U.S. patent application number 11/543646 was filed with the patent office on 2007-08-16 for system for monitoring flexible container usage.
Invention is credited to David L. Booher, Kendall Busch, Leon Farahnik, Roger M. Ruetten, Steve Tonkin.
Application Number | 20070186515 11/543646 |
Document ID | / |
Family ID | 38001981 |
Filed Date | 2007-08-16 |
United States Patent
Application |
20070186515 |
Kind Code |
A1 |
Ruetten; Roger M. ; et
al. |
August 16, 2007 |
System for monitoring flexible container usage
Abstract
An apparatus is provided for packaging items within a container.
The container is supported adjacent an indicator which determines
the addition of an individual item into the container. The number
of items added to a container is accumulated and the accumulated
data for each container during a given cycle is stored. The stored
data is then communicated to a processing unit for analyzing and
use as a management tool within the packaging operation.
Inventors: |
Ruetten; Roger M.;
(Stillwater, MN) ; Busch; Kendall; (New Auburn,
MN) ; Tonkin; Steve; (Eden Prairie, MN) ;
Booher; David L.; (Columbia, SC) ; Farahnik;
Leon; (Beverly Hills, CA) |
Correspondence
Address: |
IP GROUP OF DLA PIPER US LLP
ONE LIBERTY PLACE, 1650 MARKET ST, SUITE 4900
PHILADELPHIA
PA
19103
US
|
Family ID: |
38001981 |
Appl. No.: |
11/543646 |
Filed: |
October 5, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60773869 |
Feb 16, 2006 |
|
|
|
Current U.S.
Class: |
53/502 ;
177/25.13; 211/85.15; 248/95 |
Current CPC
Class: |
G07G 1/0036 20130101;
G01G 23/3735 20130101; G01G 19/52 20130101; G01G 23/3728 20130101;
G07G 1/0072 20130101; A47F 13/085 20130101 |
Class at
Publication: |
53/502 ;
211/85.15; 248/95; 177/25.13 |
International
Class: |
B65B 1/32 20060101
B65B001/32 |
Claims
1. An apparatus for use while packaging items within a container,
the apparatus comprising: means for substantially continuously
determining a weight of the container and its contents; means for
detecting the addition of an item into the container based on
changes to the weight; and means for accumulating the number of
items added to the container in a given cycle.
2. The apparatus according to claim 1, further comprising means for
indicating to a user when at least one predetermined condition
selected from the following group of conditions has been met: the
weight of the container and its contents exceeds a predetermined
maximum weight, or the number of items within the container exceeds
a preselected number of items.
3. The apparatus according to claim 2, further comprising means for
actuating a first visual output device, upon an item being placed
within the container, and for actuating a second visual output
device, upon the predetermined condition being reached.
4. The apparatus according to claim 1, further comprising means for
storing a plurality of containers adjacent to the weight
determining means.
5. The apparatus according to claim 4, wherein the containers are
t-shirts bags, and the container storing means comprises a pair of
arms structured to be received within a pair of apertures defined
within an upper portion of the bags, the pair of arms extending
over the weight determining means, to support at least one bag in a
position for packaging items therein.
6. The apparatus according to claim 5, wherein each arm comprises:
a substantially horizontal storage portion disposed adjacent to the
at least one vertical member, a substantially horizontal loading
portion disposed at a free end portion of the arm, and a transfer
portion disposed between the storage portion and loading portion,
the transfer portion being angled with respect to the storage
portion and the loading portion.
7. The apparatus according to claim 6, wherein the transfer portion
of each arm defines an obtuse angle with respect to the storage
portion and the loading portion.
8. The apparatus according to claim 6, further comprising a
projection disposed between the arms, the projection being
structured to fit within an aperture defined within a tab disposed
at a top of a container.
9. The apparatus according to claim 1, wherein the weight
determining means is selected from the group consisting of a scale
and a strain gauge.
10. The apparatus according to claim 1, wherein the item addition
means comprises: means for determining when the weight of the
container and its contents has stabilized, and means for comparing
a previous weight of the container and its contents with the weight
of the container and its contents.
11. The apparatus according to claim 1, wherein accumulating means
comprises an accumulator.
12. The apparatus according to claim 1, further comprising: means
for storing said accumulated item information; and means for
communicating said stored information to a processing unit for
analysis.
13. The apparatus according to claim 12, further comprising means
for calculating an average number of items packed within each
container.
14. A method of packaging items within a container, the method
comprising: providing a container; substantially continuously
determining a weight of the container and its contents; detecting
the addition of an item into the container based on changes to the
weight; and accumulating the number of items added to the container
in a given cycle.
15. The method according to claim 14, further comprising signaling
a user when the weight of the container and its contents exceeds a
predetermined maximum weight.
16. The method according to claim 15, further comprising providing
a first signal upon an item being placed within the container, and
a second signal upon the maximum weight for the container and its
contents being reached.
17. The method according to claim 14, further comprising the steps
of: determining when the weight of the container and its contents
has stabilized after the addition of an item; and comparing a
previous weight of the container and its contents with the
subsequent weight of the container and its contents.
18. The method according to claim 14, further comprising: storing
said accumulated information; and communicating said stored
information to a processing unit for analysis.
19. An apparatus for use while packaging items within a container,
the apparatus comprising: a rack, the rack comprising a base, and a
pair of arms disposed above the base, each arm having a
substantially horizontal storage portion disposed adjacent to the
at least one vertical member, a substantially horizontal loading
portion disposed at a free end portion of the arm, and a transfer
portion disposed between the storage portion and loading portion,
the transfer portion being angled with respect to the storage
portion and the loading portion.
20. The apparatus according to claim 19, further comprising at
least one vertical member extending upward from the base, the pair
of arms extending outward from the at least one vertical
member.
21. The apparatus according to claim 19, wherein the transfer
portion of each arm defines an obtuse angle with respect to the
storage portion and the loading portion.
22. The apparatus according to claim 19, further comprising a
projection disposed between the arms, the projection being
structured to fit within an aperture defined within a tab disposed
at a top of a container.
23. The apparatus according to claim 19, wherein the base includes
a scale.
24. The apparatus according to claim 23, further comprising an
accumulator operatively connected to the scale, the accumulator
adapted to record the number of items placed in the container based
upon an increase in a weight of the container with the addition of
an item therein.
25. An apparatus for use while packaging items within a container,
the apparatus comprising: a scale having a support surface for a
container; a rack for supporting a container in an open position
above the scale support surface; and an accumulator operatively
connected to the scale, the scale and accumulator being structured
to record a number of items placed in the container upon an
increase in a weight of the container.
26. The apparatus according to claim 25, wherein the rack further
comprises a means for supporting a plurality of containers in a
storage position.
27. The apparatus according to claim 25, wherein the rack
comprises: a base; at least one vertical member extending upward
from the base: and a pair of arms extending outward from the at
least one vertical member, each arm having a substantially
horizontal storage portion disposed adjacent to the at least one
vertical member, a substantially horizontal loading portion
disposed at a free end portion of the arm, and a transfer portion
disposed between the storage portion and loading portion, the
transfer portion being angled with respect to the storage portion
and the loading portion.
28. The apparatus according to claim 25, wherein the scale
comprises a signal structured to signal a user upon a preselected
maximum weight being reached.
29. The apparatus according to claim 28, wherein the scale
comprises a first signal structured to indicate successful registry
of an item placed in a container, and a second signal structured to
indicate a preselected maximum weight being reached.
30. The apparatus according to claim 25, wherein the scale and
accumulator are structured to determine when a weight of a
container and the container's contents have stabilized, and to
compare a previous weight of the container and the container's
contents with the weight of the container and its contents; whereby
an item placed in the container will result in a change in the
weight of the container, causing the accumulator to register an
additional item within the container.
31. The apparatus according to claim 25, further comprising a
processing unit in communication with at least one scale and
accumulator, the processing unit being structured to receive
information about a number of items per container from the at least
one scale and accumulator.
32. The apparatus according to claim 31, wherein the accumulator or
the processing unit is structured to calculate an average number of
items per container.
33. The apparatus according to claim 31, wherein the processing
unit is structured to control a group of settings for the at least
one scale and accumulator.
34. The apparatus according to claim 25, wherein the accumulator is
structured to calculate an average number of items per container
over a period of time.
35. The apparatus according to claim 25, wherein: the processing
unit includes a radio frequency transmitter/receiver; and the at
least one scale and accumulator includes a radio frequency
transmitter/receiver.
36. A processing unit for use with at least one scale and
accumulator combination, the at least one scale and accumulator
combination being structured to record a number of items placed in
a container disposed on the scale upon an increase in a weight of
the container, the processing unit comprising: means for receiving
information about a number of items per container or about a weight
per container from the at least one scale and accumulator
combination; and means for controlling a group of settings for the
at least one scale and accumulator combination.
37. The processing unit according to claim 36, further comprising
means for calculating an average number of items per container or
an average weight per container for the at least one scale and
accumulator combination.
38. The processing unit according to claim 36, wherein the
information receiving means and the setting control means include a
radio frequency transmitter/receiver.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional
patent application Ser. No. 60/773,869, filed Feb. 16, 2006,
entitled "Method and Apparatus for Bagging Retail Items."
FIELD OF THE INVENTION
[0002] The present invention relates to a method and apparatus for
packaging retail items, such as food in a grocery store. The
invention contemplates the accumulation of bag or container loading
information for purposes of staff training and overall operational
economics.
BACKGROUND OF THE INVENTION
[0003] The use of plastic or paper bags to load and carry retail
items, such as groceries, has become commonplace. The retail store
or shop supplies the bags and wraps the purchased items therein for
ease of the customer in transporting the goods away from the
store.
[0004] Various improvements have been created in the use of plastic
bags to increase efficiency in the checkout operation. For example,
U.S. Pat. No. 5,335,788 describes a self-opening polyethylene bag
stack which is placed upon a rack and wherein the removal of the
outer bag from the stack automatically opens the adjacent bag in a
sufficient manner to permit the placement of additional items in
the adjacent bag. The removal of this adjacent bag, which is now
the outside bag in the stack, opens the next adjacent bag, and so
on. Various bag racks and bag formations have also been proposed
which further add to the operational efficiency of the checkout
operation and the economy of using plastic bags in a retail
environment.
[0005] U.S. Pat. No. 6,894,232 discloses the combination of a bag
stack in conjunction with a scale to measure the weight of the
items within the bag. A plurality of indicators are provided in
order to indicate the relative weight of the retails items in the
bag against a target weight. The indicator identifies when the
loading within the bag has exceeded the desired weight
capacity.
[0006] Other patents and products have been defined for security
purposes in a self check-out operation within a retail environment.
Examples of such an operation are shown in U.S. Pat. No. 5,115,888
to Schneider and U.S. Pat. No. 7,066,389 B2 to Dickover et al.
SUMMARY OF THE INVENTION
[0007] In one aspect of the invention, an apparatus is defined for
packaging items within a container, such as a plastic bag. The
container is movably secured adjacent a scale or other means for
indicating the loading of items into the container. An accumulator
records the number of items added to the container in a given
cycle. The accumulated information is then stored during the given
cycle. The information is then communicated to a processing unit or
the like for purposes of analyzation. The analyzed information may
be used to train the retail staff in the placement of a correct
number and/or volume of items in a container and to allow
management to effectively monitor the average number of items in a
container for efficient use of the container inventory.
[0008] In another aspect of the invention, there is provided a
method for packaging items within a container. The method includes
the provision of a container, such as a plastic bag or the like,
adjacent a means for indicating the addition of items into the
container, such as a scale or item counter. The number of items
placed into the container is calculated for each container within a
given cycle. The calculated data per container is then stored and
accumulated for further processing. The stored data may be
transferred to a processing unit, such as a computer, for
analyzation with respect to usage of the containers and bagging
operation.
[0009] In another aspect of the invention, there is provided a rack
for holding containers such as plastic bags. The rack includes at
least one vertical member extending upward from a base, and a pair
of arms extending outward from the vertical member. Each of the
arms includes a substantially horizontal bag storage portion
adjacent to the vertical member, and a substantially horizontal bag
loading portion near its free end. A bag transfer section is
disposed therebetween, and is angled with respect to the storage
portion and loading portion. A bag is moved forward and downward
along the transfer section prior to loading, thereby facilitating
separation of the bag to be loaded from the remaining bags.
[0010] In another aspect of the invention, there is provided a
processing unit for receiving information about, for example, the
number of items per bag or the weight per bag from at least one
apparatus for packaging items in a container, and for controlling
the various settings of the apparatus. The processing unit may
communicate with each apparatus using radio frequency
communication.
[0011] Other aspects and features of the invention may be
incorporated therein and will become apparent to those skilled in
the art upon review of the present specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Without restricting the full scope of the present invention,
various preferred forms of the invention are illustrated in the
following drawings:
[0013] FIG. 1 shows a combination of a rack for supporting a
plurality of plastic bags adjacent to a scale for operation in
accordance with the present invention.
[0014] FIG. 2 shows the combination of a rack and scale as
contemplated by the present invention.
[0015] FIG. 3 further shows a rack with associated data
accumulating devices positioned thereon.
[0016] FIG. 4 shows a container support platform and scale portion
of the present invention.
[0017] FIG. 5 shows a further embodiment of a rack and scale
portion.
[0018] FIG. 6 is a front isometric view of a rack according to the
present invention.
[0019] FIG. 7 is a front elevational view of a rack according to
the present invention.
[0020] FIG. 8 is a back elevational view of a rack according to the
present invention.
[0021] FIG. 9 is a right side elevational view of a rack according
to the present invention.
[0022] FIG. 10 is a left side elevational view of a rack according
to the present invention.
[0023] FIG. 11 is a top plan view of a rack according to the
present invention.
[0024] FIG. 12 is a bottom plan view of a rack according to the
present invention.
[0025] FIG. 13 is a front isometric view of a rack according to the
present invention.
[0026] FIG. 14 is a front elevational view of a rack according to
the present invention.
[0027] FIG. 15 is a back elevational view of a rack according to
the present invention.
[0028] FIG. 16 is a right side elevational view of a rack according
to the present invention.
[0029] FIG. 17 is a left side elevational view of a rack according
to the present invention.
[0030] FIG. 18 is a top plan view of a rack according to the
present invention.
[0031] FIG. 19 is a bottom plan view of a rack according to the
present invention.
[0032] FIG. 20 is a schematic diagram of a control circuit for the
present invention.
[0033] FIG. 21 is a schematic diagram of a power supply portion of
a control circuit for use with the present invention.
[0034] FIG. 22 is a schematic diagram of an input portion of a
control circuit for the use with present invention.
[0035] FIG. 23 is a schematic diagram of a microprocessor and
memory portion of a control circuit for use with the present
invention.
[0036] FIG. 24 is a schematic diagram of a buffer and speaker
portion of a control circuit for the present invention.
[0037] FIG. 25 is a schematic diagram of a display portion of a
control circuit for use with the present invention.
[0038] FIGS. 26A-26B are a flowchart showing a set of operational
steps.
[0039] FIGS. 27A-27D are a flowchart showing another set of
operational steps.
[0040] FIG. 28 is a schematic view of a processing unit in
communication with multiple rack, scale, and accumulator assemblies
according to the present invention.
DETAILED DESCRIPTION
[0041] In the drawings, where like numerals indicate like elements
and like letters indicate connections that have been broken for
clarity within the drawings, there is illustrated in the various
figures a rack for supporting a plurality of plastic bags, or other
type containers. In FIG. 1, the rack is identified by the numeral
10. The rack 10 supports a series of flexible bag type containers
12. A scale 14 is provided in conjunction with the rack 10 and
positioned below the bags 12. The scale includes a support surface
16 which is adapted to support a series of items (not shown) within
a bag 12 that has been opened on the rack 10.
[0042] In the present invention, the container for receiving items
may take any form as desired. As illustrated, a plurality of bags
12 are provided in a stack with each adjacent bag being separately
openable. The bags may be assembled in accordance with U.S. Pat.
No. 5,335,788, which is herein incorporated by reference. However,
the use of any particular type bag is not being restricted by the
scope of the present invention. The plurality of bags 12 are
positioned on the rack 10 by providing openings 18 within the
handles of the bag. The bags as illustrated are T-shirt type bags
having handles 20 on opposite sides and a central tab 22 which is
further secured to the rack 10. The central tab 22 may in some
examples be a tab as disclosed in U.S. Pat. No. 5,845,779, which is
herein incorporated by reference. The handle arms 24 support the
bag handles 20 when the various layers of the bag are slid along
the arms 24. Each handle arm 24 includes a substantially horizontal
bag storage portion 25 at the end portion closest to the vertical
members 28, a substantially horizontal bag loading portion 27, at
the free end portion, and a bag transfer portion 29 between the
storage portion 25 and loading portion 27. The bag transfer portion
29 is angled with respect to the storage portion 25 and loading
portion 27, with the illustrated example having an obtuse angle
between the storage portion 25 and loading portion 27. The end 31
of each arm 24 may be angled upward to retain a bag 12 on the arms
24 until removal of the bag 12 is desired. The central tab 22 may
be fixably secured within the bag stack or otherwise supported on a
central projection 26 formed on the bag rack 10. In this manner, a
single bag 12 or container is pulled outward and downward over the
transfer portion 29, thereby separating the bag 12 from the other
bags 12 while opening the bag 12 over the support surface 16 of the
scale 14. The rack 10 thereby provides a means for holding the bag
12 open during placement of various items into the bag prior to
removal of the bag from the rack.
[0043] In FIG. 2 there is illustrated the rack 10 without the bags
being shown thereon. A wire frame construction is provided having a
rear panel, which supports the projecting arms 24 and the central
tab 26. The rear panel is defined by two vertical members 28 and a
series of horizontal members 30. Side loops 32 are also provided
for stabilizing the side edges of the bag during placement of items
therein. A lower portion of the rack is attached to or engages with
the scale 14 to provide a free standing unit.
[0044] In FIG. 3 there is illustrated the rack with the scale 14
removed. Exposed at the base of the rack is a cross bar 34
structured to support the scale 14 and other associated electronic
devices, including an accumulator. The accumulator may be provided,
alternatively, as part of the scale or may be separately attached
and plugged into the scale 14. As illustrated in FIG. 3, the cross
beam 34 of the illustrated example provides an opening 36 which may
be used for receipt of a corresponding projection which is part of
the scale 14, or for various electronic components of the scale 14
and/or the accumulator. In FIG. 4 there is illustrated graphically
a projection 38 having structural elements for defining the scale
and the accumulator. Various forms of scales may be utilized in
conjunction with the operation of the present invention. The
communication between the scale electronics and the accumulator may
be made in any convenient manner, including by means of electronic
cables or through some other communication means. Again, the
accumulator and scale device may be incorporated into a single
operational panel or otherwise as desired. As also illustrated, a
display panel 40 and/or other visual output devices are provided on
the scale for indicating the number of items, the weight of the
items, the total weight of the bag, menu options, or other desired
information. A visual output device is defined herein as a display
panel, a light source such as a light emitting diode (LED), or
other device that communicates visual information.
[0045] In FIG. 5 there is shown an alternate version of the rack
and scale combination. The rack 10' is positioned on the top of a
base 14' which incorporates the scale 14A therein. A display 40' is
provided on the front face of the base 14'. A secondary display 42
is also provided adjacent the upper surfaces of the rack. This
secondary display may be repositioned so as to be visible to the
consumer or other person associated with the bagging operation.
Additional visual output devices may be provided on the display,
including indicator lights or other identification information for
matching the packaging operation to the desired parameters. The
illustrated displays 40', 42 include a display screen 44, as well
as an optional reset button 64, a menu button 66, and a select
button 68, the functioning of which is described in greater detail
below. A well 16' is defined within the scale 14A to assist in
supporting and stabilizing the items within the bag (not shown).
Again, other variations of the scale and rack may be utilized.
[0046] Other embodiments of the rack 10'', 10''' are illustrated in
FIGS. 6-19. The rack 10'' of FIGS. 6-12 and the rack 10''' of FIGS.
13-19 differ only in the structure of the display 42'', 42'''. The
rack 10'', 10''' has a base 34'', 34''', with an upright back
member 11'', 11''' extending upward therefrom, and a pair of arms
24'', 24''' extending outward from the upright back member 11'',
11'''. The illustrated example of the rack 10'', 10''' utilizes a
wire frame construction, with the back 11', 11''' including a pair
of vertical members 28'', 28''', connected by horizontal members
30'', 30'''. Those skilled in the art will recognize that
alternative constructions are possible. For example, the back 11',
11''' may be formed by a portion of a wall to which the arms 24',
24''' are attached, with the base 34'', 34''' disposed adjacent to
the wall and below the arms 24'', 24'''. The base 34'', 34''' may
include a plurality of feet 35'', 35''', which may in some
embodiments be adjustable to ensure that the base 34'', 34''' is
level.
[0047] The arms 24'', 24''' of FIGS. 6-19 are substantially
straight and horizontal, with upwardly-angled ends 31'', 31''' to
resist a bag from sliding off the arms 24'', 24''' until desired by
the individual filling the bag 12. A pair of bag guides, which in
the illustrated example are formed by the side loops 32'', 32'''
extend outward from the upright back member 11'', 11''' to
stabilize a bag during loading. A central projection 26'', 26'''
extends upward from the upright back portion 11'', 11''',
structured to fit within an aperture defined within an upwardly
extending central tab formed as part of a bag 12. Someone desiring
to fill a bag 12 may open the bag 12 by pulling one side of the bag
12 outward along the arms 24'', 24''', with one of the bag's
central tabs being secured by the projection 26'', 26''', thereby
opening the bag.
[0048] The base 34'', 34''' of the rack 10'', 10''' includes a
scale 14'', 14''', structured to monitor the weight of items
contained within bags 12 that are being loaded on the rack 10'',
10'''. The scale 14'', 14''' is operatively connected with an
accumulator for keeping track of the number of items placed in the
bag 12. As before, the accumulator keeps a running total of the
number of items in the bag 12, increasing or decreasing the total
number of items based on increases and decreases in the weight
sensed by the scale. The accumulator may be disposed within the
base 34'', 34''', within a remote location, or within a display
42'', 42''' secured to the rack 10'', 10'''. The connection between
the scale 14'', 14''' and the display 42'', 42''' may be in the
form of electrical wiring, or a wireless connection. In the
illustrated example, the display 42'', 42''' is located at the top
of the upright back member 11'', 11'''. The illustrated display
42'', 42''' includes a display screen 44'', 44''' that may be an
illuminated screen or a liquid crystal display, and various
controls, for example, the illustrated buttons, including the menu
button 66'', 66''', which may be colored red, and the select button
68'', 68''', which may be colored green. Referring to FIGS. 13-19,
the display 42''' further includes an LED 45''', which may be
activated in either a constant on mode or a blinking mode when a
predetermined weight is reached or exceeded. An antenna 47''' may
extend upward from the display 42''', facilitating radio frequency
communication with a processing unit as described in greater detail
below. A clip 43''' may be provided to secure the display 42'',
42''' to the rack 10'', 10''' in any location that is convenient
for an individual utilizing the rack 10'', 10''', which in the
illustrated example is at the top of the rack 10'', 10'''. The
scale 14'', 14''' may optionally include various additional
controls, for example, for balancing and zeroing the scale.
[0049] Referring to FIGS. 20-25, various elements of an example of
a circuit 48 forming the combination of the scale 14, the
accumulator, and the display 40, 42 are illustrated in greater
detail. FIG. 20 illustrates the entire circuit 48 and the
relationship of the various portions of the circuit 48, while FIGS.
21-25 illustrate the various portions of the circuit 48 in greater
detail. The circuit is described generally herein, because the
structure and function of the various components of the circuit are
known to those skilled in the art of electronics.
[0050] Referring to FIG. 21, the circuit 48 includes a power supply
portion 50. The power supply 50 is structured to draw power from a
battery 52, which may in some preferred embodiments be a standard
flashlight-type battery. Current flows from the battery 50 through
a DC to DC converter 54 which, in combination with the remainder of
the power supply portion 50, is structured to increase the voltage
supply to the system, with a corresponding decrease in current. The
proper voltage is therefore supplied to the microprocessor, which
is described in greater detail below.
[0051] Referring to FIG. 22, the input portion 56 of the circuit 48
is illustrated. The primary input to the circuit 48 comprises
signals from the scale 14, which travel through a bridge 58, before
being amplified by an amplifier 60. Any "noise" is removed by a low
pass filter 62. The user may control the circuit 48 through the use
of any conventional switching mechanism, which in the illustrated
example are the buttons 64, 66, 68, with the buttons 66, 68
operating in the same manner as the buttons 66'', 66''', 68'', and
68'''. Button 64 is an optional reset button in the illustrated
example, while buttons 66, 68 are a menu button and a selector
button, with either of the buttons 66, 68 being capable of serving
either function, depending on the programming of the
microprocessor. For ease of explanation, the button 66 will be
designated a menu button or red button, and the button 68 will be
designated a selector button or green button. A connector 70 may be
provided to enable buttons such as buttons 66, 68 to be located
remotely. The microprocessor may be configured to exchange data
with a computer through a PC interface 72, with the exchange taking
place through either an appropriate cable or through a wireless
connection. The microprocessor may therefore be programmed remotely
through a computer, or may transmit data to a computer for further
analysis.
[0052] The operation of the circuit 48 is controlled by a control
portion 74, best illustrated in FIG. 23. The control portion 74
preferably includes a pair of microprocessors 76, 78. The
microprocessor 76 in the illustrated example is a 24-pin
microprocessor having a microcontroller therein, and preferably
includes a 10-bit analog to digital converter for converting
signals from the scale 14 into digital signals. The microprocessor
76 preferably includes a crystal, a voltage regulator, and
nonvolatile memory. Connectors 80, 82 may be connected to the
microprocessor 76 to enable diagnostic devices to interface with
the microprocessor 76. The microprocessor 78 in the illustrated
example is a 20-pin microprocessor that may be operatively
connected to a crystal 84, which serves as a clock, and a flash
memory 86. The microprocessor 78 and flash memory 86 may be
operatively connected to connectors 88, 90, respectively, which may
serve as programming ports or test ports. The microprocessors 76,
78 may be programmed to determine when the signal from the scale 14
has stabilized, compare the weight with the previous stabilized
weight to determine if items have been added to or removed from the
bag, keep a running total of the number of items in the bag,
compare the weight with the maximum weight for the bag, provide the
appropriate output signals, and calculate the average items per
bag. Methods of programming a microprocessor 76, 78 to perform
these calculations are well known and therefore not described in
detail herein.
[0053] Referring to FIG. 24, an audio signal portion 92 is
illustrated. When an audible signal is desired, for example, to
signal that an item placed in or removed from the bag 12 has been
registered by the system, or to signal that a bag has reached it
maximum weight, a signal is sent from the microprocessor 76 to the
buffer 94, where the signal is then sent to the speaker 96.
[0054] Referring to FIG. 25, a visual signal portion 98 is
illustrated. When a visual signal is desired, for example,
information about the weight of a bag and its contents, the average
number of items in a bag, or the available menu selections, the
microprocessor 76 may send a signal to the eight-bit data latch
100, which converts eight bits of serial data into eight bits of
parallel data. The parallel signal is then directed towards the LCD
interface 102, where it can then be transmitted to and displayed
upon the displays 40, 42.
[0055] One procedure for utilizing the invention during a bagging
cycle is illustrated in FIGS. 26A-26B. Referring to FIG. 26A, at
the beginning of each cycle, the scale must be tared so that it
shows a weight of zero with a bag in place, so that the weight of a
bag or other container does not count towards the weight registered
by the scale 14 at step 104. The system then resets the total
weight and number of items contained in the bag to zero at step
106, and waits for the scale to register an increase in weight at
step 108. An increase in the weight sensed by the scale 14
typically indicates that an item has been placed in the bag 12, but
could be caused by other things, for example, an item placed in a
bag 12, only to be removed to be placed in another bag 12, or an
individual placing a hand on the scale 14. Likewise, a decrease in
weight typically indicates that an item has been removed from the
bag 12, and although the present example illustrates the addition
of items to a bag 12, sensing a decrease in the weight of the bag
12 can be processed as a reduction in the number of items in the
bag 12 in a similar manner. Therefore, when a weight increase (or
decrease) is sensed at step 110, the system must next verify that
the weight change was due to an item being placed in (or removed
from) the bag at step 112. Verification could be accomplished, for
example, by verifying that the weight change stabilizes for a
specified minimum period of time. In the event that there has been
no weight change, or that the weight change was not due to an item
being placed in (or removed from) the bag, the system will check to
see if the menu button 66 has been pressed at step 114. In the
absence of a user's selection of a menu at step 114, the system
will continue to wait for the next increase in weight at step
108.
[0056] In the event that a weight change was due to an item being
placed in (or removed from) the bag 12, the weight of the item will
be added to (or subtracted from) the total weight presently
registered by the scale 14 of step 116. The number of items in the
bag 12 will also be increased (or decreased) at step 116. With the
new total weight calculated, the system will compare the new total
weight to the desired weight limit for the bag 12 at step 118. If
the weight limit for the bag 12 has not been reached, the system
will again check to see if the menu button 66 has been pressed at
step 114, and then proceed to wait for the next increase in weight
at step 108. If the weight limit has been reached, the system will
signal the user that the weight limit has been reached at step 120.
Once the weight limit has been reached and/or once the bag has been
removed (which may occur prior to the weight limit being reached if
the bag is filled with lightweight, bulky items), the system will
recalculate the average number of items per bag 12 at step 122, and
then check to see if a new bag 12 is to be packed at step 124. If a
new bag 12 is being packed, the number of items and total weight of
the bag 12 are reset to zero at step 106. If no new bag 12 is to be
packaged, the cycle may end.
[0057] Each press of the menu button 66 may cause the system to
cycle through the various menus that are offered. In the
illustrated example, each push of the menu button 66 increments the
menu count at step 126. Depending on the current menu count, which
cycles from 1 thru 3 and then returns back to 1, the appropriate
menu is selected at step 128.
[0058] Referring to FIG. 26B, in the event that the menu count
equals 1 at step 128, the beep mode menu may be selected, thereby
permitting the user to change the characteristics of the signal
generated when the weight limit of the bag is reached.
Additionally, the user may be provided with the ability to select
the characteristics of the signal provided each time an item is
registered within the bag. Initially, an indication of the menu
selected--the beep-mode menu--is displayed at step 130. The system
will next determine if selector button 68 has been actuated at step
132, and if so, will change the beep setting to the next setting in
the queue at step 134. The system will continue to change the beep
setting for each push of selector button 68 as long as the menu
button 66 is depressed, and queries the depression of the menu
button 66 at step 136. Once the menu button 66 is released, the
system proceeds to step 94 to check for an additional actuation of
the menu button 66 at step 114, and if no such actuation is
received, the system will proceed to wait for an increase in the
weight of the bag at step 108 (FIG. 26A).
[0059] In the event that the menu count equals 2 at step 128, the
clear average option will be selected. The system will first
indicate to the user that the clear average menu has been selected
at step 138. With the menu button 66 held down, and upon each press
of selector button 68 at step 140, the average number of items per
bag 12 will be cleared at step 142, so that subsequent total
calculations of the average number of items per bag 12 will include
only subsequent bags 12. Depression of the menu button 66 is
queried at step 144. Releasing the menu button 66 will again return
the system to step 114, wherein the system will determine if the
menu button 66 has been pressed a second time. If not, the system
will proceed to wait for the next increase in weight in the bag at
step 108 (FIG. 26A).
[0060] If the menu count equals 3 at step 128, the maximum weight
per bag may be changed. The system will initially indicate the menu
option selected at step 146. As long as the menu button 66 is
depressed, each press of selector button 68 at step 148 will
incrementally change the maximum weight per bag at step 150.
Depression of the menu button 66 is queried at step 152. Releasing
the menu button 66 at step 152 returns the system to step 114,
where an additional actuation of the menu button 66 will increment
the menu count at step 126, or the absence of another actuation of
the menu button 66 will bring the system to step 108 (FIG. 26A),
wherein it will wait for an increase in the weight of the bag that
is presently being loaded.
[0061] An alternative sequence of operation is illustrated in FIGS.
27A-27D. At the beginning of each cycle, illustrated in FIG. 27A,
the scale must be tared so that it shows a weight of zero with a
bag in place, so that the weight of a bag or other container does
not count towards the weight registered by the scale 14 at step
154. The system then resets the total weight and number of items
contained in the bag to zero at step 156, and waits for the scale
to register an increase in weight at step 158. An increase in the
weight sensed by the scale 14 typically indicates that an item has
been placed in the bag 12, but could be caused by other things, for
example, an item placed in a bag 12, only to be removed to be
placed in another bag 12, or an individual placing a hand on the
scale 14. Likewise, a decrease in weight typically indicates that
an item has been removed from the bag 12, and although the present
example illustrates the addition of items to a bag 12, sensing a
decrease in the weight of the bag 12 can be processed as a
reduction in the number of items in the bag 12 in a similar manner.
Therefore, when a weight increase (or decrease) is sensed at step
160, the system must next verify that the weight change was due to
an item being placed in (or removed from) the bag at step 162.
Verification could be accomplished, for example, by verifying that
the weight change stabilizes for a specified minimum period of
time. In the event that there has been no weight change, or that
the weight change was not due to an item being placed in (or
removed from) the bag, the system will check to see if the menu
(red) button 64 has been pressed at step 164, and if the select
(green) button 66 has been pressed at step 167 in conjunction with
the menu button. In the absence of a user's selection of a menu at
step 164, the system will then check to see if the minimum time
prior to entering sleep mode has elapsed since the last action at
step 169, and if so, the device will enter sleep mode at step 171,
thereby conserving power until the next action. In either case, the
device will continue to wait for the next increase in weight at
step 158.
[0062] In the event that a weight change was due to an item being
placed in (or removed from) the bag 12, the weight of the item will
be added to (or subtracted from) the total weight presently
registered by the scale 14 of step 166. The number of items in the
bag 12 will also be increased (or decreased) at step 166. With the
new total weight calculated, the system will compare the new total
weight to the desired weight limit for the bag 12 at step 168. If
the weight limit for the bag 12 has not been reached, the system
will again check to see if the menu button 66 or select button 68
has been pressed at steps 164 and 167, and then proceed to wait for
the next increase in weight at step 158. If the weight limit has
been reached, the system will signal the user that the weight limit
has been reached at step 170. Once the weight limit has been
reached and the bag has been removed, the system will recalculate
the average number of items per bag 12 at step 172, and then check
to see if a new bag 12 is to be packed at step 174. If a new bag 12
is being packed, the number of items and total weight of the bag 12
are reset to zero at step 156. If no new bag 12 is to be packaged,
the cycle may end.
[0063] Referring to FIG. 27B, in the event that both the menu 64
and select 66 buttons are pressed at steps 164 and 167 (FIG. 27A),
it is then necessary to check at step 176 to see if they have been
held down for 1 second, in which case the first menu selection will
be displayed at step 178, or for 6 seconds, in which case the
system will be locked or unlocked. To reach step 176, the system is
necessarily unlocked, and will be locked at step 180 until the next
6-second press of both buttons 66, 68 at step 182. The system will
then be unlocked at step 184, and will return to checking for
weight increases at step 158 (FIG. 27A). This function may be
removed if desired, or the lock/unlock control may be located at a
central processing station. Including this function at a central
processing station may be useful if requiring manager approval is
desired.
[0064] In the illustrated embodiment, the first menu selection is
the target number of items, although the order of menu selections
is not critical to the invention. Pressing the select button at
step 186 will toggle through the various selection options for the
target number of items at step 188. An example range of options is
from 1 to 15 items. The user may then either stop pressing the
select button for the system to return to waiting for a weight
increase at step 158 (FIG. 27A), or push the menu button at step
190 to display the next menu selection at step 192. Although the
illustrated example provides an indication of when a target weight
is reached, other examples may provide an indication of when a
target number of items is reached, or may give store managers or
other users the option of providing a signal upon reaching a
targeted weight or a targeted number of items.
[0065] In the illustrated embodiment, the second menu selection is
the target weight per bag. Pressing the select button at step 194
will toggle through the various selection options for the target
weight at step 196. An example of a range of options for the target
weight setting includes five pounds to twenty pounds. The user may
then either stop pressing the select button for the system to
return to waiting for a weight increase at step 158 (FIG. 27A), or
push the menu button at step 198 to display the next menu selection
at step 200.
[0066] In a similar manner, pressing the select button at step 202
will toggle through the various selection options for the desired
time with no actions before which the system goes into sleep mode
at step 204. An example of a range of options includes one minute
to ninety minutes. The user may then either stop pressing the
select button for the system to return to waiting for a weight
increase at step 158 (FIG. 27A), or push the menu button at step
206 to display the final menu selection at step 207.
[0067] Referring to FIG. 27C, the final illustrated menu selection
is the LED setting, which may be set to cause the LED 45'' to blink
or to display continuously upon reaching the target weight. Each
push of the selection button at step 208 toggles to the next
setting at step 210. The user may then either stop pressing the
select button for the system to return to waiting for a weight
increase at step 158 (FIG. 27A), or push the menu button at step
212 to display the first menu selection at step 178 (FIG. 27B).
[0068] Referring to FIG. 27D, if only the menu button is pressed at
steps 164 and 167, the user is given the option of selecting the
data to be displayed, and also resetting the average number of
items per bag and the average weight per bag. In the illustrated
example, pressing the menu button 66 displays the average number of
items per bag at step 214. If the menu button 66 is held down for
about one second at step 216, then the average number of items per
bag is reset at step 218. Regardless of whether the average number
of items per bag is reset, the user may press the menu button 66 at
step 220 to display the average weight per bag at step 222. Holding
the menu button down for about one second at step 224 resets the
average weight per bag at step 226. Pressing the menu button again
as step 228 results in a blank display at step 230, which is useful
for store managers who do not want their baggers watching the
display during bagging. This control may be set at a central
processing station, or may require some other type of manager
actuation. A fourth press of the menu button at step 232 toggles
back to the initial selection of displaying the number of items in
the bag at step 214.
[0069] Selection of the various menu options illustrated in FIGS.
26A-27D may be accomplished remotely from a separate processing
unit as illustrated in FIG. 28. The separate processing unit may in
some examples be a personal computer 242 having appropriate
software installed thereon, and a radio frequency
transmitter/receiver 244 attached thereto. Each display 40, 42,
42'', 42''' may also include a radio frequency transmitter/receiver
incorporated therein. Each display 40, 42, 42'', 42''' may be
identified by a unique electronic identification, thereby
permitting individual control of each rack 10, 10', 10'', 10'''
using the separate processing unit. Individual and group averages
for the number of items per bag and the average weight per bag may
be tracked by the computer 242. Radio frequency transmission of
data is well known to those skilled in the art of radio frequency
communication, and is therefore not discussed in detail herein.
Other forms of wireless transmission may also be used, for example,
infrared or Blue Tooth.
[0070] Although the illustrated examples are described using
controls on the rack itself, all settings may be controlled
remotely by either a wire or wireless connection to a separate
computer or controller. The average number of items per bag and
average weight per bag may also be monitored and studied remotely
to assist store management in optimizing the performance of
baggers.
[0071] The object of the present invention is to train staff to
place more items in each bag or container while preventing
overloading of the bag. The scale creates a signal which is
received by the accumulator and which calculates the number of
items which are placed within a bag prior to removal of the bag
from the scale. The accumulated information may then be stored over
a cycle, such as a shift for each staff member or otherwise.
Management may then download the accumulated data and analyze same
to determine the number of items placed within each bag, the
average weight of the items in the bag and other useful
information. Management may then train staff and monitor
performance to meet the desired standards of the operation. Once
the staff is properly trained, the packaging operation will make
efficient use of the available bags, thus limiting expenses for the
store or other user of the invention, while at the same time
avoiding risk of damage to items (and its associated retail effect)
when a bag is overloaded.
[0072] In operation, the bagging staff would pull a bag from the
rack over the base platform and begin filling the bag. An
electronic device in the base records each time something is placed
in the bag. An item indicator may be provided, such as a light or
pleasant sound to indicate that the bag has been added to
appropriately. As the bagging staff continues to fill the bag,
indicators may provide information on the total number of items and
the relationship with the maximum weight goal for each bag. The
device counts and records the number of items per bag and
accumulates that data over a cycle. That accumulated information
may then be downloaded to a processing unit, such as a computer, to
be analyzed by management for training and other instructural
purposes. Again, the intent of the operation is to train the
support staff to maintain optimal standards for container use.
[0073] Although the present invention has been described in
considerable detail with reference to certain preferred versions
thereof, other versions are possible. Various forms of containers
and/or support racks for the containers may be utilized. Various
forms of scales or other indicator devices may be provided, each
having various forms of power supplies and means of communicating
with various analyzation tools. Other features of the method of
analyzation may be added without departing from the scope of the
present invention. The scope of the impending claims should not be
limited by the description of the preferred versions as contained
herein.
* * * * *