Systems, apparatus, non-transient computer readable media, and methods for automatically managing and monitoring a load operation related to a logistics container using a scanning sensor node

• US 10,740,576 B2
• Filed: 01/11/2016
• Issued: 08/11/2020
• Est. Priority Date: 02/18/2015
• Status: Active Grant

• Current Assignee: Fedex Corporate Services Incorporated (FedEx Corporation)
• Original Assignee: Fedex Corporate Services Incorporated (FedEx Corporation)
• Inventors: Burch, V, Reuben F., Cawein, William
• Primary Examiner(s): Chen, George
• Assistant Examiner(s): El-Bathy, Ibrahim N
• Application Number:
  US14/992,425
• Publication Number:
  US 20160239790A1
• Time in Patent Office: 1,674 Days
• CPC Class Codes: G01B 11/00 Measuring arrangements characterised by the use of optical techniques
• CPC Class Codes: G01B 21/18 for measuring depth
• CPC Class Codes: G01F 17/00 Methods or apparatus for determining the capacity of containers or cavities, or the volume of solid bodies measuring linear dimensions to determine volume G01B
• CPC Class Codes: G06F 16/254 Extract, transform and load [ETL] procedures, e.g. ETL data flows in data warehouses
• CPC Class Codes: G06K 19/0723 the record carrier comprising an arrangement for non-contact communication, e.g. wireless communication circuits on transponder cards, non-contact smart cards or RFIDs
• CPC Class Codes: G06K 2007/10504 Data fields affixed to objects or articles
• CPC Class Codes: G06K 7/10297 arrangements for handling protocols designed for non-contact record carriers such as RFIDs NFCs, e.g. ISO/IEC 14443 and 18092 cryptographic protocols H04L9/00; network security protocols H04L63/00; real-time communication protocols in data switching networks H04L65/00; network protocols for data switching network services H04L67/00
• CPC Class Codes: G06K 7/10415 the interrogation device being fixed in its position, such as an access control device for reading wireless access cards, or a wireless ATM banking machines in general G07F19/00
• CPC Class Codes: G06K 7/10732 Light sources
• CPC Class Codes: G06K 7/10821 further details of bar or optical code scanning devices
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G06Q 10/083 Shipping
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

Apparatus, systems, non-transient media, and methods are described that use a removable scanning sensor node for managing a load operation related to a container. For example, the method has the scanning sensor node identifying an item to be shipped within the container and mapping the space within the container after the item has been placed within the container using the node as temporarily disposed within the container and oriented to map the container'"'"'s space from above the space. The method then has the scanning sensor node determining an occupied capacity within the container based upon mapping data associated with the mapped space and transmitting a notification to a managing node in communication with the removable scanning sensor node. The transmitted notification relates to the occupied capacity within the container as determined by the scanning sensor node.

Claims

1. An improved scanning sensor apparatus for managing a load operation related to a container;

the apparatus comprising;

a housing configured to mount within the container in a position located above storage space within the container;

a processing unit disposed within the housing;

a memory disposed within the housing, the memory being operatively coupled to the processing unit and maintaining at least a load operation program code section and a scanning program code section for execution by the processing unit;

a depth sensor operatively coupled to the processing unit, wherein the depth sensor is disposed and oriented to map the storage space within the container from above the storage space;

an identification scanner operatively coupled to the processing unit, wherein the identification scanner is configured to identify an item to be shipped within the container and a plurality of additional items to be shipped within the container; and

a wireless communication interface disposed within the housing and operatively coupled to the processing unit; and

wherein the processing unit, when executing the load operation program code section and the scanning program code section, is operative to

receive an identification of the item to be shipped within the container from the identification scanner,

cause the depth sensor to map the storage space within the container after the item has been placed within the container,

receive mapping data generated by the depth sensor associated with the mapped storage space within the container,

determine an occupied capacity within the container based upon the mapping data associated with the mapped storage space,

instruct the wireless communication interface to transmit a notification to a managing node in communication with the improved scanning sensor apparatus over the wireless communication interface, wherein the notification is related to the occupied capacity within the container,

cause the depth sensor to periodically map the storage space within the container from above the storage space after one or more of the additional items have been placed within the container and until a desired load status for the container is achieved, the desired load status reflecting a predetermined threshold percentage of occupancy of the container corresponding to how full the container should be when considered to be in a desired load state for the container, and

determine an updated occupied capacity within the container based upon the mapped space after each of the periodic mapping.

2. The apparatus of claim 1, wherein the identification scanner identifies the item to be shipped by receiving a signal broadcast from a device associated with the item to be shipped, wherein the signal includes data sufficient to identify the item to be shipped.

3. The apparatus of claim 2, wherein the device broadcasting the signal to the identification scanner comprises a radio transmitter operative to generate and transmit the signal to be received by the identification scanner.

4. The apparatus of claim 2, wherein the device broadcasting the signal to the identification scanner comprises at least one from the group comprising a radio, a cellular radio device, a wireless network device, a wireless data communications device operating under a lower power communication protocol and a wireless data communications device operating under a higher power communication protocol, an RFID device, an NFC device, a Bluetooth device, a ZigBee device, and a Wi-Fi device.

5. The apparatus of claim 3, wherein the identification scanner comprises an RFID reader and the device broadcasting the signal comprises an RFID tag.

6. The apparatus of claim 3, wherein the identification scanner comprises a first Bluetooth device related to the apparatus and the device broadcasting the signal comprises a second Bluetooth device related to the item.

7. The apparatus of claim 1, wherein the identification scanner comprises a barcode reader configured to identify the item to be shipped by capturing information about the item to be shipped from an encoded label on an exterior surface of the item.

8. The apparatus of claim 1, wherein the processing unit is operative to receive the identification of the item as the item is being loaded and placed within the storage space of the container.

9. The apparatus of claim 1, wherein the processing unit is further operative to record the determined occupied capacity into the memory.

10. The apparatus of claim 1, wherein the processing unit is further operative to:

determine a load time taken to load the container to the desired load status level based upon the mapping data associated with the mapped storage space over time; and

instruct the wireless communication interface to transmit a load time message to the managing node, wherein the load time message reflects the load time taken to load the container to the desired load status level.

11. The apparatus of claim 1, wherein the notification indicates a status of the container associated with the determined occupied capacity of the container.

12. The apparatus of claim 1, wherein the processing unit is further operative to:

detect if the determined occupied capacity meets a desired load status for the container; and

instruct the wireless communication interface to transmit the notification to the managing node when the determined occupied capacity at least meets the desired load status for the container.

13. The apparatus of claim 1, wherein the notification indicates a requested change to the load operation related to the container.

14. The apparatus of claim 13, wherein the requested change comprises a request for additional personnel to be involved in loading the container.

15. The apparatus of claim 1, wherein the notification indicates a summary of what has been loaded into the container associated with the determined occupied capacity of the container.

16. An improved system for managing load operations related to a plurality of containers, the system comprising:

a managing node device associated with at least one operator, the managing node device further comprising

at least a wireless communication interface; and

a display interface that generates information to be provided to the at least one operator; and

a plurality of scanning sensor nodes, wherein each of the scanning sensor nodes are in operative wireless communication with the managing node device, wherein each of the scanning sensor nodes is disposed within a respective one of the containers above a storage space within the respective container;

wherein each of the scanning sensor nodes mounted in the respective one of the containers is operative to

identify one or more items as the items are loaded into the storage space within the respective one of the containers using an identification scanner on the scanning sensor node,

map the storage space from above the storage space using a sensor on the scanning sensor node while the items are loaded into the storage space until detecting a desired load status for the container based upon mapping data of the storage space, the desired load status reflecting a predetermined threshold percentage of occupancy of the respective one of the containers corresponding to how full the respective one of the containers should be when considered to be in a desired load state for the respective one of the containers,

determine an occupied capacity within the respective one of the containers based upon the mapping data generated by the sensor related to the mapped storage space, and

transmit a notification to the managing node device, wherein the notification is related to the occupied capacity within the respective one of the containers; and

wherein the managing node device is operative to

receive the notification over the wireless communication interface from each of the scanning sensor nodes,

assess the notification received from each of the scanning sensor nodes relative to at least one loading characteristic,

generate a loading change message related to a change in the load operations related to the containers, and

provide the loading change message on the display interface.

17. The system of claim 16, wherein the identification scanner identifies the one or more items by receiving a signal from a device associated with each of the one or more items, wherein the signal includes data that identifies the respective one of the one or more items.

18. The system of claim 16, wherein the identification scanner comprises at least one of an RFID reader, a low energy Bluetooth device, and a barcode reader.

19. The system of claim 16, wherein each of the scanning sensor nodes mounted in the respective one of the containers is further operative to:

determine a load time taken to load the respective one of the containers to the desired load status level; and

transmit a load time message to the managing node device, wherein the load time message reflects the load time taken to load the respective one of the containers to the desired load status level.

20. The system of claim 16 further comprising a server device in operative communication with the managing node device over the wireless communication interface of the managing node device.

21. The system of claim 20, wherein the managing node device is operative to provide the loading change message on the display interface by being further operative to:

transmit a request to the server device for an authorization to provide the loading change message on the display interface;

receive the authorization from the server device; and

provide the loading change message on the display interface based on the received authorization.

22. The system of claim 20, wherein the notification further comprises information on the items loaded into at least one of the containers;

and

wherein the managing node device is further operative to

generate a container content message related to the notification received from each of the scanning sensor node devices, and

transmit the container content message to the server device.

23. The system of claim 16, wherein the change in load operations related to the containers comprises a workload adjustment in the load operations.

24. The system of claim 16, wherein the change in load operations related to the containers comprises an indication that loading is complete regarding at least one of the containers.

25. The system of claim 16, wherein the loading change message identifies which of the containers where assistance is needed to more efficiently load the one or more of the items associated with the identified container.

26. An improved method for managing a load operation related to a container using a removable scanning sensor node, the method comprising:

identifying, by an identification scanner in the removable scanning sensor node, an item to be shipped within the container;

mapping, by a depth sensor in the removable scanning sensor node, the space within the container after the item has been placed within the container, wherein the removable scanning sensor node being temporarily disposed within the container and oriented to map the space within the container from above the space;

determining, by the removable scanning sensor node, an occupied capacity within the container based upon mapping data associated with the mapped space;

transmitting, by the removable scanning sensor node, a notification to a managing node in communication with the removable scanning sensor node, wherein the notification is related to the occupied capacity within the container;

identifying, by the removable scanning sensor node, a plurality of additional items to be shipped within the container;

periodically mapping, by the removable scanning sensor node, the space within the container after one or more of the additional items have been placed within the container until a desired load status for the container is detected, the desired load status reflecting a predetermined threshold percentage of occupancy of the container corresponding to how full the container should be when considered to be in a desired load state for the container; and

determining, by the removable scanning sensor node, an updated occupied capacity within the container based upon the mapped space after each of the periodic mapping steps.

27. The method of claim 26, wherein the step of identifying the item further comprises identifying, by the removable scanning sensor node, the item when the item is loaded and placed within the container.

28. The method of claim 26, wherein the step of identifying the item further comprises:

conducting, by the removable scanning sensor node, an identification scan of an item to be shipped within the container; and

identifying the item to be shipped based upon scan data associated with the identification scan.

29. The method of claim 28, wherein conducting the identification scan further comprises detecting a wireless identification element related to the item.

30. The method of claim 29, wherein the wireless identification element comprises a communications device that wirelessly broadcasts information associated with the item.

31. The method of claim 29, wherein the wireless identification element comprises one from the group comprising a radio, a cellular radio device, a wireless network device, a wireless data communications device operating under a lower power communication protocol and a wireless data communications device operating under a higher power communication protocol, an RFID device, an NFC device, a Bluetooth device, a ZigBee device, and a Wi-Fi device.

32. The method of claim 28, wherein conducting the identification scan further comprises detecting a barcode element related to the item.

33. The method of claim 26 further comprising the step of recording the determined occupied capacity into a memory of the removable scanning sensor node.

34. The method of claim 26 further comprising the steps of:

tracking, by the removable scanning sensor node, a time taken to load the container until detecting the desired load status; and

transmitting, by the removable scanning sensor node, a load time message to the managing node, wherein the load time message reflects the tracked time taken to load the container.

35. The method of claim 26, wherein the notification indicates a status of the container associated with the determined occupied capacity of the container.

36. The method of claim 26, wherein the transmitting step comprises:

detecting if the determined occupied capacity meets a desired load status for the container; and

transmitting, by the removable scanning sensor node, the notification to the managing node when the determined occupied capacity at least meets the desired load status for the container.

37. The method of claim 26, wherein the notification indicates a requested change to the load operation related to the container.

38. The method of claim 37, wherein the requested change comprises a request for additional personnel to be involved in loading the container.

39. The method of claim 26, wherein the notification indicates a summary of what has been loaded into the container associated with the determined occupied capacity of the container.

40. A non-transitory computer-readable medium containing instructions which when executed on a processor of a removable scanning sensor node performs an improved method for managing a load operation related to a container using the removable scanning sensor node, the method comprising:

identifying, by an identification scanner in the removable scanning sensor node, an item to be shipped within the container;

mapping, by a depth sensor in the removable scanning sensor node, the space within the container after the item has been placed within the container, wherein the removable scanning sensor node being temporarily disposed within the container and oriented to map the space within the container from above the space;

determining, by the removable scanning sensor node, an occupied capacity within the container based upon mapping data associated with the mapped space;

transmitting, by the removable scanning sensor node, a notification to a managing node in communication with the removable scanning sensor node, wherein the notification is related to the occupied capacity within the container;

identifying, by the removable scanning sensor node, a plurality of additional items to be shipped within the container;

periodically mapping, by the removable scanning sensor node, the space within the container after one or more of the additional items have been placed within the container until a desired load status for the container is detected, the desired load status reflecting a predetermined threshold percentage of occupancy of the container corresponding to how full the container should be when considered to be in a desired load state for the container; and

determining, by the removable scanning sensor node, an updated occupied capacity within the container based upon the mapped space after each of the periodic mapping steps.

41. The non-transitory computer-readable medium of claim 40, wherein the step of identifying the item further comprises identifying, by the removable scanning sensor node, the item when the item is loaded and placed within the container.

42. The non-transitory computer-readable medium of claim 40, wherein the step of identifying the item further comprises:

conducting, by the removable scanning sensor node, an identification scan of an item to be shipped within the container; and

identifying the item to be shipped based upon scan data associated with the identification scan.

43. The non-transitory computer-readable medium of claim 42, wherein conducting the identification scan further comprises detecting a wireless identification element related to the item.

44. The non-transitory computer-readable medium of claim 43, wherein the wireless identification element comprises a communications device that wirelessly broadcasts information associated with the item.

45. The non-transitory computer-readable medium of claim 43, wherein the wireless identification element comprises one from the group comprising a radio, a cellular radio device, a wireless network device, a wireless data communications device operating under a lower power communication protocol and a wireless data communications device operating under a higher power communication protocol, an RFID device, an NFC device, a Bluetooth device, a ZigBee device, and a Wi-Fi device.

46. The non-transitory computer-readable medium of claim 42, wherein conducting the identification scan further comprises detecting a barcode element related to the item.

47. The non-transitory computer-readable medium of claim 40 further comprising the step of recording the determined occupied capacity into a memory of the removable scanning sensor node.

48. The non-transitory computer-readable medium of claim 40 further comprising the steps of:

tracking, by the removable scanning sensor node, a time taken to load the container until detecting the desired load status; and

transmitting, by the removable scanning sensor node, a load time message to the managing node, wherein the load time message reflects the tracked time taken to load the container.

49. The non-transitory computer-readable medium of claim 40, wherein the notification indicates a status of the container associated with the determined occupied capacity of the container.

50. The non-transitory computer-readable medium of claim 40, wherein the transmitting step comprises:

detecting if the determined occupied capacity meets a desired load status for the container; and

transmitting, by the removable scanning sensor node, the notification to the managing node when the determined occupied capacity at least meets the desired load status for the container.

51. The non-transitory computer-readable medium of claim 40, wherein the notification indicates a requested change to the load operation related to the container.

52. The non-transitory computer-readable medium of claim 51, wherein the requested change comprises a request for additional personnel to be involved in loading the container.

53. The non-transitory computer-readable medium of claim 40, wherein the notification indicates a summary of what has been loaded into the container associated with the determined occupied capacity of the container.