Programmable logic controller driven inventory control systems and methods of use
First Claim
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1. An inventory system, comprising:
- a plurality of product zones, each product zone of said plurality of product zones including at least one part bin for storing a plurality of parts, said at least one part bin having an associated pick module;
a computer system including a database; and
a programmable logic controller coupled to said computer system and to said pick module associated with said at least one part bin in each of said plurality of product zones, said programmable logic controller configured to send a signal to said pick module associated with said at least one part bin of at least one of said plurality of product zones in response to data received from said database identifying said at least one part bin of said at least one product zone.
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Abstract
A programmable logic controller driven inventory control system for use with a pick or assembly line. The programmable logic controller may be configured to interface with and control the various components of the pick line and inventory control system, as well as to interface with a computer system containing inventory databases. The programming of the programmable logic controller and, hence, operation of the inventory control system and pick line may be altered in real time during operation.
39 Citations
25 Claims
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1. An inventory system, comprising:
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a plurality of product zones, each product zone of said plurality of product zones including at least one part bin for storing a plurality of parts, said at least one part bin having an associated pick module;
a computer system including a database; and
a programmable logic controller coupled to said computer system and to said pick module associated with said at least one part bin in each of said plurality of product zones, said programmable logic controller configured to send a signal to said pick module associated with said at least one part bin of at least one of said plurality of product zones in response to data received from said database identifying said at least one part bin of said at least one product zone. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 17, 18, 19)
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14. A method of managing inventory on a pick line, said pick line comprising a plurality of product zones, each of said plurality of product zones including a plurality of part bins for storing parts, each of said plurality of part bins having an associated pick module, said method comprising:
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providing a programmable logic controller;
sending data to said programmable logic controller, at least a portion of said data specifying at least one associated pick module;
formatting said at least a portion of said data with said programmable logic controller to produce a formatted signal;
sending said formatted signal from said programmable logic controller to said at least one associated pick module to illuminate a user-readable output on said at least one associated pick module.
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16. A method of managing inventory on a pick line, said pick line comprising a plurality of product zones, each of said plurality of product zones including a plurality of part bins for storing parts, said method comprising:
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providing a programmable logic controller;
sending data to said programmable logic controller, said data including at least one specified part; and
identifying with said programmable logic controller a corresponding product zone of said plurality of product zones in which said at least one specified part is located and identifying a corresponding part bin of said plurality of part bins in said corresponding product zone in which said specified part is stored.
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20. A method of managing inventory on a pick line, said pick line comprising a first product zone including a first plurality of part bins, each of said first plurality of part bins storing a type of part, and at least a second product zone including a second plurality of part bins, each of said second plurality of part bins storing a type of part, said method comprising:
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providing a programmable logic controller coupled to a first plurality of pick modules, each of said first plurality of pick modules associated with one of said first plurality of part bins, and coupled to a second plurality of pick modules, each of said second plurality of pick modules associated with one of said second plurality of part bins;
transporting a pallet into said first product zone;
sending data to said programmable logic controller, said data specifying at least one type of part located in said first product zone and at least one other type of part located in said second product zone;
identifying with said programmable logic controller a first matching part bin of said first plurality of part bins in which said at least one type of part is stored;
sending a first signal with said programmable logic controller to a pick module of said first plurality of pick modules associated with said first matching part bin, said first associated pick module illuminating a user-readable output thereof in response to said first signal; and
providing a verification signal from said first associated pick module to said programmable logic controller, said verification signal indicating said at least one type of part has been picked from said first matching part bin and placed on said pallet in said first product zone. - View Dependent Claims (21, 22, 23, 24, 25)
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Specification