40a)-(40g), and
also one or more object sensors (21) for sensing the proximity of
objects aligned with the sensors. Preferably, each mount has two
antennas (4). The antennas can preferably be low gain and the outer
antennas can preferably be angled in. The antennas on the right and
left side of the pallet will help determine if a case is on the
pallet or off. Software algorithms, such as reading a RFID tag
multiple times with both antennas will determine whether a tag is
on the pallet or just adjacent to it. The combination of manual and
automatic feedback will further confirm that the right merchandise
was loaded.
[0033] The object sensors (21) near the antennas (4) are used to
determine the height of the merchandise (40a)-(40g) loaded on the
picked pallet (42) and will keep the antennas (4) several inches
above the highest layer (40c). Thus, as new merchandise (40c) is
loaded, the RFID tags (41c) of the new merchandise will be visible
to the antennas (4).
[0034] In certain circumstances of warehouse picking, some items
may have a RFID transponder and others may not. Having a bar code
reading apparatus will help identify cases that do not have a RFID
transponder or that have a defective RFID transponder. Therefore,
preferably, there is also a bar code reader (33), which could be a
digital camera imager or a laser bar code scanner, mounted next to
the object sensors (21) and antennas (4) on each antenna riser.
Because the vertically movable antennas maintain a line of sight to
the newly added cases, this will allow the bar code scanner to work
properly. Preferably, a motion sensor (34) is mounted next to the
barcode reader (33), which is used to trigger the barcode
reader.
[0035] FIG. 6 shows a preferred embodiment of a cable management
scheme for minimizing problems with the cables (22) running between
the movable antenna mounts (6) and the motor (25), interrogator
(24) and controller (26).
[0036] The cable (22) from the movable antenna mount (6) exits from
the top section (73) of the mount (6). It goes up and through a
pulley (23) at the top rail (30). It then comes down to the bottom
(74) of the antenna mount (6), where it goes through two pulleys
(71)(72). Using this arrangement of pulleys will allow a fixed
length cable to be used as the antenna mounts move up and down.
[0037] An optional fifth antenna (27) can be mounted adjacent to
the pallet (42) on top of the forks (2) in or on the equipment
compartment (29). This fifth antenna (27) can be used to read a
pallet tag (45), if one is used, when the forks (2) engage the
pallet (42). This antenna (27) can also read shelf tags, if they
are used, when the pallet is loaded into a storage area of the
warehouse.
[0038] A user interface (20) having a display which is visible to
an operator while loading the pallet conveyance, as well as
preferably a keypad for input and an audio output, is used to
communicate with the operator, confirming that the goods the
operator has loaded are the correct ones, and tracking the
inventory loaded on the conveyance. The keypad and display should
be visible and available to the operator at the point of activity,
during the loading of the pallet. The operator will immediately see
that the wrong item was loaded and can take corrective action.
Finding out that the wrong items were loaded when the operator gets
back into the cab could make the operator reluctant to go out and
change the item, fearing more time will be lost.
[0039] The interface (20) will preferably be mounted on top of one
of the antenna mounts (6), fully visible while the operator is
loading cases. This will allow the operator to get immediate
feedback that the RFID tags of the cases that were just loaded have
been read and correctly identified by the device.
[0040] FIG. 5 shows a block diagram of the invention.
[0041] Controller (26) communicates with the various components of
the invention, as well as controlling the lift motors (25) for
positioning the antenna mounts (6).
[0042] The user interface (20) includes display (60), and
preferably keypad (61) and audio output (63). The interface may be
controlled by its own computer (62), or the interface control might
be built into the main controller (26).
[0043] Interrogator (24) provides the radio-frequency (RF)
transmitter and receiver to send signals to antennas (4) (and (27),
if so equipped), and thus to the RF transponders (RFID tags)(41)
and (45), and to receive responses from the tags (41)(45) through
antennas (4) and (27). The interrogator (24) may also contain
encoder/decoder and control logic, so that the main controller (26)
will receive decoded data. Alternatively, this logic may be
included as part of the main controller (26) itself.
[0044] The controller (26) receives signals from the object sensors
(21), and also from the barcode reader (33), if the apparatus is so
equipped.
[0045] In a preferred embodiment, a pallet vehicle motion sensor
(65) will also be part of this invention. The motion sensor (65)
will determine when the conveyance is in motion, and will send
signals to the controller (26) accordingly.
[0046] The main controller (26) can interface to the infrastructure
system of the warehouse (66) via a wireless link (64). This link
can be the industry standard 802.11 a/b/g, or any other wireless
communication system that might be desired. The controller (26) can
also communicate through a short range wireless system (67), such
as Bluetooth.RTM., to a vehicle radio computer (VRC) (68) in the
cab (69) of the forklift (50). However, the apparatus will have
most of the functionality of a VRC and can reduce the overall cost
by eliminating the VRC.
[0047] Preferably, the apparatus will be powered by rechargeable
batteries (70) and may be recharged at night or when the forklift
is not in use. Alternatively, the invention can run off the
electrical system of the forklift.
[0048] FIG. 7 shows a flowchart of the method of the invention,
which uses the apparatus described above. Paragraph numbers below
refer to the numbered steps in the flowchart of FIG. 7.
[0049] The method typically starts with an empty pallet. The
antenna mounts are at the base level, and, preferably, the
interrogator is "on", ready to read an RFID tag. [0050] 80. The
operator loads the case (or possibly more than one case) (40e) onto
the picked pallet (42) with the RFID transponder (41e) facing the
antenna (4).
[0051] The bar code (43) that identifies the contents of the case
(40e) will also be located on the same face of the case as the RFID
transponder (41e) (for the purposes of FIG. 4, these are shown
facing the viewer, but it will be understood that they would really
face the antenna (4) and barcode reader (33)).
[0052] It will be understood that in some circumstances, instead of
starting with an empty pallet and placing a case on the empty
pallet, the method may start out by picking up a pallet which is
already partially full. As an example, imagine that a full pallet
was received from a manufacturer. In this case the contents of the
pallet are known to the warehouse database. The database will also
know the cases that were removed from the pallet in previous
picking operations. The apparatus of the invention will know the
identification of the pallet by reading the pallet transponder (45)
(if one is present) with fixed antenna (27), and communicating with
the warehouse computer to determine the contents of the pallet, or
by reading the cases that face the antennas as the antennas travel
vertically to get to the top of the load and associating the cases
with a known pallet already in the warehouse database.
[0053] In such a situation, this step of "loading a case" will
comprise putting the partially loaded pallet having one or more
cases loaded upon it on the pallet support of the conveyance. The
cases on the pallet are determined by the process described above
to load the identifications of the case(s) expected to be loaded on
the pallet. The method can then proceed with the following steps.
[0054] 81. The interrogator (24) interrogates the RFID tag (41) on
the case (40), and the information from the tag is sent to the
controller (26) [0055] 82. If the apparatus is so equipped, a
motion sensor (34) next to the barcode reader (33) can trigger the
barcode reader (33) to either take a picture of the newly added
case or scan the case with a laser beam, and the barcode
information is also sent to the controller. [0056] 83. The
controller software will decode the information from the RFID tag
(and bar code).
[0057] If necessary, and if the apparatus is so equipped, the
controller (26) may communicate through the wireless link (64) with
the warehouse computer (66) to translate the information,
coordinate the picking, or other tasks. [0058] 84. The display (60)
in the user interface (20) will display information to allow the
operator to confirm that the case picked was a correct one. It is
important to note that the display should show the actual items
loaded, such as "case of soap--24 count", rather than just the RFID
tag number. The display may be programmed to show the total number
of items and possibly the corresponding RFID tags read since the
picking operation was started. It may also show the total number of
items and possibly the corresponding RFID tags read since the
conveyance last stopped.
[0059] In the situation indicated in step 80, above, where the
initial loading comprised picking up a partially loaded pallet, the
identity of the cases whose transponders and/or barcodes face the
antennas can be read and confirmed as indicated here. It is
possible that the transponders or barcodes on some cases on the
pre-loaded pallet might not be visible to the antennas or barcode
readers, in which case the display could indicate which cases were
not detected and have the operator visually confirm that they are
there. [0060] 85. Optionally, the controller (26) may compare the
case picked with a pick list, to be sure that the case was intended
to be picked, and can display messages and/or initiate an audible
alarm to the operator if there has been an error, or,
alternatively, can display a confirmation on the display and/or
through an audible means. [0061] 86. If the object sensor (21)
senses that the case is blocking the antenna (4), then (step 87)
the controller (26) controls the motor (25) to raise the antenna
mount (6) until the antenna (4) is positioned to read the
transponder (41) on the next case (40). [0062] 88. The operator
locates the next item on the pick list, drives the conveyance to
another location if needed, and repeats the method from step (80),
above.
[0063] With the conveyance in motion, detected by motion detector
(65), the apparatus controller (26) will stop the interrogator (26)
from reading tags to prevent extraneous reads. Picked pallet
loading only occurs when the conveyance is stopped and the RFID
reader will be activated during that time.
[0064] Accordingly, it is to be understood that the embodiments of
the invention herein described are merely illustrative of the
application of the principles of the invention. Reference herein to
details of the illustrated embodiments is not intended to limit the
scope of the claims, which themselves recite those features
regarded as essential to the invention.
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