Item labeling, inspection and verification system for use in manufacturing, packaging, product shipment-fulfillment, distribution, or on-site operations

• US 20070210164A1
• Filed: 03/06/2007
• Published: 09/13/2007
• Est. Priority Date: 03/07/2006
• Status: Active Grant

• Current Assignee: Tension International Inc.
• Original Assignee: Maverick Enterprise, Inc.
• Inventors: Owens, Timothy J., Conlon, Kevin M.
• Granted Patent: US 7,918,402 B2
• Time in Patent Office: Days
• US Class Current: 235/462.10
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06Q 10/0875 Itemisation or classification of parts, supplies or services, e.g. bill of materials

Abstract

An item contents verification system, and associated method, for use in an assembly line of carrier-totes (if used) each containing at least one of a plurality of items having a labeling. Also, a labeling for use with a computerized inspection apparatus for verification of items, and associated method. The system includes: (a) the labeling comprising a luminescent marking and a human-visible indicia; (b) the luminescent marking comprises a coded-indicia generally invisible to a human eye without an irradiation, each of these coded-indicia contains item-information about the item to which the labeling is applied, multiple such coded-indicia will be substantively identical; (c) an inspection apparatus adapted for automatically collecting item-information from luminescent coded-indicia oriented outwardly from items passing in proximity to the inspection apparatus; (d) in communication with the inspection apparatus is a processor unit used for comparing an order of selected items against the item-information collected about all items; if the item-information collected matches the order of selected items, that carrier-tote contents is deemed verified. A reject spur is included to which any respective carrier-tote, or any respective item not matched to an order, is routed if the contents of the carrier-tote is not deemed verified.

Claims

1. An item contents verification system for use in an assembly line of carrier-totes each containing at least one of a plurality of items having a labeling, the system comprising:

(a) the labeling comprising a luminescent marking and a human-visible indicia;

(b) said luminescent marking comprising a coded-indicia generally invisible to a human eye without an irradiation, each said coded-indicia to contain item-information about the item to which the labeling is applied;

(c) an inspection apparatus adapted for automatically collecting said item-information from said luminescent coded-indicia oriented outwardly and within a respective one of the carrier-totes as it passes in proximity to said inspection apparatus;

(d) in communication with said inspection apparatus is a processor unit adapted for comparing an order of selected items against said item-information collected about each said item within said respective carrier-tote;

if said item-information collected matches said order of selected items, said respective carrier-tote contents is deemed verified; and

(e) a reject spur to which any said respective carrier-tote is routed if the contents is not deemed verified.

2. The system of claim 1, wherein:

(a) the carrier-totes are positioned for automatic movement such that said inspection apparatus is generally overhead said respective carrier-tote as it passes on a track of the assembly line;

(b) said luminescent marking further comprises a plurality of said coded-indicia that are substantively identical; and

(c) said inspection apparatus is computerized and further comprises a source of radiation emitted at said luminescent coded-indicia oriented outwardly during said collecting of said item-information therefrom.

3. The system of claim 2:

(a) wherein said source of radiation is selected from the group consisting of an ultra-violet (UV) radiation source, a near-infrared (near-IR) radiation source, and an infrared (IR) radiation source; and

(b) further comprising a tote agitation station through which said rejected carrier-tote routed to said reject spur passes prior to being routed for a second pass under said inspection apparatus.

4. The system of claim 3:

(a) wherein said processor unit is further adapted for comparing said order of selected items against a second item-information collected, during said second pass, about each said item within said agitated carrier-tote;

if said second item-information collected matches said order of selected items, said agitated carrier-tote contents is deemed verified; and

(b) a manual inspection spur to which any said agitated carrier-tote is routed if the contents is not deemed verified after said second pass under said inspection apparatus.

5. The system of claim 1 wherein:

(a) said luminescent marking further comprises a plurality of said coded-indicia organized in array fashion, at least one of said coded-indicia to overlap, at least in part, said human-visible indicia;

(b) said inspection apparatus is computerized and further comprises a source of radiation emitted during said collecting of said item-information, and a device adapted to capture said coded-indicia when illuminated by said source; and

(c) said human-visible indicia comprises a string of alphanumeric characters and a UPC barcode, both of which identify the item to which the labeling is applied.

6. The system of claim 1 further comprising:

(a) a data storage unit in communication with said processor unit, said data storage unit comprising a plurality of said orders of selected items, each said order bound for shipment to an assigned destination; and

(b) each said item-information further comprises said assigned destination of the item to which the labeling is applied.

7. The system of claim 1 wherein:

(a) the items are selected from the group consisting of a handheld computerized device, a cell phone, an optical storage disk, a magnetic storage cassette, and a packaging used for containing or otherwise clustering together smaller objects for transport;

said packages selected from the group consisting of bottles, boxes, packets, pouches, tubes, envelopes, baggies, flexible-wrap, fusion material, cans, canisters, blister-packs, vacuum-formed packs, and storage media cases; and

(b) said inspection apparatus is computerized and further comprises a source of radiation adapted for emitting at a pre-selected range during said collecting of said item-information, and a device adapted to capture said coded-indicia when illuminated by said source at said pre-selected range.

8. An item labeling and verification system for use in an assembly line of carrier-totes, the system comprising:

(a) an apparatus for automatically applying to each of a plurality of items, a labeling comprising a luminescent marking;

said labeling further comprising a human-visible indicia;

(b) said luminescent marking comprising a coded-indicia generally invisible to a human eye without an irradiation, said coded-indicia to contain item-information about the item to which the labeling is applied;

(c) an inspection apparatus adapted for collecting said item-information from said luminescent coded-indicia oriented outwardly and within a respective one of the carrier-totes as it passes in proximity to said inspection apparatus; and

(d) in communication with said inspection apparatus is a processor unit adapted for comparing an order of selected items against said item-information collected about each said item within said respective carrier-tote;

if said item-information collected matches said order of selected items, said respective carrier-tote contents is deemed verified.

9. The system of claim 8:

(a) wherein said inspection apparatus further comprises a source of radiation emitted at said luminescent coded-indicia oriented outwardly during said collecting of said item-information therefrom; and

(b) further comprising a reject spur to which any said respective carrier-tote is routed if the contents is not deemed verified, and a tote agitation station through which said rejected carrier-tote routed to said reject spur passes prior to being routed for a second pass under said inspection apparatus.

10. The system of claim 8 wherein:

(a) said luminescent marking further comprises a plurality of said coded-indicia organized in array fashion, at least one of said coded-indicia to overlap, at least in part, said human-visible indicia;

(b) said inspection apparatus is computerized and further comprises a source of radiation adapted for emitting at a pre-selected range during said collecting of said item-information, and a device adapted to capture said coded-indicia when illuminated by said source at said pre-selected range; and

(c) said human-visible indicia comprises a string of alphanumeric characters and a UPC barcode, both of which identify the item to which the labeling is applied.

11. An item labeling and verification system for use in an assembly line, the system comprising:

(a) a labeling applied to each of a plurality of items, said labeling comprising a luminescent marking and a human-visible indicia;

(b) said luminescent marking comprising a coded-indicia generally invisible to a human eye without an irradiation, said coded-indicia to contain item-information about the item to which the labeling is applied;

(c) a computerized inspection apparatus adapted for collecting said item-information from said luminescent coded-indicia oriented outwardly as it passes in proximity to said inspection apparatus in the assembly line; and

(d) in communication with said inspection apparatus is a processor unit adapted for accessing an order of items associated with the item to which the labeling is applied, and recording said item-information collected.

12. The system of claim 11 further comprising an apparatus for automatically applying said labeling to each of said items, and wherein:

(a) said luminescent marking further comprises a plurality of said coded-indicia that are substantively identical;

(b) said luminescent marking and said human-visible indicia both having been applied to a label medium selected from the group consisting of a clear label material, an opaque label material, a multi-layer label, and a coated label material; and

(c) said inspection apparatus is computerized and further comprises a source of radiation adapted for emitting at a pre-selected range during said collecting of said item-information, and a device adapted to capture said coded-indicia when illuminated by said source at said pre-selected range.

13. The system of claim 11 wherein:

(a) said luminescent marking further comprises a plurality of said coded-indicia organized in array fashion, at least one of said coded-indicia to overlap, at least in part, said human-visible indicia;

(b) said inspection apparatus is computerized and further comprises a source of radiation emitted during said collecting of said item-information, and a device adapted to capture said coded-indicia when illuminated by said source; and

(c) said human-visible indicia comprises a string of alphanumeric characters.

14. The system of claim 11 for use with a plurality of carrier-totes, each containing at least one of the plurality of items having the labeling, and wherein:

(a) the carrier-totes are positioned for automatic movement such that said inspection apparatus is generally overhead said respective carrier-tote as it passes on a track of the assembly line; and

(b) said inspection apparatus further comprises a source of radiation emitted at said luminescent coded-indicia oriented outwardly during said collecting of said item-information therefrom.

15. The system of claim 11:

(a) wherein the items are selected from the group consisting of a handheld computerized device, a cell phone, an optical storage disk, a magnetic storage cassette, and a packaging used for containing or otherwise clustering together smaller objects for transport;

said packages selected from the group consisting of bottles, boxes, packets, pouches, tubes, envelopes, baggies, flexible-wrap, fusion material, cans, canisters, blister-packs, vacuum-formed packs, and storage media cases; and

(b) further comprising a data storage unit in communication with said processor unit, said data storage unit comprising a plurality of records of said item-information collected for subsequent verification of said item.

16. The system of claim 11 wherein said inspection apparatus is a computerized hand-held unit, and further comprising:

(a) a data storage unit in communication with said processor unit, said data storage unit comprising a plurality of records of said item-information collected for subsequent verification of said item; and

(b) a reject spur to which any said item is routed if not deemed verified.

17. A labeling for use with a computerized inspection apparatus for verification of items:

(I) the labeling comprising;

(a) a luminescent marking and a human-visible indicia; and

(b) said luminescent marking comprising a plurality of substantively identical coded-indicia generally invisible to a human eye without an irradiation, each said coded-indicia to contain item-information about an item to which the labeling is applied; and

(II) the inspection apparatus comprising;

(a) a source of radiation emitted for collection of said item-information; and

(b) a device adapted to capture said coded-indicia when illuminated by said source of radiation.

18. The labeling of claim 17 wherein:

(a) said plurality of coded-indicia is organized in array fashion;

(b) said luminescent marking is applied after said human-visible indicia is present on the item; and

(c) the items are selected from the group consisting of a handheld computerized device, a cell phone, an optical storage disk, a magnetic storage cassette, and a packaging used for containing or otherwise clustering together a smaller object for transport;

said packages selected from the group consisting of bottles, boxes, packets, pouches, tubes, envelopes, baggies, flexible-wrap, fusion material, cans, canisters, blister-packs, vacuum-formed packs, and storage media cases.

19. The labeling of claim 17 applied to each of a plurality of items moving within an assembly line comprising the inspection apparatus, and wherein:

(a) said luminescent marking is applied to a label medium after said human-visible indicia is present thereon; and

(b) said label medium selected from the group consisting of a clear label material, an opaque label material, a multi-layer label, and a coated label material.

20. The labeling of claim 19 wherein said label medium comprises said multi-layer label and said luminescent marking is applied to a clear layer laminated atop a second layer having said human-visible indicia.

21. The labeling of claim 17 wherein:

(a) said human-visible indicia comprises a string of alphanumeric characters to identify the item to which the labeling is applied;

(b) said luminescent marking and said human-visible indicia both having been applied to a label medium selected from the group consisting of a clear label material, an opaque label material, a multi-layer label, and a coated label material; and

(c) said inspection apparatus is computerized and further comprises a source of radiation adapted for emitting at a pre-selected range during said collecting of said item-information, and a device adapted to capture said coded-indicia when illuminated by said source at said pre-selected range.

22. The labeling of claim 17 applied to each of a plurality of items, at least one of which is contained in each of a plurality of carrier-totes moving within an assembly line, and wherein:

(a) said luminescent marking overlaps, at least in part, said human-visible indicia;

(b) said human-visible indicia further comprises a Uniform Product Code (UPC) barcode to identify the item to which the labeling will be applied; and

(c) said item-information further comprises a security code assigned to the item for a subsequent verification thereof.

23. The labeling of claim 17 applied to each of a plurality of items, at least one of which is contained in each of a plurality of carrier-totes moving within an assembly line, and wherein:

the inspection apparatus is in communication with a processor unit adapted for comparing an order of selected items against said item-information collected about each said item contained within a respective carrier-tote; and

if said item-information collected by the inspection apparatus matches said order of selected items, said respective carrier-tote contents is deemed verified.

24. A method of labeling items for verification of contents within each of a plurality of carrier-totes in an assembly line, the method comprising the steps of:

(a) applying a labeling to each of a plurality of items comprising applying a luminescent marking and a human-visible indicia;

(b) said luminescent marking comprising a coded-indicia, generally invisible to a human eye without an irradiation, that contains item-information about the item to which said labeling is applied;

(c) collecting said item-information from said luminescent coded-indicia oriented outwardly of said items within a respective one of the carrier-totes; and

(d) comparing an order of selected items against said item-information collected about each of the items within said respective carrier-tote;

if said item-information collected matches said order of selected items, said respective carrier-tote contents is deemed verified;

but if said item-information collected does not match said order of selected items, said respective carrier-tote is routed to a reject spur.

25. The method of claim 24, further comprising the steps of:

(a) if said respective carrier-tote is routed to said reject spur, agitating the contents of said once-rejected respective carrier-tote; and

(b) routing said agitated once-rejected carrier-tote for a second pass under said inspection apparatus.

26. The method of claim 24, further comprising the steps of:

comparing said order of selected items against a second item-information collected, during said second pass, about each said item within said agitated once-rejected carrier-tote;

if said second item-information collected does not match said order of selected items, said agitated once-rejected carrier-tote contents is not deemed verified, then routed to a manual inspection spur.

27. The method of claim 24 wherein said step of applying said labeling to each of a plurality of items further comprises:

(a) automatically applying said luminescent marking to a label medium after said human-visible indicia is present thereon; and

(b) automatically applying said label medium with said luminescent marking and said human-visible indicia, to each of said items according to order instructions stored in a data storage unit.

28. The method of claim 24:

(a) wherein said step of applying said labeling to each of a plurality of items further comprises automatically applying said luminescent marking after said human-visible indicia is present on each of said items; and

said step of collecting said item-information further comprises passing said respective one of the carrier-totes in proximity to an inspection station and recording said item-information collected for each said items; and

(b) further comprising the step of, using a second inspection apparatus at a later time, recollecting item-information from said luminescent coded-indicia of a respective said item and comparing said recollected item-information against a database of a plurality of said item-information collected and recorded earlier, for a subsequent verification.

29. A method of labeling items for verification within an assembly line, the method comprising the steps of:

(a) applying a labeling to each of a plurality of items, comprising applying a luminescent marking and a human-visible indicia;

(b) said luminescent marking comprising a coded-indicia, generally invisible to a human eye without an irradiation, that contains item-information about the item to which said labeling is applied;

(c) collecting said item-information from said luminescent coded-indicia oriented outwardly of each said item as it passes in proximity to an inspection apparatus in the assembly line; and

(d) accessing an order of items associated with the item to which the labeling is applied, and if said item-information collected for a respective one of the items matches said order of items, it is deemed verified;

but if said respective one of the items does not match said order of items, route said respective one of the items to a reject spur.

30. The method of claim 29 wherein:

(a) said step of applying said labeling further comprises applying said luminescent marking to comprise a plurality of said coded-indicia that are substantively identical;

(b) said step of collecting said item-information further comprises emitting radiation at a pre-selected range from a source and reading said coded-indicia when illuminated by said source at said pre-selected range.

31. A method of labeling items for verification thereof, the method comprising the steps of:

(a) applying a labeling to each of a plurality of items comprising automatically applying a luminescent marking;

said labeling further comprising a human-visible indicia;

(b) said luminescent marking comprising a plurality of substantively identical coded-indicia, generally invisible to a human eye without an irradiation, that contains item-information about the item to which said labeling is applied; and

(c) using a computerized inspection apparatus within an assembly line through which said plurality of items are passed, automatically collecting and recording said item-information from said luminescent coded-indicia.

32. The method of claim 31 wherein the verification is of contents of any of the items within each of a plurality of carrier-totes in said assembly line, and further comprising the step of:

comparing an order of selected items against said item-information collected about each of the items within a respective carrier-tote;

if said item-information collected matches said order of selected items, said respective carrier-tote contents is deemed verified;

but if said item-information collected does not match said order of selected items, said respective carrier-tote is routed to a reject spur.

33. The method of claim 31 wherein said step of applying said labeling to each of a plurality of items further comprises:

(a) automatically applying said luminescent marking to a label medium after said human-visible indicia is present thereon;

(b) automatically applying said label medium with said luminescent marking and said human-visible indicia, to each of said items according to order instructions stored in a data storage unit; and

(c) using a second inspection apparatus at a subsequent time, recollecting item-information from said luminescent coded-indicia and comparing said recollected item-information against a database of a plurality of said item-information collected and recorded earlier, for the verification.

34. The method of claim 31 wherein said step of applying said labeling to each of a plurality of items further comprises automatically applying said luminescent marking after said human-visible indicia is present on each of said items, said item-information further comprises a security code assigned to said item for the verification thereof.