Detection module for storage devices with sensor devices for detecting a shortage or overfill level of stored goods by means of optical distance measurement

Description

[0001] The invention relates to a storage device, a warehouse management system and a method for retrofitting a storage device.

[0002] The logistical handling of large warehouses traditionally represents a major challenge, especially when the quantities of goods are large, the types of goods are highly diversified, the goods and the inventory are subject to frequent changes and the individual storage locations of the goods are geographically far apart or the storage locations change frequently.

[0003] Such inventories are traditionally managed computer-aided. People monitor the inventory in a decentralized manner and reorder goods locally as needed. This process is slow, time-consuming, and labor-intensive, requiring numerous decentralized resources due to the local processing of individual inventories.

[0004] WO 2017 / 084649 A1 discloses a storage device with shelves assigned to optical sensors for detecting the filling or fill level of the shelves with goods. WO 2017 / 084649 A1 discloses a device for storing piece goods, comprising at least one shelf with a top side on which the piece goods can be stored in a monitoring space, and with a bottom side and openings extending from the top side to the bottom side, as well as signal transmitters with associated signal receivers, wherein at least one type of product is arranged in the openings on the bottom side and a signal from the signal transmitter is detectable by the signal receivers, as well as control electronics with a control system that supplies the signal transmitters and signal receivers with power and processes signals from the signal receivers and identifies them in order to identify whether the monitoring space is occupied with piece goods based on the presence of a signal at the respective signal receiver.

[0005] The system according to WO 2017 / 084649 A1 is powerful but requires a relatively large number of sensors.

[0006] DE 20 2016 105 648 U1 discloses a bearing device having the features of the preamble of claim 1.

[0007] WO 2007 / 012099 A1 discloses a detection device and two measuring devices, each connected to an external control unit of the computer system. The detection lines are arranged in a V-shape.

[0008] DE 203 19293 U1 discloses a device for measuring the fill level of stored goods. DE 10 2013 222263 A1 discloses an inventory management system. DE 197 14 799 A1 discloses an inventory recording and control system, for example, for food vending machines.

[0009] It is an object of the present invention to enable monitoring of a stock with little effort and high precision.

[0010] This object is achieved by the subject matter according to the independent patent claims. Preferred embodiments are set forth in the dependent patent claims.

[0011] According to the present invention, a storage device is provided, comprising mounting structures, in particular shelf bars, for mounting, in particular replaceable or retrofitting, detection modules; the detection modules that are mounted or mountable on the mounting structures; and a plurality of receiving areas, each of which is designed to receive stored goods; wherein each sensor device of the at least one detection module is assigned to a respective receiving area and is designed to detect the sensor information indicative of the missing quantity and / or the fill quantity of stored goods in the respectively assigned receiving area; wherein the detection modules are configured for mounting, in particular replaceable or retrofitting, on a storage device and comprise the following: a carrier body; and a plurality of sensor devices that are attached to and / or in the carrier body;wherein each of the sensor devices is configured to detect sensor information within the scope of an optical distance measurement, which sensor information is indicative of a missing quantity and / or a filling quantity of stored goods in a receiving area of the storage device for receiving stored goods, which receiving area is assigned to a respective sensor device;and the sensor devices are attached to the carrier body in such a way that each of the sensor devices can emit an electromagnetic primary beam parallel to one another, in particular inclined or perpendicular to the main surface of the carrier body, from the same main surface of the carrier body, wherein each of the sensor devices is designed to detect an electromagnetic secondary beam reflected by the stored goods in response to the emission of the electromagnetic primary beam, wherein the detection modules have a first detection module with a control device and a second detection module without its own control device, which can be controlled by means of the control device of the first detection module; and the storage device has at least one of the following features: wherein the first detection module and the second detection module are mounted vertically one above the other, in particular the first detection module is mounted vertically above the second detection module;wherein the first detection module has a larger dimension than the second detection module;

[0012] According to yet another embodiment of the present invention, a warehouse management system is provided which comprises a plurality of storage devices having the features described above and a management device which is configured to manage an inventory of stored goods in the receiving areas based on the sensor information detected by the sensor devices.

[0013] According to yet another embodiment of the present invention, a method for retrofitting a storage device having receiving areas for receiving stored goods is provided, wherein the method comprises mounting at least one detection module with the features described above on mounting structures (in particular shelf bars) of the storage device, performing an optical distance measurement by means of a respective sensor device of the at least one detection module assigned to a respective receiving area for detecting the sensor information indicative of a missing quantity and / or a fill quantity of stored goods in a respectively assigned receiving area, and monitoring the stock of stored goods in the storage device by evaluating the sensor information,

[0014] In the context of this application, the term "detection module" can be understood in particular as a modular and preferably plate-shaped component into which a plurality of sensor devices are already integrated. Therefore, the detection module as a whole can be attached, built-in, or otherwise mounted to a bearing device—even a conventional one. Since such a detection module, in one embodiment, does not require any specific adaptation of interacting bearing devices, such a detection module can also be used interchangeably or retrofitted to a bearing device.

[0015] In the context of this application, the term "sensor device" can be understood in particular to mean a device that is designed to carry out an optical measurement. Such a sensor device can have a detection unit for detecting electromagnetic radiation (in particular visible light or infrared radiation), for example a photodiode. Optionally, such a sensor device can also have an emitting unit for emitting electromagnetic radiation (in particular visible light or infrared radiation), for example a laser source (in particular a laser diode) or a light-emitting diode. Such a sensor device can, for example, measure in reflection, i.e., detect a distance to a stored item by detecting electromagnetic radiation reflected from the stored item.

[0016] In the context of this application, the term "optical distance measurement" can be understood, in particular, as a measurement using electromagnetic radiation (in particular visible light or infrared light) with which a spatial distance between a sensor device and stored goods in a receiving area assigned to the sensor device can be determined by measurement. In particular, the stored goods whose distance from the sensor device is to be determined can be the rearmost stored goods in an arrangement of several consecutively arranged stored goods, which can be arranged, in particular, parallel to an electromagnetic measuring beam in the receiving area.

[0017] In the context of this application, the term "receiving area" can be understood in particular to mean a storage location or other spatial sub-area of a storage device (for example, part of a support surface of a shelf compartment or an entire shelf compartment) designed to store assigned storage items. In other words, each receiving area of a storage device or a warehouse management system can be assigned a specific storage item (for example, a container with specific screws or specific dowels). A specific storage item can be assigned to each receiving area in a database of the warehouse management system. Furthermore, the corresponding dimensions of the receiving area can also be stored in the warehouse management system database for each receiving area (for example, a defined shelf dimension of 500 mm).In particular, at least some of the receiving areas can be at least partially equipped with stored goods, in particular in the form of storage boxes, goods containers and / or bulk goods.

[0018] For the purposes of this application, the term "shortage" can be understood, in particular, as a difference between the quantity of stored goods when a receiving area of a storage device is fully filled and the (particularly smaller) actual quantity of stored goods in the receiving area of the storage device. For example, users can remove stored goods from the storage device, which can increase the shortfall. New stored goods can be added to the storage device through subsequent deliveries, which can reduce the shortfall again.

[0019] For the purposes of this application, the term "fill quantity" can be understood in particular as a residual quantity (e.g., a remaining quantity) of stored goods contained in a receiving area of a storage device. For example, users can remove stored goods from the storage device, which can cause the fill quantity, fill level, or fill level to decrease. New stored goods can be added to the storage device through subsequent deliveries, which increases the fill quantity again.

[0020] In the context of this application, the term "storage device" can be understood in particular as a box-like rack with one or preferably several storage inserts, which is designed for setting up, depositing, storing, etc., stored goods. Such a rack can stand on the floor and / or be attached to a wall. For example, the storage device can be designed as a storage shelf or storage cabinet. If such a rack is at least partially open, it can be designed, for example, as a shelf. If designed as a cabinet, the rack can be provided with doors that can optionally be lockable. However, it is also possible, for example, to use a trunk or cargo area of a vehicle as a storage device or to design a mobile storage device in another way.

[0021] In the context of this application, the term "warehouse management system" can be understood, in particular, as an arrangement of storage devices that may be fully or partially filled with stored goods or unfilled and are managed by a management device (e.g., a processor or server). The degree of filling or emptying can be detected by sensors for each specific stored goods or storage location. A management device, e.g., configured as a processor, can automatically place or trigger a reorder based on the sensor-detected degree of filling or emptying of the storage devices with the various types of stored goods, for example, if the remaining stock of a particular stored good has fallen below a predefined threshold.

[0022] For the purposes of this application, "warehouse goods" can be understood, in particular, as a tradable physical body or commodity element that, together with many other commodity elements, forms a stock of goods that may be subject to continuous change. Examples of such warehouse goods or commodity elements include, in particular, technical items or components, such as tool components (e.g., hammers, screwdrivers, etc.) or consumable components (e.g., screws, nails, dowels, etc.), particularly packaged in packaging units such as containers. Examples of the nature or type of warehouse goods or commodity elements include the contents of suitcases, machine components, the contents of a machine case, tool inserts, canisters, cans, bottles, cartridges, tubes, and / or drawer contents. Warehouse goods, such as bulk goods, can also be stored in storage boxes or cartons.For example, stored goods can be small parts packaging, such as a cardboard container with 100 screws.

[0023] According to the invention, a detection module is created which has a plurality of sensor devices integrated into a common carrier body for each carrying out an optical distance measurement. With the optical distance measurement for determining a spatial distance between a respective sensor device and stored goods in a receiving area which is spatially assigned to the respective sensor device, a missing quantity or a filling quantity of the said stored goods in this receiving area can be determined simply and in a fault-robust manner. If, for example, the stored goods in the receiving area are pushed forward to a removal side of the storage device and the respective sensor device is arranged on a side of the storage device opposite or opposite to the removal side, a greater spatial distance as a result of removed stored goods in this receiving area corresponds to a greater missing quantity or a filling quantity.a smaller fill level than a smaller distance. With a distance measurement, a single sensor device is sufficient for stored goods arranged along an entire row in the receiving area to record the stored goods fill level in the entire receiving area. Therefore, a small number of sensor devices are sufficient for monitoring many receiving areas for stored goods. It is also advantageously possible to mount such a recording module interchangeably in an existing storage device or to retrofit an existing storage device with such a recording module to provide automatic monitoring of the fill level of assigned receiving areas. Apart from retrofitting with one or more recording modules, an adaptation of the storage device can advantageously be dispensed with in order to implement monitoring of a stock. On the basis of the automatically determined missing quantity orBy determining the fill quantity of stored goods in multiple receiving areas of one or more storage devices, inventory monitoring can be achieved with little effort and with minimal error proneness, even for extremely complex warehouses, without the need for user involvement. Advantageously, the universal recording module can be attached to the storage device independently of a specific storage device and without, or without, significant structural changes to the storage device itself. This predestines a recording module according to an exemplary embodiment of the invention for universal mounting on essentially any storage device or for retrofitting to essentially any existing storage device.For example, equipping a storage device with recording modules is possible for stationary storage devices (e.g. storage shelves) as well as for mobile storage devices (e.g. as vehicle equipment).

[0024] Additional embodiments of the detection module, the storage device, the warehouse management system and the method are described below.

[0025] If a receiving area assigned to a respective sensor device is completely emptied of stored goods, distance measurement may no longer be possible, since a light beam or similar emitted by the sensor device can no longer be reflected by the stored goods in this receiving area. A non-detectable reflected secondary electromagnetic beam may therefore allow the conclusion that the remaining fill level in the receiving area is zero or that a shortfall corresponds to the maximum capacity of stored goods in the receiving area.

[0026] According to one embodiment, the carrier body can be designed as a carrier plate. For example, such a carrier plate can be designed as a flat body whose thickness is a maximum of one-fifth of its length and width. For example, the plate can be designed as a sheet metal plate or a plastic plate. Such a carrier plate can be easily mounted or retrofitted to an existing storage device (e.g., a storage rack) as a rear wall.

[0027] According to one embodiment, the carrier plate can have a width of at least 500 mm, in particular at least 1000 mm. According to one embodiment, the carrier plate can have a height of less than 150 mm (in particular if the detection module has a control device) or less than 100 mm (in particular if the detection module does not have a control device). According to one embodiment, the carrier plate can have a thickness of less than 20 mm.

[0028] According to one embodiment, the sensor devices are mounted on the carrier body in such a way that each of the sensor devices can emit an electromagnetic primary beam parallel to one another, starting from the same main surface of the carrier body. For example, it is possible for the electromagnetic primary beams to be emitted at an angle or perpendicular to the main surface of the carrier body. Illustratively, a sensor device can emit an electromagnetic parallel beam, e.g., in the form of a light beam, in the direction of the stored goods.

[0029] According to one embodiment, each of the sensor devices is configured to detect an electromagnetic secondary beam reflected by the stored item in response to the emission of the electromagnetic primary beam. In this way, a distance to the stored item closest to the sensor device in the associated receiving area can be determined by means of an optical reflection measurement, in that said electromagnetic primary beam is reflected back from the nearest stored item to the sensor device and detected there.

[0030] According to one embodiment, the acquisition module can have a control device (for example, a processor) that transmits sensor data transmitted by the sensor devices of the acquisition module associated with the control device and / or by sensor devices of another acquisition module without a control device to a central management device for further processing. The actual processing of the sensor data, sensor signals, or sensor information can then be performed by the central management device. In this way, a decentralized control device with manageable resources can be provided. Central intelligence can be concentrated at the level of the central management device for the actual data evaluation. This reduces the overall effort required to create the warehouse management system.

[0031] Alternatively, the control device of a detection module can be configured to determine, based on sensor data acquired by the sensor devices of the detection module, a respective distance to a respective stored item for each of the sensor devices and, from the respective distance, a respective missing quantity and / or a respective fill level. The sensor data or sensor information from the sensor devices of a detection module can thus be forwarded to the control device (provided jointly for all sensor devices of a detection module), which processes this sensor data or sensor information and uses this to calculate, for each sensor device and therefore also for each assigned receiving area, a spatial distance to the stored item closest to the respective sensor device.Illustratively, a common control device can be implemented for multiple sensor devices, which bundles and evaluates the sensor signals and uses these to determine a shortage and / or fill level of stored goods for each receiving area assigned to the detection module. The control device can then serve as the central intelligence of the detection module and perform processor services for the majority of sensor devices of the detection module. Advantageously, the individual sensor devices can then be designed with only a low level of processor intelligence or even without any processor intelligence at all, thus requiring little resource expenditure. The combination of central intelligence (in the form of the control device) with several decentralized dummies (in the form of the sensor devices) thus keeps the overall hardware expenditure for manufacturing a detection module low.

[0032] According to one exemplary embodiment, the control device can be configured to determine a respective distance to a respective assigned stored item based on sensor data acquired by sensor devices of another detection module (in particular another detection module without a control device) that is communicatively coupled to the control device, and to determine a respective missing quantity or fill level from the respective distance. It is thus also possible for a control device of a detection module to also evaluate sensor data or sensor information from sensor devices of another detection module and to determine related missing quantities and / or fill levels. This can be advantageous, for example, if the other detection module itself does not have a control device. In this way, the warehouse management system can be designed to be compact and with little equipment complexity.

[0033] According to one embodiment, the control device can be communicatively coupled to the sensor devices, in particular, via a wired communication connection. The sensor data from the sensor devices of the detection module having the control device and / or sensor data from sensor devices of another detection module without a control device can be transmitted to the control device via a corresponding communication connection. Over the short distances within a detection module or between spatially adjacent detection modules, wire connections for the wired transmission of sensor data can be easily integrated onto and / or into the carrier body or arranged to run between carrier bodies. Alternatively, a wireless communication protocol can also be implemented for communication between the control device and sensor devices of a detection module or neighboring detection modules.

[0034] According to one embodiment, the control device can be communicatively coupled to a management device, wirelessly coupled, in particular via WLAN or Bluetooth. In this way, the control device of a detection module can feed the sensor data it has collected and optionally already (pre-)processed to a central management device (e.g., another processor), where said sensor data can optionally be (post-)processed. However, it is preferred that the control device of a detection module merely summarizes or bundles the sensor data from the sensor devices assigned to it and provides corresponding data packets to the central management device for actual evaluation.The central management device (which can be descriptively described as the data evaluation device in the backend) can then perform the data processing that leads to the determination of a distance for each receiving area and, consequently, to the determination of a full or missing stock in each receiving area. Communication between the control device(s) and the management device can preferably be wireless, since the central management device, on the one hand, and different control devices of different acquisition modules of different storage facilities, on the other hand, can be arranged at a large spatial distance from one another. Over such large distances, wireless communication is easier to implement than wired communication.

[0035] According to one exemplary embodiment, the detection module without a control device can be coupled in a communicative manner, in particular via a master-slave communication connection, to a control device provided externally by the detection module (in particular of another detection module) and can be designed to transmit sensor data or sensor information detected by the sensor devices to the external control device for determining a missing quantity and / or fill level. In this context, a master-slave communication connection can be understood in particular as a hierarchical management of access to a shared resource in the form of a shared data channel for control purposes. In such an implementation, the detection module with a control device thus functions as the master, whereas the detection module without a control device, which is coupled to it in a communicative manner, functions as the slave.Thus, the acquisition module without a control device submits itself to the control of the acquisition module with a control device. Due to this master-slave architecture, a set of multiple acquisition modules can operate with a common control device, enabling implementation with minimal resource expenditure.

[0036] According to one embodiment, each of the sensor devices can be designed to determine a distance to the filling material, for example by means of an optical transit time measurement, an optical phase position measurement and / or by means of triangulation (in particular laser triangulation).

[0037] With optical time-of-flight measurement, for example, a sensor device can emit a short light pulse into the assigned detection area to strike a stored item. The pulse time of flight is the time it takes for the light beam to travel from the sensor device to the reflected stored item and back to the sensor device. By measuring this time of flight, the distance between the sensor device and the nearest stored item in the detection area can be determined using the speed of light.

[0038] An optical phase position measurement utilizes the fact that a phase shift of a reflected coherent light beam (particularly a laser beam) or its modulation compared to a light beam originally emitted by the sensor device is distance-dependent. This phase shift can be measured and used to determine the distance traveled from the sensor device to the nearest stored item in the receiving area and back to the sensor device. If the frequency of the original light beam (particularly a laser frequency) itself is used for superposition, the sensor device can function as a laser interferometer, in which the relative change upon displacement of the nearest stored item in the receiving area serving as the target or a reference mirror is determined.

[0039] With a sensor device that operates by triangulation, a light beam emitted by the sensor device (e.g., a laser beam or radiation from an LED) can be directed at the nearest stored item in the detection area and observed with an optical detection unit of the sensor device (e.g., a spatially resolving photodiode, a CCD array, or a camera). If the distance of the nearest stored item from the sensor device changes, the angle at which the light point is observed also changes, and thus the position of its image on the detection unit. From the change in position, the distance of the stored item from the sensor device can be determined using angular functions.

[0040] According to one embodiment, each of the sensor devices can be configured to acquire sensor information as part of the optical distance measurement, wherein the sensor information is indicative of a quantitative distance between a respective sensor device and the nearest stored item in the respectively assigned receiving area. After quantitatively determining this distance (e.g., in centimeters or millimeters), a shortage or residual fill level of these stored items in this receiving area can be determined, given a previously known spatial dimension of the stored item in this receiving area (e.g., ascertainable by accessing a corresponding database).

[0041] According to one exemplary embodiment, the detection module or the storage device can have at least one image recording device (for example, attached to and / or in the carrier body) for recording image data for identifying at least part of the stored goods in the recording areas assigned to the sensor devices. Such an image recording device can, for example, record an image of the stored goods (for example, product packaging) and, based on the optically detected information contained therein, identify the stored goods or at least determine a product type. This can be done, for example, using optical image recognition methods. Optionally, this can also be done by comparing the determined information with information from a database. The said image recording device can, for example, be provided jointly for several or even all sensor devices of a detection module.Alternatively, such an image recording device can also be provided jointly for several acquisition modules, for example, for an entire storage device. Alternatively, it is also possible to implement one image recording device per sensor device.

[0042] According to one embodiment, the detection module may have an electrical power supply connection for supplying the sensor devices, and optionally a control device, with electrical power. For example, a detection module may be provided with a cable, at the end of which is a power plug for plugging into the public power grid.

[0043] According to one embodiment, the receiving areas can be designed such that their upper side is inclined relative to the horizontal for receiving the stored goods, in particular is inclined downwards towards a user, so that the stored goods slide forward to a front side of the respective receiving area. For example, an angle of inclination can be between 3° and 30°. Supported by the force of gravity, the stored goods are then caused to slide forward to the front side of the receiving area by the inclination of a shelf or the like. Behind the remaining stored goods, a missing quantity and thus also a remaining quantity of the stored goods in this receiving area can then be determined by means of the distance measurement, without human user intervention being required.

[0044] According to one embodiment, the receiving areas can alternatively or additionally be equipped with conveyor devices (in particular roller and / or ball bearings) to promote the movement of the stored goods towards a front side of the respective receiving area. By providing roller and / or ball bearings in a (preferably also inclined) shelf, low-friction sliding can cause remaining stored goods (for example, after removal of a frontmost stored item) to slide forward automatically. An optical distance measurement behind the stored goods sliding forward can thus provide a high-precision inventory shortage or remaining inventory in a specific receiving area.

[0045] According to one embodiment, the receiving areas can alternatively or additionally have another mechanism, in particular a spring mechanism, for urging the stored goods towards a front side of the respective receiving area. Mechanical springs pressing from the back to the front can thus ensure that stored goods in a receiving area are always located on a front side (i.e., facing a user) of a storage device. This measure also reduces the risk of incorrectly determining a missing quantity and / or a fill level of stored goods in a receiving area due to optical distance measurement. Thus, stored goods in the receiving areas can be urged away from an associated sensor device and towards one end (in particular a stop at one end) of the respective receiving area. Said end can be opposite another end of the respective receiving area facing the associated sensor device.Advantageously, the pushing of the stored goods away from the associated sensor device can be effected by an automatic mechanism. Such a mechanism can be, for example, a mechanism based on the force of gravity (for example, by an inclination of storage locations), a friction-reducing mechanism (for example, by a low-friction bearing in a floor supporting the stored goods), and / or a spring-loaded mechanism (for example, by a mechanical spring that pushes stored goods away from the sensor device). In particular, when some of the stored goods in a receiving area are removed, any stored goods remaining in the receiving area can advantageously be pushed further away by the associated sensor device, so that the removal process is detected by the associated sensor device using optical distance measurement.

[0046] According to one embodiment, the at least one detection module can be attached or attachable to the mounting structures in a vertically oriented manner. Preferably, a detection module can be mounted as the vertical rear wall of a storage device, for example, designed as a shelf.

[0047] The first detection module and the second detection module are mounted vertically one above the other, in particular the first detection module is mounted vertically above the second detection module, and / or the first detection module is larger than the second detection module. Both detection modules can each form part of a rear wall of a common storage device. A short connecting line is sufficient between the two vertically oriented detection modules to transmit sensor signals from the sensor devices of the second detection module to the control device of the first detection module.

[0048] The compact design of a corresponding storage device can be further improved by designing the second detection module without a control device with a lower height than the first detection module.

[0049] According to one embodiment, a control device of a detection module can fulfill several functions. Firstly, the control device can be designed to receive sensor data, sensor signals or sensor information from the assigned sensor devices. Optionally, the control device can serve to process this sensor information to derive the distance to be determined. It is also possible for the control device to transmit the sensor information to a management device. For this purpose, the control device can be equipped with a communication unit for communicating (in particular wirelessly communicating) the sensor information to the management device. The sensor device can be designed in one piece, i.e. as a component for providing at least part of the aforementioned functionality.Alternatively, the control device can also be divided into different interacting components, for example a data receiving component and a data transmitting component.

[0050] According to one embodiment, at least some of the receiving areas can be formed by receiving surfaces of a common storage compartment. Illustratively, the receiving areas of a common storage compartment can be storage locations (e.g., physically or virtually subdivided or delimited) of a common shelf.

[0051] According to one embodiment, a specific storage item can be assigned to each receiving area in the management device, and the respective specific storage item can be managed depending on sensor signals from the associated sensor device. In particular, a reorder of the respective specific storage item can be carried out or triggered as needed. For example, a reorder can be triggered if the missing quantity of storage item in a respective receiving area determined by the optical distance measurement exceeds a predeterminable threshold. Which storage item is stored or is to be stored in a specific receiving area can be stored in a retrievable manner, for example, in a database of the warehouse management system.Alternatively or additionally, it is also possible to take images of the stored goods using an image recording device of a recording module, a storage device or the warehouse management system and to derive from this information which stored goods are stored in which recording area.

[0052] According to one embodiment, the optical distance measurement can be used to detect a distance between the respective sensor device and a stored item closest to this sensor device. Based on this distance, the quantity of missing or remaining stored items in the receiving area assigned to this sensor device can be determined. Advantageous information regarding the dimensions of stored items and the dimensions of a receiving area can, for example, be previously known, measured by sensors, or stored in a database.

[0053] According to one embodiment, a reorder of the respective stored item can be triggered if the fill level of a respective stored item falls below a predeterminable threshold. Alternatively, a reorder of the respective stored item can be triggered if a shortage of the stored item exceeds a predeterminable threshold. For example, the first-mentioned threshold is zero, so that a reorder is only triggered when a receiving area is completely emptied. However, a reorder can advantageously be triggered as soon as a sensor-determined remaining stock in a receiving area has fallen below a predeterminable threshold or a sensor-determined shortage in a receiving area has risen above a predeterminable threshold. The respective threshold can, for example, be defined specifically for the stored item or the receiving area.In particular, the respective threshold can be set based on historical consumption rates for certain inventory items. If experience shows that certain inventory items are consumed faster than others, the threshold for reordering when a certain fill level is undershot can be set higher for the former than for the latter.

[0054] In the following, exemplary embodiments of the present invention are described in detail with reference to the following figures. Figure 1 shows a detection module of a storage device according to an exemplary embodiment of the invention. Figure 2 shows a storage device with detection modules according to an exemplary embodiment of the invention. Figure 3 shows a warehouse management system with several storage devices, each with several recording modules according to an exemplary embodiment of the invention.

[0055] The same or similar components in different figures are provided with the same reference numerals.

[0056] Before exemplary embodiments are described with reference to the figures, some basic considerations will be summarized on the basis of which exemplary embodiments of the invention have been derived.

[0057] According to an exemplary embodiment of the invention, an intelligent monitoring system for the inventory of stored goods in a complex warehouse can be created, which system has storage devices (e.g., shelves) with various receiving areas (e.g., delimited areas of a storage compartment, e.g., a shelf). For this purpose, for example, receiving areas of a storage compartment can be equipped or retrofitted with a detection module that has a plurality of preferably linearly arranged sensor devices for determining a shortage or fill level of stored goods in each of the receiving areas. For this purpose, each of the sensor devices advantageously performs an optical distance measurement to determine a distance between the sensor device and the rearmost stored goods of a number of stored goods arranged one behind the other in the receiving area.The spatial distance between the sensor device and the rearmost stored item in the receiving area allows a conclusion to be drawn about a shortage or remaining fill level of stored items in this receiving area. If a distance measurement based on the reflection of light from the stored item is no longer possible due to the removal of the last stored item from a receiving area because a light beam emitted by the sensor device can no longer be reflected back to the sensor device by the rearmost stored item in the receiving area, this provides the information that the receiving area is completely empty.

[0058] According to an exemplary embodiment, a distance between a sensor device emitting the light beam and a stored item located at the rearmost position in an assigned receiving area can be determined using a light beam, in particular a laser light beam. This also allows the inventory of stored items in this receiving area to be determined. Measuring a shortage or fill level using a light beam leaves the stored items completely unaffected, which is particularly advantageous, for example, when monitoring the inventory of hazardous goods.

[0059] Clearly, any storage device can be easily equipped or retrofitted with an interchangeable sensor plate in the form of a detection module and the distance measurement performed by the sensor devices attached to the sensor plate to automatically monitor its fill level with stored goods. Such a detection module forms, for example, a rear wall for a shelf of a storage device designed as a rack. Such a wall-shaped detection module is independent and can be variably moved from one storage device to another. Therefore, it is also advantageous to convert or retrofit a rack or other storage device with a detection module for automatically monitoring the fill level with stored goods.This monitoring can serve as a basis for electronic reordering of stored goods if the filling level of the corresponding receiving area with stored goods falls below a critical value.

[0060] Advantageously, a database can be used to store which stored goods (for example, cans of contact spray or boxes of M8 screws) are stored in which receiving area of a storage device (for example, in which shelf compartment and in which compartment of the shelf compartment). The stock shortage and / or remaining stock level determined from the distance measurement for a specific receiving area of the warehouse can then be compared with the information in the database regarding which type of stored goods are stored in precisely this receiving area. The result of this comparison can then form the basis for reordering, ensuring that the warehouse's inventory can always be maintained at the desired level by triggering reorders in a timely manner.

[0061] Figure 1shows a cross-sectional view of a storage device 102, which is only partially shown and designed as a storage rack, with a (for example, replaceable or retrofittable) detection module 100 according to an exemplary embodiment of the invention.

[0062] The detection module 100 is attached to (for example, vertical) mounting structures 124 of the storage device 102, which can be designed as shelf bars. The detection module 100 contains a plate-shaped support body 104, which can be, for example, a metal or plastic plate. Attached to the support body 104 are, for example, equidistant and perpendicular to the paper plane Figure 1 a plurality of sensor devices 106 are mounted (for example in the Figure 2 manner shown).

[0063] Each of the optical sensor devices 106 serves to optically capture sensor information by means of an optical distance measurement. This optical distance measurement quantitatively measures a distance D between the respective sensor device 106 and a nearest stored item 110 in a receiving area 108. Each receiving area 108 is assigned to a respective sensor device 106. Clearly, sensor information indicative of a shortage of already removed stored items 110 can be captured using each of the sensor devices 106. Clearly, the shortage of already removed stored items 110 is proportional to the distance D, since the distance D increases accordingly with each removal of a stored item 110. Remaining stored items 110 automatically slide toward the front side 126 of the receiving area 108 (as described in more detail below).By determining the distance D, a shortage of stored goods 110 and, indirectly, also a remaining fill quantity of stored goods 110 in a receiving area 108 of the storage device 102 assigned to a respective sensor device 106 can be determined. The remaining fill quantity can be determined from the sensor-detectable and subsequently calculable shortage if the dimensions of the receiving area 108 or of the stored goods 110 are known in advance. For example, the dimensions of the individual receiving areas 108 and of the individual stored goods 110 can be stored in a database 142 and retrieved therefrom as needed. For example, the optical distance measurement can be performed using an optical time-of-flight measurement, an optical phase position measurement, and / or laser triangulation.

[0064] The sensor devices 106 are attached to the carrier body 104 such that each of the sensor devices 106 can emit an electromagnetic primary beam 114 from the same main surface 112 of the carrier body 104 in the direction of the stored goods 110 of an associated receiving area 108. This is achieved via an optical emitter of the sensor device 106 for emitting the electromagnetic primary beam 114. The optical emitter can be, for example, a laser diode or a light-emitting diode. Furthermore, each of the sensor devices 106 is configured to detect an electromagnetic secondary beam 116 reflected by the nearest stored goods 110 in response to the emission of the electromagnetic primary beam 114. This is accomplished by an optical receiver of the respective sensor device 106, for example, a photodiode.

[0065] In addition, a common control device 118, embodied, for example, as a processor, can be provided for all sensor devices 106 of the acquisition module 100, which can be communicatively coupled to all sensor devices 106 of the acquisition module 100. The control device 118 can be configured to determine, based on sensor data acquired by the sensor devices 106 of the acquisition module 100, a respective distance D to the respective nearest stored item 110 for each of the sensor devices 106 and, from the respective distance D, a respective missing quantity and / or fill quantity of stored item 110. Said missing quantity and / or fill quantity can then be transmitted to a central management device 120 (e.g., also embodied as a processor), for example, as a basis for deciding on the necessity and triggering of reorders.Alternatively, it is also possible for the control device 118 to receive the sensor signals from the sensor devices 106 assigned to it and transmit them to the central management device 120 for further processing without further processing. The determination of distance D or a missing quantity and / or fill quantity can then be carried out by the management device 120.

[0066] Preferably, the communicable coupling of the control device 118 with the sensor devices 106 of the detection module 100 can be implemented by wiring. Corresponding electrical connections 179 can be implemented by electrical connecting lines on and / or in the carrier body 104. Furthermore, the control device 118 can also be communicatively coupled to the central management device 120, but preferably wirelessly, for example via WLAN or Bluetooth. Said wireless transmission is described in Figure 1with reference numeral 181. In this way, short-distance communication can be wired and long-distance communication can be wireless, which overall results in low overhead in connection with data transmission.

[0067] Figure 1also shows that an optical image recording device 140 (for example, a CCD camera or a CMOS camera) for recording image data can be attached to the carrier body 104 (alternatively separate from the carrier body 104). For example, the optical image recording device 140 can be provided jointly for all sensor devices 106 of the detection module 100. Images of the backs of the storage goods 110 stored in the receiving areas 108, taken by the optical image recording device 140, can be used, for example, to identify them. In this way, it can be ensured with particularly little effort that a determined shortage or fill level refers to the correct storage goods 110. Alternatively, the type of a storage item 110 in a receiving area 108 can also be taken from a database 142, which can be accessed, for example, by the central management device 120.

[0068] Figure 1also shows that the illustrated receiving area 108 is delimited by a storage compartment 128. The upper side of the storage compartment 128 or of the receiving area 108 is inclined at an acute angle to the horizontal to receive the stored item 110 and is designed to slope downwards toward a user at a front side 126 of the storage device 102. Supported by the gravitational force (see the g-vector 152), when a stored item 110 is removed from the front side 126, any stored item 110 remaining slides toward the front side 126 of the respective receiving area 108. In this way, remaining storage goods 110 in a receiving area 108 always border on a front stop 136, so that the distance D detectable by means of the optical distance measurement is a measure of a shortage of storage goods 110, which in turn provides an indication of a remaining quantity of storage goods 110 in the receiving area 108.In order to determine the remaining quantity of stored goods 110 from the distance D, dimensional information of the receiving area 108 and / or the stored goods 110 can also be taken from the central database 142. In order to additionally support the gravity-assisted positioning of stored goods on the front side 126, according to . Figure 1 The receiving area 108 is provided with a conveyor device 140 in the form of roller or ball bearings. The conveyor device 140 can operate purely passively or be assisted by a drive (e.g., an electric motor). The conveyor device 140 additionally promotes a movement of the stored goods 110 toward the front side 126 of the respective receiving area 108, thereby ensuring high error robustness and reliability of the determined fill level.

[0069] This ensures that stored goods 110 in a respective receiving area 108 are pushed away from an associated sensor device 106 towards the stop 136 at one end 134 of the receiving area 108, which is opposite another end 138 of the respective receiving area 108 facing said sensor device 106.

[0070] Figure 2 shows a storage device 102 with detection modules 100 according to an exemplary embodiment of the invention.

[0071] The storage device 102 has mounting structures 124 for mounting the detection modules 100.

[0072] Storage locations or receiving areas 108 are designed to receive specifically assigned storage goods 110. Each sensor device 106 of a respective detection module 100 is assigned to a respective receiving area 108 and serves to detect the information indicative of a shortage or fill quantity of storage goods 110 in a respectively assigned receiving area 108, as described with reference to Figure 1 described.

[0073] According to Figure 2 uppermost detection module 100 can be designed as according to Figure 1 and is designed in particular with the control device 118 for receiving the sensor signals of all sensor devices 106 of the uppermost detection module 100. According to Figure 2 In addition, a lower second detection module 100 is provided, which can be designed with regard to the design of the sensor devices 106 as in Figure 1described. However, the lower second detection module 100 does not have its own control device 118. Instead, the second detection module 100 is communicatively coupled to the control device 118 of the first detection module 100 via a preferably wired communication connection (see electrical connections 179). The communication between the first detection module 100 and the second detection module 100 takes place by means of a master-slave communication connection, in which the first detection module 100 with its control device 118 acts as the master and the second detection module 100 without a control device acts as the slave. The control device 118 of the first detection module 100 can therefore also receive the sensor signals of the sensor devices 106 of the second detection module 100 and, by means of a Figure 2 with reference numeral 154 to a central management device 120 (not shown in Figure 2 ).

[0074] As shown, the plate-shaped first detection module 100 and the plate-shaped second detection module 100 are mounted vertically one above the other and form rear walls of the storage device 102. More specifically, the first detection module 100 is arranged vertically above the second detection module 100. For example, the support plate 104 of the first detection module 100 can have a width b of 1000 mm, a height h of, for example, 140 mm, and a thickness d of, for example, 10 mm. The second detection module 100 can have a smaller height of, for example, 90 mm, but the same width and thickness as the first detection module 100. The smaller dimensions of the second detection module 100 compared to the first detection module 100 are due to the reduced functionality and consequently smaller space requirements of the components of the second detection module 100, in particular due to the lack of a dedicated control device in the second detection module 100.

[0075] Furthermore, in Figure 2It is shown that the first detection module 100 has an electrical power supply connection 122 for supplying the sensor devices 106 and its control device 118 with electrical energy. The electrical power supply connection 122 can have a power cable and a plug for connection to the public power grid. According to one embodiment, the first detection module 100 can also supply the second detection module 100 with electrical energy via its electrical power supply connection 122. Alternatively, the second detection module 100 can also be equipped with an electrical power supply connection (not shown).

[0076] As also in Figure 2As shown, receiving areas 108 of a respective detection module 100 are formed by receiving surfaces of a common storage compartment 128 or shelf. In this case, a portion of the receiving areas 108 is partially filled with stored goods 110, here formed by cuboid-shaped or circular-cylindrical goods containers.

[0077] Figure 3 shows a warehouse management system 130 with three storage devices 102 according to an exemplary embodiment of the invention.

[0078] Each of the storage devices 102 is equipped with four detection modules 100. The uppermost detection module 100 of each storage device 102 has a control device 118 and serves as the master, whereas the three lower detection modules 100 of each storage device 102 are controlled by the control device 118 of the uppermost detection module 100 and function as slaves.

[0079] The illustrated warehouse management system 130 thus contains several communicatively coupled storage devices 102 of the functionality according to Figure 1 or Figure 2 However, each of the bearing devices 102 is more complex than in accordance with Figure 1 or Figure 2, i.e. with more detection modules 100, more receiving areas 108 and more communication connections. The management device 120, designed as a server or the like, is supplied wirelessly by the control devices 118 of the respective storage devices 102 with the sensor signals of the sensor devices 106 assigned to the individual receiving areas 108 and associated stored goods 110. The management device 120, if necessary by accessing data in database 142, then determines an inventory of the individual stored goods 110 in the individual receiving areas 108 based on the sensor signals of the sensor devices 106 and manages this inventory accordingly. In the management device 120, each receiving area 108 is assigned a specific stored item 110. Furthermore, the respective specific stored item 110 is managed depending on sensor signals from the associated sensor device 106.For example, if necessary, a reorder of the respective specific stored item 110 is carried out or triggered by a reordering device 160 linked via a communications network. The reorder of a specific stored item 110 can be triggered, in particular, by the management device 120 through a corresponding communication message to the reordering device 160 if, after determining a shortage and / or fill level in a receiving area 108 assigned to this stored item 110, it has been determined based on the optical distance measurement described above that the fill level there has fallen below a critical threshold. This ensures that replenishment arrives in a timely manner and can be replenished in the assigned receiving area 108.

[0080] A particular advantage of embodiments of the invention can be seen in the fact that the interchangeable or freely attachable detection modules 100 can be easily used to retrofit a conventional storage device without inventory monitoring. For this purpose, it is easily possible to retrofit mounting structures 124 of the conventional storage device, for example, designed as shelf bars, with one or more of the detection modules 100 described above. A complex conversion of the storage device is not required for this purpose.

[0081] Additionally, it should be noted that "comprising" does not exclude other elements or steps, and "a" or "an" does not exclude a plurality. Furthermore, it should be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims are not to be considered as limitations.

Claims

1. Storage device (102), comprising mounting structures (124), in particular shelf rods, for mounting, in particular exchangeably or retrofitting, detection modules (100); the detection modules (100) which are mounted or can be mounted on the mounting structures (124); and a plurality of receiving regions (108), each of which is designed to receive storage goods (110); wherein each sensor device (106) of the at least one detection module (100) is assigned to a respective receiving region (108) and is designed to detect the sensor information which is indicative of the missing quantity and / or the filling quantity of storage goods (110) in the respectively assigned receiving region (108); wherein the detection modules (100) are configured for mounting, in particular exchangeably or retrofitting, on a storage device (102) and comprise the following: a carrier body (104); and a plurality of sensor devices (106) which are mounted on and / or in the carrier body (104); wherein each of the sensor devices (106) is set up to detect sensor information within the scope of an optical distance measurement, which sensor information is indicative of a missing quantity and / or a filling quantity of storage goods (110) in a receiving region (108), assigned to a respective sensor device (106), of the storage device (102) for receiving storage goods (110); and the sensor devices (106) are mounted on the carrier body (104) in such a way that each of the sensor devices (106), proceeding from the same main surface (112) of the carrier body (104), can emit an electromagnetic primary beam (114) parallel to one another, in particular inclined or perpendicular to the main surface (112) of the carrier body (104), wherein each of the sensor devices (106) is designed to detect an electromagnetic secondary beam (116) reflected by the storage goods (110) in reaction to the emission of the electromagnetic primary beam (114), characterized in that the detection modules (100) comprise a first detection module (100) with a control device (118) and a second detection module (100) without its own control device, which can be controlled by means of the control device (118) of the first detection module (100); and the storage device (102) comprises at least one of the following features: wherein the first detection module (100) and the second detection module (100) are mounted vertically one above the other, in particular the first detection module (100) is mounted vertically above the second detection module (100); wherein the first detection module (100) has a larger dimension than the second detection module (100).

2. Storage device (102) according to claim 1, wherein the carrier body (104) is formed as a carrier plate, comprising at least one of the following features: wherein the carrier plate has a width (b) of at least 500 mm; wherein the carrier plate has a height (h) of less than 150 mm, in particular of less than 100 mm; and / or wherein the carrier plate has a thickness (d) of less than 20 mm.

3. Storage device (102) according to one of claims 1 to 2, comprising the control device (118), which is configured: to receive the sensor information detected by the sensor devices (106) of the detection module (100) and to transmit it to a management device (120) for further processing; or on the basis of sensor information detected by the sensor devices (106) of the detection module (100), to determine for each of the sensor devices (106) a respective distance (D) from respectively assigned storage goods (110) and from the respective distance (D) the respective missing quantity and / or filling quantity.

4. Storage device (102) according to claim 3, comprising at least one of the following features: wherein the control device (118) is configured to receive the sensor information detected by sensor devices (106) of another detection module (100), in particular of the second detection module (100) without its own control device, and to transmit it to a management device (120) for further processing; wherein the control device (118) is configured, on the basis of sensor information detected by sensor devices (106) of another detection module (100), in particular of the second detection module (100) without its own control device, which can be coupled or is coupled to the control device (118) in a communicable manner, to determine for the sensor devices (106) of the other detection module (100) a respective distance (D) from respectively assigned storage goods (110) and from the respective distance (D) the respective missing quantity and / or filling quantity; wherein the control device (118) is coupled to the sensor devices (106) in a communicable manner, in particular is coupled in a communicable manner by wire; wherein the control device (118) can be coupled or is coupled to a management device (120) in a communicable manner wirelessly, in particular via WLAN or Bluetooth.

5. Storage device (102) according to one of claims 1 to 4, comprising at least one of the following features: wherein the second detection module (100) can be coupled to the control device (118) provided externally by the first detection module (100) in a communicable manner, in particular via a master-slave communication connection, and is designed to transmit sensor information detected by the sensor devices (106) to the external control device (118), in particular for determining the missing quantity and / or filling quantity by the control device (118) and / or a management device (120) which can be coupled or is coupled to the control device (118) in a communicable manner; wherein each of the sensor devices (106) is designed, within the scope of the optical distance measurement, to determine a distance (D) from filling material (110) of the assigned receiving region (108) by means of an optical propagation time measurement, an optical phase position measurement and / or triangulation; wherein each of the sensor devices (106) is set up to detect sensor information within the scope of the optical distance measurement in such a way that the sensor information is indicative of a quantitative minimum distance (D) between a respective sensor device (106) and a nearest storage goods (110) in the respectively assigned receiving region (108); comprising at least one image recording device (140) mounted on and / or in the carrier body (104) for recording image data for identifying at least a part of the storage goods (110) in the receiving regions (108) which are assigned to the sensor devices (106).

6. Storage device (102) according to one of claims 1 to 5, comprising at least one of the following features: designed as a storage shelf or storage cabinet; wherein the receiving regions (108) are designed in such a way that their upper side for receiving the storage goods (110) is inclined with respect to a horizontal, in particular is inclined downwards towards a user, so that the storage goods (110) slide forwards to a front side (126) of the respective receiving region (108); wherein the receiving regions (108) are designed with conveying devices (140), in particular roller and / or ball bearings, for conveying a movement of the storage goods (110) towards a front side (126) of the respective receiving region (108); wherein the receiving regions (108) comprise a mechanism, in particular a spring mechanism, for forcing the storage goods (110) towards a front side (126) of the respective receiving region (108); wherein at least the first or second detection module (100) is mounted or can be mounted as an, in particular vertical, rear wall on the mounting structures (124); wherein at least a part of the receiving regions (108) is formed by different receiving surfaces of a common storage compartment (128); wherein at least a part of the receiving regions (108) is at least partially equipped with storage goods (110), in particular in the form of storage boxes, goods containers and / or bulk goods.

7. Storage management system (130), comprising: a plurality of storage devices (102) according to one of claims 1 to 6; a management device (120), which is configured, on the basis of the sensor information detected by the sensor devices (106), to manage a stock of storage goods (110) in the receiving regions (108) of the storage devices (102).

8. Storage management system (130) according to claim 7, wherein in the management device (120) a specific storage goods (110) is assigned to each receiving region (108) and the respective specific storage goods (110) is managed on the basis of sensor information of the associated sensor device (106), in particular if necessary a reordering of the respective specific storage goods (110) is carried out or triggered, further in particular if the missing quantity of the storage goods (110) in a respective receiving region (108) exceeds a predefinable threshold value or if the filling quantity of the storage goods (110) in a respective receiving region (108) falls below a predefinable threshold value.

9. Method for retrofitting a storage device (102) according to one of claims 1 to 6, comprising receiving regions (108) for receiving storage goods (110), wherein the method comprises: mounting the first and second detection module (100) on mounting structures (124), in particular shelf rods, of the storage device (102); carrying out an optical distance measurement by means of a respective sensor device (106), assigned to a respective receiving region (108), of the at least one detection module (100) for detecting the sensor information which is indicative of a missing quantity and / or a filling quantity of storage goods (110) in a respectively assigned receiving region (108); and monitoring the stock of storage goods (110) of the storage device (102) by evaluating the sensor information.

10. Method according to claim 9, wherein the method comprises forcing storage goods (110) in the receiving regions (108) away from an assigned sensor device (106) towards an end (134), in particular a stop (136) at an end (134), of the respective receiving region (108), which end (134) lies opposite an other end (138), facing the assigned sensor device (106), of the respective receiving region (108), wherein the method comprises in particular causing the storage goods (110) to be forced away from the assigned sensor device (106) by an automatic mechanism, in particular a gravity mechanism, a friction-reducing mechanism and / or a spring pretensioning mechanism.

11. Method according to claim 10, wherein the method comprises, when a part of the storage goods (110) is removed from a front side (126) of a receiving region (108), further forcing remaining storage goods (110) in the receiving region (108) away from the assigned sensor device (106), so that the removal from the assigned sensor device (106) is detected by means of the optical distance measurement on account of a distance (D), increased by the removal, between the sensor device (106) and the remaining storage goods (110).

12. Method according to one of claims 9 to 11, wherein the method comprises: determining a distance (D) between the respective sensor device (106) and a storage goods (110) lying closest to this sensor device (106) by means of the optical distance measurement; and determining the missing quantity and / or a filling quantity of storage goods (110) in the receiving region (108) assigned to this sensor device (106) on the basis of the determined distance (D).

13. Method according to one of claims 9 to 12, wherein the method comprises triggering a reordering of the respective storage goods (110) if the missing quantity of the respective storage goods (110) exceeds a predefinable threshold value or the filling quantity of the respective storage goods (110) falls below a predefinable threshold value.