Image-based inventory control system

• US 8,353,456 B2
• Filed: 08/07/2009
• Issued: 01/15/2013
• Est. Priority Date: 08/08/2008
• Status: Active Grant

• Current Assignee: Snap-On Incorporated
• Original Assignee: Snap-On Incorporated
• Inventors: Jackson, David A., Rogers, Steven W., Bryan, Eric
• Primary Examiner(s): Haupt, Kristy A
• Application Number:
  US12/538,100
• Publication Number:
  US 20100121482A1
• Time in Patent Office: 1,257 Days
• Field of Search: 235/385, 235/454, 700/214, 382/103, 348/143
• US Class Current: 235/454
• CPC Class Codes: B25H 3/00 Storage means or arrangements for workshops facilitating access to, or handling of, work tools or instruments containers or packages with special means for dispensing contents B65D83/00; nail dispensers B25C3/00
• CPC Class Codes: B25H 3/028 by sliding extraction from within a common frame
• CPC Class Codes: G06Q 10/00 Administration; Management
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06T 2207/10004 Still image; Photographic image
• CPC Class Codes: G06T 2207/20224 Image subtraction
• CPC Class Codes: G06T 2207/30108 Industrial image inspection
• CPC Class Codes: G06T 7/0008 checking presence/absence
• CPC Class Codes: H04N 23/80 Camera processing pipelines; Components thereof
• CPC Class Codes: H04N 23/90 Arrangement of cameras or camera modules, e.g. multiple cameras in TV studios or sports stadiums

Abstract

Inventory control systems for monitoring the removal and replacement of objects are described. An exemplary system includes at least one storage drawer, each storage drawer includes at least one storage location for storing objects, and configured to move in a first direction allowing increasing access to storage locations of the drawer, and a second direction allowing decreasing access to storage locations of the drawer. An image sensing device is provided to form at least one first image of the storage locations when a respective storage drawer moves in the second direction. The system includes a data processor configured to receive information representing images of the storage locations generated by the image sensing device, and determine an inventory condition of the objects stored in the respective storage drawer according to the at least one first image.

Claims

1. An inventory control system for monitoring the removal and replacement of objects, the system comprising:

at least one storage drawer, each storage drawer including at least one storage location for storing objects, wherein each storage drawer is configured to move in a first direction allowing increasing access to storage locations of the drawer, and a second direction allowing decreasing access to storage locations of the drawer;

at least one image sensing device configured to form at least one first image of the storage locations while a respective storage drawer moves in the second direction;

a data processor configured to receive information representing the at least one first image of the storage locations, and determine an inventory condition of the objects stored in the respective storage drawer according to the at least one first image.

2. The system of claim 1, wherein:

each image sensing device is configured to form at least one second image of the storage locations when the respective storage drawer moves in the first direction; and

the data processor is configured to determine a change of the inventory condition of the objects stored in the respective storage drawer according to a difference of the at least one first image and the at least one second image.

3. The system of claim 1, wherein:

the at least one storage drawer includes multiple storage drawers;

except for a bottom storage drawer, each of the multiple storage drawers is disposed on top of another storage drawer; and

the at least one image sensing device is disposed at a location sufficient to form an image of at least a portion of the storage locations of each respective storage drawer.

4. The system of claim 3, wherein the at least one image sensing device includes a camera disposed above the moving path of each respective storage drawer.

5. The system of claim 3, wherein:

the at least one image sensing device has a viewing field over a moving path of each respective storage drawer;

the at least one image sensing device is disposed at a location sufficient to form an image of at least a portion of the respective storage drawer when the portion of the storage drawer moves past the sensing field; and

the at least one image sensing device is configured to capture multiple partial images of the respective storage drawer at different points in time when the storage drawer passes the viewing field.

6. The system of claim 5, wherein the data process system is configured to form a combined image of the storage drawer by combining the multiple partial images of the storage drawer captured at different points in time, and determines an inventory condition of the storage drawer based on the combined image.

7. The system of claim 5 further comprising a position detector configured to detect a position of each respective storage drawer;

wherein the data processor forms the combined image of the storage drawer according to the multiple partial images and information of positions of the storage drawer detected by the position detector.

8. The system of claim 3, wherein:

the at least one image sensing device includes a camera and a light redirecting device;

the light redirecting device is configured to direct light reflected from each respective storage drawer to the camera;

the camera is disposed at a location remote from the light redirecting device.

9. The system of claim 8, wherein the light redirecting device includes one or more mirrors, a prism or one or more fiber optic devices.

10. The system of claim 8 wherein the light redirecting device is disposed at a location above a moving path of each respective storage drawer.

11. The system of claim 1, wherein in forming the at least one first image, the image capturing device forms an image of storage locations of the storage drawer that are not accessible by a user after detecting the storage drawer stops moving in the second direction.

12. The system of claim 1, wherein the data processor is configured to associate the determined inventory condition with time information indicating the time when the at least one first image was formed.

13. The system of claim 1, wherein:

when a user is authenticated to access to a respective storage drawer, the at least one image sensing device is configured to capture at least one second image of the storage locations of the respective storage drawer when the respective storage drawer moves in the first direction, before the respective storage drawer moves in the first direction, or after the respective drawer stops moving in the first direction; and

the data processor is configured to determine a change in the inventory condition of the objects stored in the respective storage drawer according to a difference between the at least one first image and the at least one second image.

14. The system of claim 1, wherein:

the at least one image sensing device includes multiple cameras, each camera is configured to capture a partial image of the storage drawer; and

the data processor is configured to form a combined image of the storage drawer from the partial image of the storage drawer captured by each respective camera.

15. The system of claim 1 further comprising an input device configured to receive information submitted by a user accessing the system;

wherein the data processor is configured to authenticate the user based on the received information, and selectively grant or deny the user access to the system according to a result of the authenticating.

16. The system of claim 15, wherein for each authenticated user who is granted access to the system, the data processor is configured to associate information related to the user to an inventory condition associated with the granted access.

17. The system of claim 1, wherein:

each storage location is configured to store a pre-designated object; and

the system has access to prestored information identifying a relationship between each storage location and the corresponding pre-designated object.

18. The system of claim 17, wherein:

the data processor has access to a baseline image of the storage locations having each storage location occupied by the corresponding pre-designated object; and

the data processor is configured to determine the inventory condition according to a difference between an image of the storage locations and the baseline image.

19. The system of claim 17, wherein:

the data storage device stores a baseline image of the storage locations having each storage location unoccupied by the corresponding pre-designated object; and

the data processor is configured to determine the inventory condition according to a difference between a captured image of the storage locations and the baseline image.

20. The system of claim 17, wherein the data processor is configured to determine an inventory condition of objects by evaluating the at least one first image and the relationship between each respective storage location and the corresponding pre-designated object.

21. The system of claim 1, wherein:

each respective storage location is associated with an identifier;

depending on whether the storage location is being occupied by an object, the associated identifier appears in an image captured by the at least one image sensing device in one of two different manners; and

the data processor is configured to determine the inventory condition of objects by evaluating how each identifier appears in the image captured by the image sensing device.

22. The system of claim 21, wherein:

the identifier is not viewable by the at least one image sensing device when an object is stored in the respective storage location, and is viewable by the at least one image sensing device when an object is not stored in the respective storage location;

or

the identifier is viewable by the at least one image sensing device when an object is stored in the respective storage location, and is not viewable by the at least one image sensing device when an object is not stored in the respective storage location.

23. The system of claim 21, wherein:

each storage location is configured to store a pre-designated object;

the data processor has access to information identifying a known relationship between each pre-designated object and each corresponding storage location configured to store the pre-designated object; and

the data processor is configured to determine an inventory condition of objects by evaluating how each identifier appears in the image captured by the at least one image sensing device, and the relationship between each pre-designated object and each respective storage location.

24. The system of claim 21, wherein:

the identifier is unique to a corresponding object stored in the storage location;

the data processor has access to information identifying each object stored in the system and information identifying a relationship between each identifier and each corresponding object;

the data processor is configured to determine an inventory condition of the objects by evaluating how each identifier appears in the image captured by the at least one image sensing device, the information identifying each object stored in the system, and the information identifying the relationship between each identifier and each corresponding object.

25. The system of claim 1, wherein:

each object includes an attached identifier unique to each object;

the data processor has access to prestored information identifying a relationship between each pre-designated object and a respective identifier unique to each pre-designated object; and

the data processor is configured to determine an inventory condition of objects by evaluating the existence of at least one identifier in an image of the storage locations captured by the at least one image sensing device, and the relationship between each pre-designated object and a respective identifier unique to each pre-designated object.

26. The system of claim 1, wherein:

the data processor has access to information identifying all objects stored in the storage unit and image characteristics unique to each object;

the data processor is configured to determine which objects are missing or which objects are in the system based on the captured image and the image characteristics unique to each object.

27. The system of claim 1, wherein:

each object includes an attached identifier unique to each object;

the data processor has access to prestored information identifying each object stored in the system and information identifying a relationship between each pre-designated object and a respective identifier unique to each pre-designated object; and

the data processor is configured to determine an inventory condition of objects by evaluating the existence of at least one identifier in an image of the storage locations captured by the at least one image sensing device, the information identifying each object stored in the system, and the relationship between each pre-designated object and a respective identifier unique to each pre-designated object.

28. The system of claim 1, wherein:

the data processor has access to information identifying all objects stored in the storage unit and image characteristics unique to each object;

the data processor is configured to determine the inventory condition of the objects based on the captured image and the image characteristics unique to each object.

29. An inventory control system for monitoring the removal and replacement of objects, the system comprising:

at least one storage drawer, each storage drawer includes at least one storage location for storing objects, and each storage drawer is configured to move between a first position, which allows no access to any storage locations in the storage drawer, and a second position, which allows access to at least one storage location in the storage drawer; and

at least one image sensing device configured to form images of the storage drawers, wherein while a respective storage drawer moves from the second position to the first position, the at least one image sensing device is configured to form at least one image of the storage locations of the respective storage drawer; and

a data processor configured to determine an inventory condition of the respective storage drawer according to the at least one image of the storage locations formed after the respective storage drawer moves from the second position to the first position.

30. The system of claim 29, wherein the at least one image sensing device includes a scan device configured to project a scan light moving over the storage drawer and a camera configured to receive the reflected scan light for forming images of the storage drawer.

31. A networked inventory control system comprising:

multiple storage systems, each respective storage system including at least one image sensing device configured to form at least one image of objects stored in the storage system, and a data storage device configured to store the image and user information with respect to a user accessing the storage system;

a data processing system coupled to the multiple storage systems via a data transmission network;

wherein the respective storage system is configured to transmit at least one of inventory condition, stored image and user information to the data processing system for each access to the respective storage system;

wherein each respective storage system includes at least one storage drawer, each storage drawer including storage locations for storing the objects, and configured to move in a first direction allowing increasing access to the storage locations of the drawer, and a second direction allowing decreasing access to the storage locations of the drawer; and

wherein the at least one image sensing device is configured to form at least one first image of the storage locations while a respective storage drawer moves in the second direction.

32. The system of claim 31, wherein each storage system further includes a data processor configured to determine an inventory condition of the objects stored in the storage system according to the image captured by the at least one image sensing device, and transmit information related to the inventory condition to the data processing system.

33. The system of claim 31, wherein one of the storage systems includes multiple storage drawers and access to each storage drawer is granted independently.

34. A network-enabled inventory control system comprising:

a storage unit for storing objects;

a data input device configured to receive user information from a respective user requesting access to the inventory control system;

at least one image sensing device configured to capture at least one image of the storage locations corresponding to each access to the inventory control system by the respective user;

a data storage device configured to store the user information and the image captured by the at least one image sensing device;

a communication device configured for data communication with a remote data processing system; and

a data processor configured to control transmission of data representing the image or inventory condition information, the user information and the corresponding access to the remote data processing system;

wherein the storage unit includes at least one storage drawer, each storage drawer including at least one storage location for storing objects, and configured to move in a first direction allowing increasing access to the storage locations of the drawer, and a second direction allowing decreasing access to the storage locations of the drawer;

wherein the at least one image sensing device is configured to form at least one first image of the storage locations while a respective storage drawer moves in the second direction; and

wherein the data processor is configured to receive information representing images of the storage locations generated by the at least one image sensing device, and determine an inventory condition of the objects stored in the respective storage drawer according to the at least one first image.

35. The system of claim 34, wherein:

the storage unit includes multiple storage drawers; and

each storage drawer includes an access control device configured to selectively grant access to the storage drawer.

36. The system of claim 34 further comprising an access control system configured to selectively granting or denying access to the storage unit, wherein:

the communication device receives authorization data from the data processing system;

the data processor is configured to authenticate a user requesting access to the storage unit by determining a user authorization according to user information input by the user via the data input device and the authorization data, and selectively control the access control device to grant access to the storage unit according to the determined user authorization.