Tool storage system with programmable sensor array

Abstract

According to a first aspect of the application, there is provided a tool storage system comprising: a board having an array of sensors, each sensor being configurable to be reserved for tool storage or vacant; a decoder for monitoring usage of the array of sensors; a remote terminal for processing signals received by the decoder, the remote terminal being configured to: learn locations of reserved sensors and vacant sensors from signals received during initialisation of the board; receive input providing details of storage of tools on the reserved sensors; detect removal of tools from the reserved sensors and return of tools to the reserved sensors from signals when the board is in use; and determine whether to transmit a message that an incorrectly returned tool has been returned when the decoder relays that at least one of the reserved sensors was falsely triggered during return of the tool; and a data storage device for holding details of tools stored by the reserved sensors, locations of the reserved sensors and locations of the vacant sensors.

Description

Technical Field

[0001] This invention relates to a tool storage system with a programmable sensor array. Background Technology

[0002] Tools are typically stored in drawers within a tool cabinet. An inventory control system is then needed to monitor the removal and return of tools to the cabinet.

[0003] Existing monitoring methods include using RFID tags attached to tools. However, RFID tags may fall off after a period of wear and tear.

[0004] To avoid this wear and tear, non-RFID methods use cameras and vision with learning capabilities. In one implementation, the drawer is illuminated by an internal light source when it is pulled open, allowing the camera to detect the tool being removed or taken out. Within military facilities, this method is sometimes rejected because products or equipment equipped with camera technology are considered a potential risk of information leakage.

[0005] Using weight sensing for tracking is another method. However, this method has low reliability.

[0006] This invention attempts to address the aforementioned drawbacks. Summary of the Invention

[0007] According to a first aspect of the invention, a tool storage system is provided, comprising: a board having a sensor array, each sensor being configurable to be reserved for tool storage or left vacant; a decoder for monitoring the use of the sensor array; a remote terminal for processing signals received by the decoder, the remote terminal being configured to: learn the positions of reserved and vacant sensors from signals received during board initialization; receive input providing detailed information about a tool stored on the reserved sensors; detect, from signals during board use, the removal of a tool from and return to the reserved sensors; and determine whether to transmit a message indicating the return of an erroneous tool when the decoder relay is erroneously triggered during tool return; and a data storage device for storing detailed information about the tool stored by the reserved sensors, the positions of the reserved sensors, and the positions of the vacant sensors. Attached Figure Description

[0008] This document describes representative embodiments of the invention by way of example only, with reference to the accompanying drawings, in which:

[0009] Figure 1 The components of a tool storage system according to one embodiment of the present invention are shown.

[0010] Figure 2 This is an isometric view of a tool cabinet with drawers used for storing... Figure 1 The board used in the tool storage system.

[0011] Figure 3 This shows how to return the error tool to... Figure 1 The tool storage system board.

[0012] Figure 4 It shows Figure 1 The tool storage system board is configured to store various tools of different sizes and profiles.

[0013] Figure 5 It shows Figure 4 A cross-sectional view of one of the stored tools.

[0014] Figure 6 A tool storage system for use with peripheral storage devices is shown.

[0015] Figure 7 It shows from Figure 1 The flowchart shows the process of removing the tool from the board and placing it into the external storage device.

[0016] Figure 8 The tool was shown returning from the peripheral storage device. Figure 1 The flowchart of the board.

[0017] Figure 9 A flowchart for board initialization is shown.

[0018] Figure 10 A flowchart is shown for removing and retrieving tools from the initialized board.

[0019] Figure 11 Depicting Figure 1 The tool storage system is a component of the remote terminal.

[0020] Figure 12 It shows the location Figure 1 Foam cutouts on the sensor array of the tool storage system board.

[0021] Figure 13 It shows the use of Figure 2 An example of a sensor on a plate shown. Detailed Implementation

[0022] This application relates to a tool storage system for storing tools. A tool refers to an instrument used for a specific purpose, such as repairing and maintaining equipment parts. The tool tracking system includes a tool cabinet, in one implementation having multiple drawers. Each drawer has a sensor array layer, with a cut layer located on top of the sensor array layer. The cut layer is used to hold tools in proper positions on the sensor array layer, wherein the shape of each cut corresponds to the tool it holds. The sensor array layer is used to detect the presence or absence of a tool at its cut location.

[0023] The tool storage system also monitors tool removal and return. Besides preventing tools from being lost or stolen, tracking tool movement over several usage instances is crucial, such as ensuring that all removed tools are returned immediately after a task is completed. In the repair or maintenance of aircraft engines, any tools left inside after work can cause catastrophic damage. Similarly, in the case of surgical instruments, it must be ensured that no tools remain inside the patient after surgery. For custom-made tools (such as those used to repair aircraft parts), monitoring contributes to accountability, as they can be expensive and difficult to replace.

[0024] The sensor array layer is programmable during initialization, during which the tool storage system learns the tools that the sensor array layer will monitor and their positions on the sensor array layer.

[0025] During initialization, sensors in the sensor array are assigned to be either reserved for tool storage during use or remain idle during use. Idle sensors are those not occupied by tools during use. Reserved sensors are those retained for tool storage during use, but not necessarily in contact with the stored tool. Reserved sensors can be in an active or idle state. In the active state, the sensor is programmed to detect the presence or absence of a tool during tool return. In the idle state, the sensor remains silent and does not send a signal regardless of whether a tool is present. The active and idle states will be described in more detail later.

[0026] When learning is automated, initialization includes a tool training phase, where the tool is placed on a board with a sensor array, and an algorithm determines the tool's position, and the number and arrangement of adjacent sensors needed to adapt to each tool's shape, for example, by detecting which sensors are in contact with the tool. The algorithm will remember the position and number of sensors that need to be reserved to monitor each tool, based on the shape of the tool on the sensor array during initialization. The algorithm will also remember the positions of unused sensors. Therefore, the tool training phase allows the tool's position to be automatically learned after it has been placed on the sensor array.

[0027] When learning is performed manually, initialization prompts the user to input the coordinates of reserved and unused sensors. Compared to automated methods, manual initialization does not require placing tools on the sensor array.

[0028] Therefore, sensor array layers are particularly suitable for storing custom tools, as they may not fit into cut layers with generic cutout shapes. The programmability of the sensor array also provides flexibility by allowing users to customize the position of tools (both custom and generic), specifying the desired position by placing detection (in the automatic initialization method) or inputting stored coordinates (in the manual initialization method). The tool's position on the sensor array can also be changed as needed by reprogramming the sensor array.

[0029] When one or more of the reserved sensors are found to have erroneously triggered during tool return, a message indicating a return of an erroneous tool can be transmitted. Triggering refers to how the reserved sensors react during tool return. Whether a reserved sensor is triggered correctly or incorrectly depends on whether it was specified (as part of the initialization described above) to be active, anticipating the presence or absence of the tool during tool return. If, during tool return, a reserved sensor returns a state contrary to its initial specification (i.e., whether it was programmed to anticipate the presence or absence of the tool during tool return) due to detecting an unexpected result, the reserved sensor will be erroneously triggered. Various tool return scenarios will be described in more detail below.

[0030] Algorithms for determining tool placement, or separate algorithms, allow for the rearrangement of reserved sensors, where the rearranged reserved sensors are still capable of monitoring the tool. For example, after initialization, the algorithm can activate most of the reserved sensors falling within or around the boundaries of the tool shape (e.g., a rectangle) to store the tool. After a predefined period, the algorithm can rearrange the active sensors, allowing for fewer or more active sensors. Alternatively, the same number of active sensors may remain after rearrangement, but their layout differs from before, although there may be overlap between the active sensors in the subsequent and previous layouts. Allowing such reconfiguration aims to prevent attempts to derive sensor combinations, where incorrect tool placement could mislead the sensor array into returning the correct tool. During sensor layout reconfiguration, the boundaries containing the reserved sensors and their positions remain unchanged.

[0031] Various embodiments of the tool storage system according to the invention will now be described with reference to the accompanying drawings, wherein like reference numerals generally refer to like features in the drawings. It will be understood that the tool storage system may have additional components not described for simplicity.

[0032] Go to Figure 1According to one embodiment of the present invention, the tool storage system has the following components: a board 100 having an array of sensors 104; a decoder 106; and a remote terminal 108.

[0033] Decoder 106 communicates electrically with board 100, for example, via a physical or wireless connection. Similarly, remote terminal 108 communicates electrically with decoder 106 via a physical or wireless connection. Decoder 106 acts as an interface to facilitate communication between board 100 and remote terminal 108. For example, decoder 106 relays signals regarding the use of the sensor array 104 from board 100 to remote terminal 108. Decoder 106 can also be used to adjust the sensitivity of each sensor in sensor 104, such as whether the reading of sensor 104 satisfies the condition of the presence of an indicating tool. Remote terminal 108 processes the signals received by decoder 106, thereby enabling remote terminal 108 to control the operation of the sensor array 104 via decoder 106 (e.g., by hosting an algorithm for programming the sensor array 104). Decoder 106 may be integrated with board 100 or remote terminal 108; or, in another embodiment of the invention, may be a separate component.

[0034] Board 100 can be placed in drawer 202 of tool cabinet 200. Figure 2 This is an isometric view of a tool cabinet 200. The tool cabinet 200 may have several drawers 202, wherein one or more drawer-supporting panels 100 are located in the drawers 202. The tool cabinet 200 has a computing terminal 108, which can be used as a remote terminal for the tool storage system. Therefore, the remote terminal for the tool storage system can be housed together with the panel 100 and does not necessarily need to be located separately or remotely.

[0035] Figure 1 The implementation uses a board 100 with a 14x11 array of sensors 104, but other sizes (not shown) are also possible. Each of the sensors 104 can be configured to be reserved for tool storage or left unused.

[0036] As described above, the multiple sensors 104 are configured as follows:

[0037] a) Reservation for tool storage (i.e., referring to sensors 110 reserved for tool storage during use): Due to the space occupied by tools, multiple adjacent sensors are typically reserved for tool storage. In one method, more sensors are reserved for tool storage than are needed. For example, a 6x6 sensor array area can be reserved for a tool that only requires 4x4 sensor array space. Therefore, the reserved sensors 110 do not necessarily need to contact the tool they are reserved for storage; or

[0038] b) Unoccupied / vacant (i.e., referring to sensor 112 that is not occupied by the tool during use).

[0039] During the initialization of board 100, remote terminal 108 learns the positions of reserved sensor 110 and idle sensor 112 from signals received from decoder board 106, for example, by placing a tool on board 100. See below. Figure 9 In step 908, the letter "y" indicates that the status light on board 100 turns yellow to indicate that board 100 is learning the shape of tool 116. Alternatively, remote terminal 108 learns the positions of reserved sensor 110 and idle sensor 112 by having the user input the coordinates during initialization.

[0040] When reserved for tool storage, sensor 110 can be in an active or empty state. In the active state, reservation sensor 110 is programmed to detect the presence or absence of a tool during tool return. Tool presence occurs when reservation sensor 110 detects contact with a portion of the returned tool 116. Tool absence occurs when reservation sensor 110 does not detect contact with any portion of the returned tool. Each active sensor can also be in a positive or negative logic state.

[0041] An active sensor in a positive logic state is configured to anticipate the presence of the tool during tool return, i.e., to contact a portion of the returning tool 116 during tool return. If such a positive logic state sensor does not detect the presence of the tool during tool return, it will send an error signal. However, if the sensor detects the presence of the tool during tool return, it will not send an error signal.

[0042] An active sensor in a negative logic state is configured to anticipate that the tool is not present during tool return, i.e., it will not contact a portion of the returning tool 116 during tool return. For example, a sensor 114 located outside the perimeter of the tool 116 resting on plate 100 can be designated as a negative logic state sensor. Other examples are sensors that do not contact portions of the tool 106 when flush-mounted on plate 100 (see [link to relevant documentation]). Figure 5 Thus, these sensors remain within the perimeter of the tool 106 on board 100. If a negative logic state sensor detects the presence of the tool during tool return, it will send an error signal. However, if the sensor does not detect the presence of the tool during tool return, it will not send an error signal.

[0043] In the empty state, the sensors are in a sleep or unresponsive state and remain silent regardless of whether the tool is present or not. If tool 106 is present during tool return, the empty-state sensors do not send a signal. If the tool is not present during tool return, they also do not send a signal.

[0044] After initialization, board 100 is ready for use (i.e., in the state where monitoring tool 106 has returned). When board 100 is in use, remote terminal 108 detects the removal of tool 106 from reserved sensor 110 and returns tool 106 to reserved sensor based on the signal sent from decoder 106.

[0045] If the reserved sensor 110 anticipates the presence of the tool during tool return and detects its presence (i.e., detects a portion of tool 106 during tool return), then the reserved sensor 110 will be correctly triggered. The decoder 106 will send a signal indicating that the reserved sensor 110 was correctly triggered. If the reserved sensor 110 anticipates the presence of the tool during tool return but detects its absence (i.e., no tool is detected during tool return), then the reserved sensor 110 will be incorrectly triggered. The decoder 106 will send a signal indicating that the reserved sensor 110 was incorrectly triggered.

[0046] Similarly, if the reservation sensor 110 anticipates the tool's absence during tool return and detects its absence (i.e., no tool is detected during tool return), the reservation sensor will be correctly triggered. The decoder 106 will send a signal indicating that the reservation sensor 110 was correctly triggered. If the reservation sensor 110 anticipates the tool's absence during tool return but detects its presence (i.e., a portion of the tool is detected during tool return), the reservation sensor will be incorrectly triggered. The decoder 106 will send a signal indicating that the reservation sensor 110 was incorrectly triggered.

[0047] When decoder 106 relays a message indicating that at least one of the reserved sensors 110 has been erroneously triggered during tool return, remote terminal 108 determines whether to transmit a message indicating that the tool has been returned incorrectly. In one configuration, the tool storage system transmits this message when at least one of the reserved sensors 110 is detected to have been erroneously triggered during tool return. However, in another configuration, detecting at least one erroneously triggered reserved sensor 110 does not automatically lead to the transmission of an error message. In this other configuration, the message indicating that the tool has been returned incorrectly is transmitted only if certain criteria regarding the erroneous triggering of reserved sensors 110 are met. Examples of these criteria include: the number of erroneously triggered reserved sensors 110 exceeds a threshold (such as three or more); or the erroneously triggered reserved sensors need to be located in a specific location (such as the middle of the monitored tool 106). Therefore, remote terminal 108 does not need to transmit a message indicating that the tool has been returned incorrectly as long as it detects that any reserved sensor 110 has been erroneously triggered.

[0048] During the tool training / board 100 initialization according to the automated method, the tool (for simplicity, Figure 1Only one tool 106 is shown, placed spaced apart across plate 100. Decoder 106 communicates with sensors 104 to learn which of them detect a tool on it (i.e., are in contact with a tool) to determine which sensors are to be reserved for tool storage and which are unoccupied / vacant. As an alternative to learning by tool placement, sensors 104 can be manually reserved for each tool 106, wherein coordinates for reserved sensors 110 and vacant sensors 112 are provided via remote terminal 108, and the presence of a tool on sensor 104 is optional.

[0049] Regardless of the method used during tool training / board 100 initialization, decoder 106 programs reserved sensors 110 to put one or more sensors into an active positive logic state; an active negative logic state; and / or an empty state. The algorithm specified for such sensors can be the same as the algorithm used for automatic board 100 initialization, or it can be a separate algorithm.

[0050] For example, in a first algorithm implementation, all reserved sensors 110 are in an active positive logic state, such that if any of these sensors 110 detects that the tool is not present during tool return, the decoder 106 transmits an error message. In a second algorithm implementation, some reserved sensors 110 are in an active positive logic state, while the remaining reserved sensors 110 are in an active negative logic state. If any sensor 110 in an active positive logic state detects that the tool is not present during tool return, or any sensor 110 in an active negative logic state detects that the tool is present during tool return, the decoder 106 transmits an error message. In a third algorithm implementation, a first group of reserved sensors 110 are in an active positive logic state; a second group of reserved sensors 110 are in an active negative logic state; and the remaining reserved sensors 110 are in an empty state. If any sensor 110 in an active positive logic state detects that the tool is not present during tool return, or any sensor 110 in an active negative logic state detects that the tool is present during tool return, the decoder 106 transmits an error message. Decoder 106 will not receive signals from sensor 110 when it is in an empty state.

[0051] Then, the remote terminal 108 saves the position of each set of reserved sensors 110 to delineate the area of ​​board 100 reserved for tool storage. Details of the tools 116 stored on the reserved sensors 110 are input to the remote terminal 108, for example, by indicating the tool type / part number stored by each set of reserved sensors 110. In one approach, this can be achieved by the user inputting the tool type / part number at each location placed on board 100. In another approach, the remote terminal 108 can automatically assign tool types / part numbers by mapping active sensors to a tool database. Other details include the weight of each tool 116 stored in peripheral storage, which will be referenced below. Figures 6 to 8 To provide a more detailed description.

[0052] Data storage device 120 stores detailed information about tool 116 stored by reserved sensor 110, the location of reserved sensor 110, and the location of idle sensor 112. Data storage device 120 can be integrated with remote terminal 108 or located independently, such as through cloud storage devices.

[0053] During use (i.e., after tool training / board 100 initialization), decoder 106 evaluates whether the correct tools should be returned to their allocated storage space. This is achieved by decoder 106 determining whether the active sensors within the sensors 110 reserved for tool storage are correctly triggered, such as when none of the sensors 110 in the active positive logic state transmits a signal that the tool is not present, and none of the sensors 110 in the active negative logic state transmits a signal that the tool is present. That is, decoder 106 receives the correct signal (i.e., tool detected) from sensors 110 programmed to detect the presence of the tool during tool return; and receives the correct signal (i.e., tool not detected) from sensors 110 programmed to detect the absence of the tool during tool return. On the other hand, if the reserved sensors 110 are erroneously triggered, decoder 106 will send an error message that an incorrect tool has been returned. This occurs if any sensor 110 in the active positive logic state transmits a signal that the tool is not present; this occurs if any sensor 100 in the negative logic state transmits a signal that the tool is present; or both. Decoder 106 is programmed to ignore signals received from idle sensor 112.

[0054] To illustrate, Figure 1 It is shown that a total of 11 sensors are reserved for storage tool 106 during initialization, and all 11 sensors are designated to be in an active positive logic state. Therefore, remote terminal 108 expects all 11 reserved sensors 110 to detect in Figure 3The tool is present during the tool return process shown. However, during the tool return process, instead of returning a tool that contacts all 11 sensors, a smaller tool 316 that only contacts 7 of the 11 sensors (sensors denoted as "G") returns. The 7 sensors 320 do not send error signals because they detect the presence of the tool. However, since the tool is not present, each of the other 4 sensors 322 (also denoted as "R") sends an error signal. The overall effect is that sensor 110 (see...) is reserved. Figure 1 The error was triggered incorrectly. The remote terminal 108 will send an error signal to indicate that the error tool 316 has been returned.

[0055] Figure 4 This shows that during tool training / board 100 initialization, board 100 has been configured to store tool 116 (see [link]). Figure 1 ) and tools 418 and 420 (in Figure 5 (As shown in the image). Regarding Figure 3 The response of board 100 during the return of error tool 316 was discussed, and therefore will not be elaborated further.

[0056] For storage device 418, more sensors than are required can be reserved. Figure 4 In the design, a 4x5 sensor array 422 (a total of 20 sensors) is reserved for a storage tool 418, which is located only on sensors 2, 3, 4, 6, 7, 8, 10, 11, 12, 13, 14, and 18. Therefore, the tool 418 only contacts a total of 12 sensors.

[0057] In the first implementation, sensors 2, 3, 4, 6, 7, 8, 10, 11, 12, 13, 14, and 18 can be programmed to be in an active positive logic state, while the remaining sensors 1, 5, 9, 15, 16, 17, 19, and 20 can be programmed to be in an active negative logic state. If an erroneous tool (not shown) is returned, causing any active positive logic state sensor to fail to detect the tool's presence (e.g., sensors 3 and 4), the overall effect is that the reserved sensors are erroneously triggered. The decoder 106 then sends an error message indicating that the erroneous tool was returned.

[0058] If the erroneous tool is returned, causing all active positive logic state sensors to detect the tool's presence, and any active negative logic state sensors to also detect the tool's presence (e.g., sensors 19 and 20), the overall effect is that the reserved sensors are erroneously triggered. Decoder 106 will still send an error message indicating that the erroneous tool was returned.

[0059] In the second implementation, the learning algorithm may select only the sensors programmed to be in an active positive logic state, such as sensors 2, 4, 7, 11, 14, and 18, where tool Y is located. Other sensors 3, 6, 8, 10, 12, and 13 are programmed to be in an empty state. The remaining sensors 1, 5, 9, 15, 16, 17, 19, and 20 can be programmed to be in an active negative logic state.

[0060] If any active positive logic state sensor detects that the tool is not present during the tool return (example sensors 4, 11, and 14 only, not sensors 2, 7, and 18), decoder 106 will still send an error message that the tool was returned incorrectly because the reserved sensor was erroneously triggered. If all active positive logic state sensors detect the presence of the tool, but any active negative logic state sensor also detects its presence, this would be another instance of the reserved sensor being erroneously triggered. Decoder 106 will still send an error message that the tool was returned incorrectly. Empty state sensors 3, 6, 8, 10, 12, and 13 will not send a signal regardless of whether the tool is present or not.

[0061] The second implementation helps prevent attempts to deduce the correct sensor combination from board 100, which has already been returned.

[0062] A 2x4 sensor array 424 (8 sensors in total) can be reserved for a storage tool 420 that is not flush with the plate 100 when placed on it (see...). Figure 5 (Cross-sectional view). Tool 424 contacts sensors 25, 26, 31 and 32, but not sensors 27 to 30.

[0063] During tool training / board 100 initialization, the learning algorithm detects that the tool is not in contact with sensors 27 to 30 and can be programmed to be in an active negative logic state. Then, the remaining sensors 25, 26, 31, and 32 can be programmed to have a combination of sensors in an active positive logic state or an empty state.

[0064] If any active negative logic state sensors 27 to 30 detect the presence of the tool during tool return (example sensors 27 and 28), the decoder 106 will still send an error message that an incorrect tool (not shown) was returned because the reserved sensor was erroneously triggered. If all active negative logic state sensors 27 to 30 detect the absence of the tool during tool return, but any active positive logic state sensor within sensors 25, 26, 31, and 32 detects the absence of the tool, the decoder will still send an error message that an incorrect tool was returned because the reserved sensor was erroneously triggered. The empty state sensors within sensors 25, 26, 31, and 32 will not send a signal regardless of whether the tool is present or not.

[0065] The trained board 100 can be reinitialized / reset, providing a means of periodically rearranging the reserved sensors for each tool on the board 100 to prevent attempts to derive a sensor combination where placing the wrong tool could mislead the sensor array into thinking the correct tool has been returned. During this reinitialization, the tools remain in their original positions.

[0066] Using the sensors reserved for array 422 as an example, if sensors 3, 6, 8, 10, 12, and 13 are currently in an empty state, reset board 100 may cause one or more of the sensors to change to a positive logic state. If sensors 2, 4, 7, 11, 14, and 18 are currently in a positive logic state, rearrangement may cause one or more of the sensors to change to an empty state. If sensors 1, 5, 9, 15, 16, 17, and 19 are currently in an active negative logic state, reset board 100 may cause one or more of the sensors to change to an empty logic state. If sensors 1, 5, 9, 15, 16, 17, and 19 are currently in an empty state, rearrangement may cause one or more of the sensors to change to a negative logic state.

[0067] During the reset of board 100, the area reserved for the reserved sensors on board 100 may remain unchanged or change. When the number of reserved sensors (i.e., the number of sensors reserved for the tool) remains unchanged, the boundary where the reserved sensors are located remains unchanged before and after the reserved sensors are rearranged. When the number of reserved sensors (i.e., the number of sensors reserved for the tool) changes, the boundary where the reserved sensors are located changes before and after the reserved sensors are rearranged. In both cases, the position of the boundary on board 100 remains unchanged.

[0068] The tool storage system of the present invention also allows monitoring of tools stored in peripheral storage devices, such as... Figure 6 The auxiliary toolbox 626 is shown. The auxiliary toolbox 626 may have wheels for easy movement. The auxiliary toolbox 626 communicates wirelessly with the remote terminal 108 via a wireless tag based on, for example, Bluetooth, WiFi, or NFC technology 624.

[0069] The auxiliary toolbox 626 provides a means of storing a subset of tools from board 100, and is useful in scenarios where the project only requires selecting the tools stored on board 100. For example, the project may only need 10 tools, in which case these 10 tools can be removed from board 100 and placed into auxiliary toolbox 626 for easy access to perform tasks.

[0070] The remote terminal 108 compares the weight records of each tool stored on the board 100 (as described above, one of the tool details stored in the data storage device 120) with the weight readings of the weight sensors provided in the auxiliary toolbox 626, and records the auxiliary toolbox 626 in which the removed tools were placed (both of which will be described below). Figure 7 (More details will be provided below) to track the tools removed from the sensor 104 array.

[0071] Figure 7 A flowchart is shown illustrating the process of removing a tool from board 100 and placing it into the auxiliary toolbox 626 assigned to the user. At step 702, the user logs in using their ID (such as an employee tag or access card) (e.g., at a computer terminal at remote terminal 108 or board 100). At step 704, an identifier (such as a serial number) of the auxiliary toolbox 626 is captured when the user approaches board 100 via, for example, Bluetooth or NFC. The user ID, auxiliary toolbox ID, and board ID are indexed together in database 718. This database may be the same as the database in data storage device 120 used to store tool details, but in another approach, both may be separate databases.

[0072] Step 706 occurs when the user removes a tool from board 100. Board 100 transmits the currently vacant sensors to remote terminal 108 so that remote terminal 108 can identify the removed tool / part number.

[0073] Step 708 occurs when the user places the removed tool into the auxiliary toolbox 626. Then, the weight sensor in the auxiliary toolbox 626 measures the weight of the tool placed in the auxiliary toolbox 626.

[0074] In step 710, the weight reading is compared with the recorded weight of the removed tool / part number identified in step 706. In one method, the weight reading is transmitted to a remote terminal 108 to perform the comparison.

[0075] If the comparison in step 710 matches (i.e., the weight reading matches the recorded weight), step 712 occurs. In step 714, a signal is sent to update database 718, indicating that the removed tool has been registered as lent to a user, thereby allowing remote terminal 108 to track the auxiliary toolbox 626 containing the removed tools / part numbers, and the users who lent them. The flowchart then ends in step 720.

[0076] On the other hand, if the comparison in step 710 does not match (i.e., the weight reading does not match the recorded weight, which may be due to, for example, external vibration affecting the weight sensor in the auxiliary toolbox 626), then step 716 occurs. A notification (such as an error message displayed on the computer terminal at remote terminal 108 or board 100; or an error light activated at board 100) communicates the mismatch. Step 716 occurs when the user returns the removed tool to the designated position on board 100. Board 100 then returns to the state of step 706, waiting for the tool removal to be detected.

[0077] Figure 8 A flowchart illustrating the process of a tool returning from the auxiliary toolbox 626 to the board 100 is shown. At step 802, the user logs in using their ID (such as an employee tag or access card) (e.g., at a computer terminal at remote terminal 108 or board 100). At step 804, an identifier (such as a serial number) of the auxiliary toolbox 626 is captured when it approaches board 100 via, for example, Bluetooth or NFC. The auxiliary toolbox ID and board ID are transmitted to database 822 for monitoring tools stored in peripheral storage. This database 822 may be the same as the database in data storage device 120 used to store tool details, but in another approach, both are separate databases. Database 822 cross-references the user ID and the received auxiliary toolbox ID and board ID received at step 802 with an index of user ID, auxiliary toolbox ID, and board ID in the database (see [link to database]). Figure 7 (of 718).

[0078] When the user returns tools from the auxiliary toolbox 626 to the board 100, step 806 occurs, and their weights are calculated as follows. In steps 808 and 810, the board 100 communicates with the remote terminal 108 to obtain the weight of each of the returned tools based on the sensor identification of the returned tool / part number, while the weight sensor in the auxiliary toolbox 626 transmits the detected reduction in the weight of the tools placed in the auxiliary toolbox 626. Upon returning each tool, in step 812, the weight reduction of the tool in the auxiliary toolbox 626 is compared with the weight of the tool returned to the board 100.

[0079] If the comparison in step 812 fails (i.e., the decrease in weight reading does not match the recorded weight of the tool / part number assigned to the sensor for tool return), such as when the user returns a tool that does not belong to board 100, step 814 occurs. A notification (such as an error message displayed on remote terminal 108 or a computer terminal at board 100; or an error light activated at board 100) communicates the mismatch. This notification serves to remind the user to check that they have returned the correct tool to board 100. After removing the mismatched tool, board 100 returns to the state of step 806 to await detection of tool return.

[0080] On the other hand, if the comparison in step 814 matches (i.e., the decrease in weight reading matches the recorded weight of the tool / part number assigned to the sensor for tool return), then step 816 occurs. In step 820, a signal is sent to update database 822, indicating that the correct tool has been returned to board 110.

[0081] After the user has correctly returned to all tools, they can log out at step 818. The flowchart then ends at step 824.

[0082] Therefore, a "mother / child" relationship is established between board 100 and auxiliary toolbox 626, which allows monitoring of the number of tools removed from the "mother" board 100 and placed into the "child" auxiliary toolbox 626. Using a weight sensor in the auxiliary toolbox 626 also benefits compactness, as the auxiliary toolbox 626 may not have enough space to accommodate a sensor board. When a tool is returned from the auxiliary toolbox 626 to board 100, the remote terminal 108 will verify the above-mentioned... Figures 3 to 5 The described method retrieves the correct tool from the signal received by decoder 106. If a tool is lost or an incorrect tool is returned, remote terminal 108 will display a warning message indicating which tool is incorrect or lost.

[0083] Figure 9 A flowchart 900 for initializing the tool training / board 100 is shown. Figure 9 and Figure 1 and Figure 2 They are described together as follows.

[0084] Board initialization begins at step 902 and tool training continues at step 904. In the automated method, tools are placed spaced apart from the sensor 104 array on board 100. Decoder 106 communicates with sensors 104 to learn which of them detect tools on them, determining which sensors are to be reserved for tool storage and which are unoccupied / vacant. In the manual method, coordinates for reserving sensors 110 and vacant sensors 112 are provided via remote terminal 108, where the presence of tools on sensors 104 is optional. Therefore, in step 906, both the automated and manual methods activate the sensors.

[0085] When the sensors are activated, at step 908, the status light on tool cabinet 200 turns yellow to reflect that the sensors are collecting data about the tools, such as their shape and size, so that a database is built at step 910 for the learning logic program to determine the number of sensors that need to be reserved to store the tools. Testing and evaluation occur at step 912, thereby repeating step 910 to ensure that the reserved sensors can accurately detect the presence of the tools. The process repeats at step 914 when the database has enough data to extract to determine the sensor arrangement that needs to be reserved for the tools placed on board 100.

[0086] At step 916, the learning logic algorithm is programmed to reserve the positions of sensor 110 (and which of them are in a positive logic state, a negative logic state, or an empty state) and vacant sensor 112, and this information is saved. The learning algorithm will also provide detailed information about the tools stored on the reserved sensors 110. At step 918, the learning algorithm ends.

[0087] Figure 10 A flowchart 1000 is shown for removing and retrieving tools from the initialization board 100. Figure 10 and Figure 1 and Figure 2 They are described together as follows.

[0088] Learn logic programs (see) Figure 7 Step 716) will check whether the correct tool has been returned, which is indicated by a status light on the tool cabinet 200 turning green or red. If the user returns the correct tool, the status light will be green; otherwise, it will be red.

[0089] The flowchart begins at step 1002. At step 1004, the user is requested to log in using, for example, an RFID card located in tool cabinet 200. At step 1006, remote terminal 108 or tool cabinet 200 determines whether the user is registered. If the user is not identified, access is denied, and the flowchart returns to step 1004.

[0090] If a user is identified, they are granted access to board 100, and the flowchart proceeds to step 1010. Remote terminal 108 will detect whether there are tools on board 100 via decoder 106.

[0091] If there is at least one tool on board 100, step 1008 occurs, where a green light appears at tool cabinet 200. At step 1014, board 100 checks if any tools have been removed. If a tool has been removed and remote terminal 108 records the removed tool, step 1016 occurs. If no tool has been removed, end 1026 occurs.

[0092] Returning to step 1010, if there are no tools on board 100, step 1012 occurs, where a red light will appear at tool cabinet 200. At step 1018, board 100 checks if any tools have been removed. If no tools are returned, end 1026 occurs. If tools are returned, step 1020 occurs, where, at step 1022, the tool placement sensor sends a signal to remote terminal 108 regarding whether they have been correctly triggered. At step 1024, the remote terminal receives the signal. If the sensor detects that the correct tool has been returned, end 1026 occurs. If the sensor is erroneously triggered, step 1012 occurs, where a red light will appear.

[0093] The possible operating sequence of the tool storage system of the present invention is as follows.

[0094] a) Starting from board 100 with sensor array 104

[0095] b) Place the tools on plate 100 simultaneously.

[0096] c) Toolboard 100 determines which of its sensor arrays detects the tool placed on it.

[0097] d) The learning algorithm determines the location of the sensors with tools on them. The algorithm designates these sensors as reserved for tool storage and the remaining sensors as unoccupied / empty. The sensor locations are saved, and the tool / part number is entered.

[0098] e) Then, a foam pad with the shape cut at the learned location is placed on board 100. In step d), decoder 106 will ignore the signal from the sensor where the foam is located, since the foam is designated as unoccupied / empty. The sensor detection tool corresponding to the cut location on the board is removed and returned.

[0099] f) If the tool returning to the cut position does not trigger the correct sensor reserved for tool storage, the board will send a signal that the erroneous tool has been returned.

[0100] Figure 11 Depicting Figure 1 The components of the remote terminal 108 shown.

[0101] like Figure 11 As shown, the exemplary remote terminal 108 includes a processor 1104 for executing software routines. Although a single processor is shown for clarity, the remote terminal 108 may also include a multiprocessor system. The processor 1104 is connected to a communication infrastructure 1106 for communicating with other components of the remote terminal 108. The communication infrastructure 1106 may include, for example, a communication bus or a network.

[0102] The remote terminal 108 also includes main memory 1108, such as random access memory (RAM), and secondary memory 1110. Secondary memory 1110 may include, for example, a hard disk drive 1112, a removable storage drive 1114 (which may be a USB flash drive, flash memory device, solid-state drive, or memory card). As those skilled in the art will understand, hard disk drive 1112 and removable storage drive 1114 may store computer-executable program code instructions and / or data.

[0103] Remote terminal 108 also includes at least one communication interface 1124. Communication interface 1124 allows software and data to be transferred between remote terminal 118 and external devices via communication path 1126. In various embodiments of the invention, communication interface 1124 allows data to be transferred between remote terminal 118 and data communication networks (such as public or private data communication networks). Communication interface 1124 can be used to exchange data between other remote terminals (not shown), such that the remote terminals form part of an interconnected computer network. Examples of communication interface 1124 may include a modem, a network interface (such as an Ethernet card), a communication port (such as serial, parallel, printer, GPIB, IEEE 10394, RJ45, USB), an antenna with associated circuitry, etc. Communication interface 1124 may be wired or wireless. Software and data transmitted via communication interface 1124 are in the form of signals, which may be electronic signals, electromagnetic signals, optical signals, or other signals that can be received by communication interface 1124. These signals are provided to the communication interface via communication path 1126.

[0104] like Figure 11 As shown, the remote terminal 108 also includes a display interface 1102, which performs the operation of rendering an image to the associated display 1130.

[0105] The computer program (also known as computer program code) is stored in main memory 1108 and / or auxiliary memory 1110. The computer program can also be received via communication interface 1124.

[0106] The software can be stored in a computer program product and loaded into a remote terminal 118 using a removable storage drive 1114 or a hard disk drive 1112. Alternatively, the computer program product can be downloaded to the remote terminal 118 via communication path 1126. When executed by processor 1104, the software enables the remote terminal 108 to learn the positions of reserved and idle sensors during the initialization of a board with a sensor array; receive input providing detailed information about tools stored on the reserved sensors; detect from signals during board use that tools are removed from and returned to the reserved sensors; and determine whether to transmit a message indicating that an erroneous tool has been returned when at least one reserved sensor is erroneously triggered during tool return.

[0107] Figure 13 An example of sensors that can be used with board 100 is shown, including an inductive sensor 1302, an optical sensor 1304 (operating in the infrared, ultraviolet, or visible spectrum), an radio frequency sensor 1306, and a capacitive sensor 1308. These sensors 1302, 1304, 1306, and 1308 can be configured to implement positive and negative logic states based on how monitored parameters in each of them react to the presence or absence of an instrument, as will be explained in further detail below.

[0108] The inductance sensor 1302 detects the presence of a tool by monitoring changes in magnetic flux. In a negative logic state, the decoder 106 is configured not to anticipate a change in the magnetic flux reading from the inductance sensor 1302 during tool detection and tool return. A change in the magnetic flux reading would indicate the presence of a tool, which would lead to a false trigger. On the other hand, in a positive logic state, the decoder 106 is configured to anticipate a change in the magnetic flux reading from the inductance sensor 1302 during tool return if the tool is removed during tool detection. During tool return, a change in the magnetic flux reading does not lead to a false trigger because the presence of the tool is expected.

[0109] The light sensor 1304 may have, for example, a pair of UV LED emitters 1310 and receivers 1312. The presence of a tool can be detected by the tool blocking light from the emitter 1310 to the receiver 1312. In a negative logic state, the decoder 106 is configured to expect the light sensor 1304 to emit a signal indicating that the receiver 1312 is continuously receiving light. Detecting light obstruction will indicate the presence of a tool, which will lead to a false trigger. On the other hand, in a positive logic state, the decoder 106 is configured to expect the light sensor 1304 to emit a light obstruction signal during tool return if the tool is removed during tool detection. During tool return, a change in the reading of the light sensor 1304 will not lead to a false trigger because the presence of the tool is expected.

[0110] Radio frequency (RF) sensor 1306 acts as a power source by transmitting radio waves 1316 to excite receiver tag 1314 located near a tool (not shown), thereby generating a resonance detected by RF sensor 1306. In a negative logic state, decoder 106 is configured not to anticipate a return resonant frequency signal from RF sensor 1306 during tool detection and tool return. Detection of the return resonant frequency signal would indicate the presence of a tool, leading to a false trigger. On the other hand, in a positive logic state, decoder 106 is configured to anticipate a return resonant frequency signal from RF sensor 1306 during tool return if the tool is removed during tool detection. During tool return, a change in the reading of RF sensor 1306 does not cause a false trigger because the presence of the tool is expected.

[0111] When tool 1318 is placed on capacitive sensor 1308, the capacitive sensor detects a change in capacitance. In a negative logic state, decoder 106 is configured not to anticipate a change in capacitance reading from capacitive sensor 1308 during tool detection and tool return. A change in capacitance reading would indicate the presence of a tool, which would lead to a false trigger. On the other hand, in a positive logic state, decoder 106 is configured to anticipate a change in capacitance reading from capacitive sensor 1308 during tool return if tool 1318 is removed during tool detection. During tool return, a change in capacitance reading will not lead to a false trigger because the presence of the tool is expected.

[0112] In summary, the decoder 106, the board 100 with the sensor array 104, and the remote terminal 108 provide the following functions / capabilities:

[0113] i) Tool training / board 100 initialization is performed by placing the tools to be stored onto a sensor board that acts as the base of the tool tray. The sensor board determines which of its sensors are reserved for tool storage (by detecting the tools on them) and which sensors are unoccupied / idle (no tools are detected on them). The purpose of reserving sensors is to specify the location on the board for tool storage, thereby monitoring these sensors during tool return. The remaining sensors are then considered unoccupied / idle and are not monitored for tool return. Then a layer of foam 1202 (see...) Figure 12 The sensor array 1204 is placed on the sensor array, where cutouts allow access to sensors reserved for tool storage.

[0114] This helps monitor the tool's return from the cut, visually indicating to the user the designated location for the tool's return.

[0115] The simple operating mode allows all reserved sensors to be in an active positive logic state, where the evaluation tool returns incorrectly if any of the reserved sensors detects that the tool is not present during the tool return process.

[0116] In advanced operating mode, a combination of sensors in active positive logic states, active negative logic states, and empty states is used to evaluate whether the tool was returned correctly. If at least one sensor in an active positive logic state detects that the tool was not present during tool return, or at least one sensor in an active negative logic state detects that the tool was present during tool return, then an incorrect tool return is evaluated. Advanced operating mode increases the difficulty of deriving the correct combination of sensors to deceive the sensor board into believing that the correct tool has been returned.

[0117] In one implementation, the learning algorithm can randomly determine which reserved sensors are designated as active positive logic states; active negative logic states; or empty states, provided that the determined combination does not send an error message to the tool that returned the correct response.

[0118] After board 100 has been trained, it can be reinitialized by executing a reset command to relearn the positions of tools already present on board 100. Therefore, the reset command can be used to leverage the learning algorithm to periodically change the sensor combinations, making them more difficult to derive from attempts to fool the sensor board. In another implementation, the combinations can be manually selected. For example, after determining the positions of reserved sensors based on tool training / board 100 initialization, a remote terminal can be used to change one or more sensors (specified as being in an active positive logic state during tool training / board 100 initialization) to an empty state.

[0119] ii) Learning Tool Placement and Tool Type / Part Number Labeling: The location of each set of reserved sensors is saved to delineate the reserved area on the sensor plate for tools. Each set of reserved sensors is then labeled by indicating the type of the stored tool / part number, i.e., the user will input the tool type / part number to be placed at each location on the sensor plate. This constructs a record of the tools / part numbers stored in the tool tray and their assigned locations. The tools are then secured by a foam board placed on top of the sensor plate, the foam board having cutouts for each tool corresponding to the tool's outline (see below). Figure 7 ).

[0120] iii) Tool user registration to identify users who have accessed the tool tray and the tools they have removed.

[0121] iv) Sensing tools remove and update tool detection records (to facilitate tracking of users and the tools they detect).

[0122] v) Verify that the tool returned and was placed correctly. If the returned tool does not trigger the correct sensor, it is determined to be an incorrect tool return. Oversized tools will not return because they are not suitable for foam cuts.

[0123] vi) Adding Additional Tools. New tool / part numbers can be stored on any part of the sensor board with sufficient space. The dimensions of the new tool / part number and its intended storage location on the sensor board can be sent to a remote terminal to reserve the required number of unoccupied / empty sensors at the intended storage location. Enter the new tool / part number and update the record of the tool / part number stored in the tool tray. Existing foam boards need to be modified by removing the foam section where the new tool / part number is inserted. If the number of tools placed does not match the number of reserved sensors during the process of adding additional tools, an error message will be issued.

[0124] vii) Repositioning existing tools. The positions of existing tools can be rearranged. Reserved sensors at the existing locations are released (i.e., no longer reserved), while the required number of unoccupied / empty sensors for the tool to be repositioned at the new location are reserved for storing the repositioned tool. It may be necessary to replace the existing foam board with a new one.

[0125] Update the tool / part number records stored in the tool tray.

[0126] viii) A "parent / child" relationship with the auxiliary storage device is used to store a subset of tools from the sensor board. This is achieved by comparing the weight of the tools removed from the sensor board with the recorded weight.

[0127] The weight of the tool in the auxiliary storage device is used to track the movement of the tool.

[0128] In this application, unless otherwise stated, the terms “comprising,” “comprise,” and their grammatical variations are intended to indicate an “open” or “inclusive” language that includes the stated elements but also allows for the inclusion of additional elements not explicitly stated.

[0129] Although the invention has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from the scope of the invention. Furthermore, modifications can be made to adapt the teachings of the invention to different situations and materials without departing from the basic scope of the invention. Therefore, the invention is not limited to the examples disclosed in this specification, but covers all embodiments falling within the scope of the appended claims.

Claims

1. A tool storage system, comprising: A board with a sensor array, each sensor can be configured to be reserved for tool storage or left unused; A decoder for monitoring the use of the sensor array; A remote terminal, configured to process signals received by the decoder, is configured to: The positions of reserved and unused sensors are learned from the signals received during the initialization of the board; Receive input providing detailed information about the tools stored on the reserved sensors; The detection tool removes from and returns to the reserved sensor from the signal when the board is used; as well as When at least one of the reserved sensors relayed by the decoder during the tool's return is erroneously triggered, it determines whether to transmit a message that the erroneous tool has been returned. as well as A data storage device for storing detailed information about the tool stored by the reserved sensors, the location of the reserved sensors, and the location of the vacant sensors.

2. The tool storage system according to claim 1, wherein, If the reserved sensor returns to the opposite state as specified during initialization during tool return, the reserved sensor is erroneously triggered.

3. The tool storage system according to claim 1 or 2, wherein, The reserved sensors include: a sensor in a positive logic state configured to anticipate the presence of a tool during tool return; and a sensor in a negative logic state configured to anticipate the absence of a tool during tool return, wherein an error trigger occurs when the sensor in the positive logic state detects the absence of a tool during tool return, or when the sensor in the negative logic state detects the presence of a tool during tool return.

4. The tool storage system according to claim 3, wherein, The sensor in the positive logic state is further configured to send an error signal when it detects that the tool is not present during the tool return; and the sensor in the negative logic state is further configured to send an error signal when it detects that the tool is present during the tool return.

5. The tool storage system according to claim 3 or 4, wherein, The reserved sensors also include an empty state sensor configured to be silent.

6. The tool storage system according to any one of the preceding claims, wherein, The remote terminal learns the locations of reserved and vacant sensors by placing tools on the sensor array.

7. The tool storage system according to claim 6, wherein, The assignment of the reserved sensor to the positive logic state, the negative logic state, or the empty state is determined randomly.

8. The tool storage system according to any one of claims 5 to 7, wherein, The remote terminal is also configured to rearrange the reserved sensors for the tool on the board in response to a reset command.

9. The tool storage system according to any one of claims 1 to 5, wherein, The remote terminal learns the positions of reserved and vacant sensors by inputting coordinates.

10. The tool storage system according to any one of the preceding claims, wherein, The transmission error tool returns a message when one or more of the following conditions occur: the number of the erroneously triggered reserved sensors exceeds a threshold, or the erroneously triggered reserved sensors are located at a specific location.

11. The tool storage system according to any one of the preceding claims, wherein, The remote terminal is also configured to: Communicating with a weight sensor to obtain weight readings; and Compare the obtained readings with the weight records of tools that are removed from or returned to the sensor array.

12. The tool storage system according to claim 11, wherein, The weight sensor is disposed in the auxiliary toolbox, and the weight reading is a weight reading of the tool stored in the auxiliary toolbox.

13. The tool storage system according to claim 12, wherein, The remote terminal is also configured to obtain the identifier of the wireless tag provided in the auxiliary toolbox when it is near the board.

14. The tool storage system according to claim 13, wherein, The remote terminal is also configured to record the identifier of the auxiliary toolbox together with one or more of the identity of the board or the users to whom the auxiliary toolbox is assigned.

15. The tool storage system according to any one of claims 12 to 14, wherein, The remote terminal is also configured to transmit an error notification in response to detecting a mismatch between the weight record of the tool removed from or returned to the sensor array and the weight reading from the weight sensor.

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