Radio frequency identification system for tracking and managing materials in a manufacturing process

• US 8,690,057 B2
• Filed: 04/05/2013
• Issued: 04/08/2014
• Est. Priority Date: 03/06/2012
• Status: Expired due to Fees

• Current Assignee: A-1 Packaging Solutions Incorporated
• Original Assignee: A-I Packaging Solutions Incorporated
• Inventors: Schoening, Kenneth F., Greaves, William J.
• Primary Examiner(s): TRAIL, ALLYSON NEEL
• Application Number:
  US13/857,616
• Publication Number:
  US 20130233922A1
• Time in Patent Office: 368 Days
• Field of Search: 235/385, 340/10.41, 340/572.1
• US Class Current: 235/385
• CPC Class Codes: G06F 16/245 Query processing
• CPC Class Codes: G06K 7/10366 the interrogation device being adapted for miscellaneous applications
• CPC Class Codes: G06Q 10/063114 Status monitoring or status determination for a person or group
• 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
• CPC Class Codes: H01Q 1/2216 used in interrogator/reader equipment
• CPC Class Codes: H01Q 3/24 varying the orientation by switching energy from one active radiating element to another, e.g. for beam switching

Abstract

A process management system uses a radio frequency identification (RFID) detection system in the form of, for example, a phased array antenna based RFID detection system to track and manage material storage and flow in a manufacturing process or plant. The process management system operates in conjunction with the various machines that implement manufacturing stages or steps of the manufacturing process to assure that the correct materials and processing procedures are used at or on the various production machines of the process to produce a particular product as defined by a job number or job order. The process management system is thereby able to increase the efficiencies of the plant and to increase the quality of the plant production by reducing or eliminating waste, manufacturing errors and shipping errors in the production facility.

Claims

1. An inventory tracking system for use in tracking placement of physical items within an inventory tracking region, comprising:

a radio frequency tag detection system including;

a plurality of radio frequency antennas disposed in a spaced apart manner within the inventory tracking region; and

a detection controller coupled to the plurality of radio frequency antennas, the detection controller including a beam-steering control system that controls the operation of each of the radio frequency antennas, wherein one of the plurality of radio frequency antennas uses a beam to scan a portion of the inventory tracking region to detect a current physical location of one or more radio frequency tags disposed in a scanned portion of the inventory tracking region, wherein the current physical location corresponds to a position defined by two coordinate units in a multi-dimensional coordinate system and the value of each of the two coordinate units is determined by the one of the plurality of radio frequency antennas, and wherein the detection controller generates indications of the one or more detected radio frequency tags and the current physical locations of the one or more detected radio frequency tags in the scanned portion within the inventory tracking region; and

a tracking system coupled to the radio frequency tag detection system to receive the indications of the one or more detected radio frequency tags and the current physical locations of the one or more detected radio frequency tags in the scanned portion within the inventory tracking region, the tracking system including;

a memory for storing inventory item information for each of a plurality of inventory items, the inventory item information for each of the plurality of inventory items including an inventory item radio frequency tag identifier, inventory item identification information defining the identity of the inventory item, and an indication of the current physical location of the inventory item within the inventory tracking region; and

an access system that accesses the memory and provides at least a subset of the inventory item information for one or more of the inventory items to a user for determining the current physical location of the one or more of the inventory items within the inventory tracking region,

wherein the tracking system updates the indication of the current physical location of at least one particular inventory item within the inventory tracking region as stored in the memory for the at least one particular inventory item based on the indication of the current physical location of the one or more detected radio frequency tags for at the least one particular inventory item as produced by the detection controller.

2. The inventory tracking system of claim 1, wherein the subset of inventory item information includes the indication of the current physical location of the one or more of the inventory items within the inventory tracking region.

3. The inventory tracking system of claim 2, wherein the tracking system stores, for each of the plurality of inventory items, inventory item identification information including two or more defining characteristics of the inventory item.

4. The inventory tracking system of claim 2, wherein the inventory item identification information for the at least one of the inventory items includes a type of material associated with the inventory item, a source of the inventory item, or an amount of material associated with the inventory item.

5. The inventory tracking system of claim 2, wherein the access system includes a user display system that graphically displays the current physical location of the one or more of the inventory items based on the indication of the current physical location of the one or more of inventory items.

6. The inventory tracking system of claim 5, wherein the user display system displays the current physical location of the one or more of the inventory items in a graphical manner juxtaposed with an indication of at least a portion of the inventory region.

7. The inventory tracking system of claim 5, wherein the user display system graphically displays the current physical location of the one or more of the inventory items by displaying an indication of a two dimensional geographical location of the one or more of the inventory items within the inventory tracking region.

8. The inventory tracking system of claim 1, wherein the access system includes an auditory system that generates auditory signals based on the current physical location of one or more of the inventory items.

9. The inventory tracking system of claim 1, wherein the access system includes a visual system that generates lighted signals based on the current physical location of one or more of the inventory items.

10. The inventory tracking system of claim 1, further including an inventory control system that receives the current physical location of at least one of the inventory items from the access system and determines if the one of the plurality of inventory items is in a desired location.

11. The inventory tracking system of claim 10, wherein the inventory control system compares the current physical location of the at least one of the inventory items to a desired location of the at least one of the inventory items as defined by a job identifier associated with a job that uses the at least one of the inventory items.

12. The inventory tracking system of claim 11, wherein the inventory control system produces a warning signal when the location of the at least one of the inventory items associated with the job identifier is not at the desired location for the inventory item for the job defined by the job identifier when running the job.

13. The inventory tracking system of claim 11, wherein the desired location is associated with a location of the at least one of the inventory items within a manufacturing process during execution of the manufacturing process during the job.

14. The inventory tracking system of claim 11, wherein the inventory control system detects movement of the at least one of the inventory items based on the job identifier and compares movement of the inventory item with a desired movement of the inventory item as specified by the job identifier.

15. The inventory tracking system of claim 1, wherein the position defined by the two coordinate units in the multi-dimensional coordinate system corresponds to an exact position.

16. The inventory tracking system of claim 1, wherein the position defined by the two coordinate units in the multi-dimensional coordinate system corresponds to a range of positions between two numerical values.

17. A method of tracking inventory within an inventory region, comprising:

periodically scanning the inventory region with one or more radio frequency antennas using a beam steering scanning technique, wherein one of the one or more radio frequency antennas scans a portion of the inventory region to detect one or more radio frequency tags disposed in a scanned portion of the inventory region, each of the one or more radio frequency tags being associated with an inventory item;

determining a current physical location for the one or more detected radio frequency tags in the scanned portion within the inventory region based on the detection of the one or more radio frequency tags within a scan, wherein the current physical location corresponds to a position defined by two coordinate units in a multi-dimensional coordinate system and the value of each of the two coordinate units is determined by the one of the one or more radio frequency antennas, and wherein the current physical location for the one or more detected radio frequency tags is resolved to a region less than the coverage area of any of the radio frequency antennas;

storing, in a computer readable memory, for each of the one or more detected radio frequency tags, inventory item information, wherein the inventory item information for a radio frequency tag includes an inventory item radio frequency tag identifier, inventory item identification information defining the identity of the inventory item, and current physical location information for the inventory item;

updating the current physical location information of at least one inventory item within the inventory region as stored in the computer readable memory based on the determined current physical location of the one or more detected radio frequency tags for the at the least one inventory item as determined during one or more scans; and

accessing the stored inventory item information to determine the current physical location of the one or more of the set of inventory items within the inventory region.

18. The method of tracking inventory of claim 17, further including storing, as part of the inventory item identification information, an amount of material associated with the inventory item.

19. The method of tracking inventory of claim 17, further including displaying the physical location of the one or more of the inventory items within the inventory region on a display device.

20. The method of tracking inventory of claim 19, wherein displaying the physical location of the one or more of the inventory items includes graphically displaying an indication of the current physical location of the one or more of the inventory items on a user display device juxtaposed on an indication of at least a portion of the inventory region.

21. The method of tracking inventory of claim 19, wherein displaying the current physical location of the one or more of the inventory items includes displaying at least a portion of the inventory item identification information along with an indication of the current physical location of one or more of the inventory items on a user display device.

22. The method of tracking inventory of claim 17, further including generating a visual alarm signal based on current physical location of one or more of the inventory items.

23. The method of tracking inventory of claim 17, further including using the physical location of one of the inventory items as stored in the memory to determine if the one of the inventory items is in a desired location as defined by a job identifier.

24. The method of tracking inventory of claim 17, including using the physical location of one of the inventory items as stored in the memory to detect movement of the one of the inventory items within the inventory region and determining if the detected movement of the one of the inventory items is a desired movement based on a job identifier.

25. The method of tracking inventory of claim 17, further including enabling or disabling the operation of a portion of a manufacturing process based on the physical location of one of the inventory items.

26. The method of tracking inventory of claim 17, wherein the position defined by the two coordinate units in the multi-dimensional coordinate system corresponds to an exact position.

27. A method of tracking inventory within an inventory region, comprising:

periodically scanning the inventory region with one or more radio frequency antennas using a beam steering scanning technique, wherein one of the one or more radio frequency antennas scans a portion of the inventory region to detect one or more radio frequency tags disposed in a scanned portion of the inventory region, each of the one or more radio frequency tags being associated with a different inventory item;

determining a current physical location for the one or more detected radio frequency tags in the scanned portion within the inventory region based on the detection of the one or more radio frequency tags within a scan, wherein the current physical location corresponds to a position defined by two coordinate units in a multi-dimensional coordinate system, and the value of each of the two coordinate units is determined by the one of the one or more radio frequency antennas, and wherein the current physical location of the one or more detected radio frequency tags is resolved to a region less than the coverage area of any of the radio frequency antennas;

storing inventory item information in a computer readable memory for each of the different inventory items, the inventory item information for a particular inventory item including a radio frequency tag identifier, inventory item identification information defining the identity of the inventory item, and current physical location information for the inventory item;

updating the current physical location information of each of the inventory items within the inventory region as stored in the computer readable memory based on the determined current physical location of the one or more detected radio frequency tags for the inventory items as determined during one or more scans; and

enabling access to the stored inventory item information for each of the inventory items to determine the current physical location of the inventory items within the inventory region.

28. The method of tracking inventory of claim 27, further including displaying the physical location of a multiplicity of the inventory items within the inventory region on a display device.

29. The method of tracking inventory of claim 28, wherein displaying the physical location of the multiplicity of the inventory items includes graphically displaying an indication of the current physical location of the multiplicity of inventory items on a user display device juxtaposed on an indication of at least a portion of the inventory region.

30. The method of tracking inventory of claim 27, wherein the position defined by the two coordinate units in the multi-dimensional coordinate system corresponds to a range of positions between two numerical values.