Adaptive RFID inventory system

Abstract

An adaptive inventory management system for use in a material handling facility storing a plurality of items, each associated with a radio frequency identification (RFID) tag, the management system including a global inventory database subsystem and an RFID interrogator subsystem comprising a plurality of RFID interrogators, each of the plurality of RFID interrogators configured to read a unique identifier of an RFID tag associated with each of the plurality of items within a defined boundary of at least one scan zone generated by the respective RFID interrogator, and to communicate to the global inventory database subsystem a unique identifier of each scanned RFID tag identified within each scan zone of the respective RFID interrogator.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 149,016, filed February 12, 2021, entitled "ADAPTIVE RFID INVENTORY SYSTEM," the disclosures of which are incorporated herein by reference in their entirety, and claims the benefit of U.S. Provisional Patent Application No. 63 / 219,613, filed July 8, 2021, and further claims priority to U.S. Provisional Patent Application No. 63 / 300,365, filed January 18, 2022, now U.S. Patent No. 11,288,412, issued March 22, 2022. It is a continuation-in-part of U.S. Patent Application No. 17 / 972,996, filed on October 25, 2022, which is a continuation-in-part of U.S. Patent Application No. 17 / 686,776, filed on March 4, 2022, now U.S. Patent No. 11,537,984, which issued on December 27, 2022, which is a continuation-in-part of U.S. Patent Application No. 17 / 484,885, filed on September 24, 2021, now U.S. Patent No. 11,537,984.

[0002] (Technical field) The present disclosure relates generally to systems, apparatus, and methods in the field of tracking items (e.g., objects, packages, equipment), and more specifically to various aspects involving systems, apparatus, and methods for improved asset identification and location services using an adaptive warehouse racking radio frequency identification inventory system. [Background technology]

[0003] Supply chain management is utilized to manage the storage and movement of goods (including raw materials, work in progress, and finished goods) from the point of origin to the point of purchase or consumption. Reasons for accurately accounting for goods in warehouses include tracking shipments from suppliers, reducing inventory for just-in-time manufacturing operations, reducing inventory shrink due to breakage and theft, managing claims against manufacturers, and verifying sales and other transfers of goods. With the continued growth of companies such as retail and warehousing operations for both online commerce and physical brick-and-mortar stores and their emphasis on efficiency, it becomes increasingly important to account and track actual inventory at each company location in real time. The ability to identify items and locate their location is a core competency for companies that use various forms of warehousing for product or parts inventory. Companies typically invest in creating and maintaining highly organized networks to track their items, e.g., packages, objects, etc., to reduce costs and improve operational efficiency.

[0004] Traditionally, this identification and tracking capability may be provided by a variety of known mechanisms and systems. Machine-readable bar codes are one way that organizations track items. In one example, to track inventory, operators typically scan or otherwise capture an image of the bar code on each item, so that a back-end portion of the operator's operations can track what is coming into and leaving their warehouse. Additionally, when an item is removed from the premises, the bar code for that item is scanned or captured to track inventory levels. However, bar codes have the disadvantage that personnel must manually scan each bar code on each item to effectively track the item.

[0005] Radio Frequency Identification (RFID) tags are another known mechanism for tracking items. In contrast to bar codes, RFID tags do not typically require manual scanning. RFID systems typically include an RFID reader and an RFID device, such as a tag or label. The RFID reader transmits a radio frequency ("RF") carrier signal to the RFID device. In operation, the RFID device may respond to the RF carrier signal (or interrogator signal) with a data response signal (or authentication return signal) encoded with information stored on the RFID device. Traditionally, RFID devices may store information, such as a unique identifier or electronic product code ("EPC"), associated with an article or item.

[0006] To address these requirements, a system is needed that can monitor data about objects and efficiently extend visibility of such objects. Thus, there remains a need for an improved system that provides more extensive and robust identification and tracking of items within a warehouse environment, and that can do so in a cost-effective manner. Summary of the Invention [Means for solving the problem]

[0007] Disclosed herein is a warehouse inventory management system and method of use that utilizes novel functionality to improve upon the state of the art. The system includes a global inventory database subsystem for inventorying a plurality of inventory items, each of the items being identified by at least a unique identification code, such as an Electronic Product Code (EPC), and a Radio Frequency Identification (RFID) interrogator subsystem, the RF interrogator subsystem operative to read an RFID tag associated with each of the plurality of inventory items, each of the RFID tags being programmed with at least a unique identification code for its associated item. The disclosed system and method provide improved single item identification / location, confirmation of shipment and receipt of multiple inventory items, and functionality for inventory operations utilizing multiple RFID interrogators that are mountable on a warehouse racking assembly. The warehouse inventory management system may also include a motion detection subsystem for detecting and identifying any inventory items moving from a first physical zone to a second physical zone. The disclosed system and method for simulating the operation of a warehouse inventory management system may be used to design and optimize the system.

[0008] In general, the disclosed method for maintaining inventory data in a warehouse inventory management system utilizes an RFID interrogator subsystem and includes the functionality of reading RFID tags associated with inventory items. In such an exemplary system, the RFID interrogator subsystem can be configured to receive at least one unique identification code for an item from a global inventory database subsystem, scan the RFID tags of the items contained in the physical location, and report to the inventory database subsystem whether an item associated with the global at least one unique identification code is present in the warehouse and the item's physical location. The RFID interrogator subsystem is further operable to receive a shipping notice (SN) from the global inventory database subsystem (the SN identifying multiple new inventory items to be received at the warehouse) and scan the RFID tags of all items contained within the shipment (whereby receipt of all expected items identified in the SN may be confirmed).

[0009] The RFID interrogator subsystem can be configured to selectively determine when all items in the warehouse have been scanned, and can be configured to transmit a report to the global inventory database subsystem identifying at least one of the presence or absence of each of the plurality of items at a physical location. The physical location can be, for example, the location of the item on a rack of a warehouse rack assembly. It is therefore envisioned that the report can cause the global inventory database subsystem to update the physical location of one of the plurality of items scanned by the RF interrogator subsystem. As one skilled in the art would understand, the global inventory database subsystem can maintain at least one attribute related to each of the plurality of inventory items.

[0010] The RFID interrogator subsystem may comprise a plurality of fixed RFID interrogators mounted on a portion of each rack located in the warehouse. As will be appreciated, it is envisioned that the warehouse will comprise a plurality of racks positioned in an array throughout the warehouse floor space. The location of each of the plurality of fixed RFID interrogators for each rack has a known geospatial relationship stored in the global inventory database subsystem. Thus, the global inventory database subsystem knows the relative position of each of the plurality of fixed RFID interrogators for each rack, and therefore also knows the relative position of each of the plurality of fixed RFID interrogators with respect to all racks located in the warehouse. Optionally, the plurality of RFID interrogators forming the RFID interrogator subsystem may include at least one handheld RFID interrogator, each operative to share data associated with the scanned item with the global inventory database subsystem.

[0011] Optionally, multiple RFID tags can be positioned on each respective rack within the warehouse. The rack-mounted RFID tags are not associated with inventory items, but rather are positioned on each respective rack within a known location array stored within the global inventory database subsystem. It is envisioned that the combination of the known location of each fixed RFID interrogator on each rack and the known location of each rack-mounted RFID tag on each rack will help positionally fix the geospatial location of the inventory items within the warehouse environment.

[0012] Optionally, the multiple RFID interrogators can be configured to share data associated with the scanned items, where it is envisioned that the data includes at least a unique identification code for each scanned item. Illustratively, the data associated with the scanned items can include the date and time of the scan event, such that a warehouse inventory management system can synchronize data associated with each inventory item received from different RFID interrogators. In some embodiments, data is shared in real-time between the RFID interrogators, and data can be shared between the RFID interrogators directly via wireless connections or indirectly via a global inventory database subsystem.

[0013] The warehouse inventory management system may further include a motion detection subsystem, such as, for example, an infrared sensor, a microwave sensor, an ultrasonic sensor, or a video camera sensor. In one aspect, it is contemplated that the motion detection subsystem may be mountable within at least one of the fixed RFID interrogators mounted on racks within the warehouse. In operation, the motion detection subsystem may be configured to detect movement within an area between the first physical zone and the second physical zone, and in response to detecting movement, enable the RFID interrogator subsystem to identify any inventory items moving from the first physical zone to the second physical zone, and report the identity of each identified inventory item to the global inventory database subsystem, whereby the global inventory database system may update the physical location of each item from the first physical zone to the second physical zone.

[0014] Optionally, it is envisioned that fixed RFID interrogators positioned within warehouse racks may be positioned such that their associated read zones, e.g., a first fixed RFID interrogator in a first rack and a second fixed RFID interrogator in a second neighboring rack, do not overlap. In this operational scenario, if the first fixed RFID interrogator reads the RFID tag of an item before the second fixed RFID interrogator, a movement of the item from a first physical zone proximate the first fixed RFID interrogator to a second physical zone proximate the second fixed RFID interrogator is indicated, and if the second fixed RFID interrogator reads the RFID tag of the item before the first fixed RFID interrogator, a movement of the item from the second physical zone to the first physical zone is indicated.

[0015] Optionally, an adaptive inventory control system for use in a material handling facility can include multiple bins, a global inventory control system, and an RFID interrogator subsystem, as described in detail herein. In this aspect, the multiple bins, such as the illustrated racks, can be configured to receive one or more of the multiple items, each of the multiple items being associated with a radio frequency identification (RFID) tag. In this aspect, each RFID tag is envisioned to store a unique identifier, as described herein.

[0016] In this aspect, the global inventory database subsystem has a processing system having at least one memory of the processing system configured to store program instructions. It is envisioned that the RFID interrogator subsystem includes a plurality of RFID interrogators, at least one of which may be mounted within a fixed geospatial location within the material handling equipment. Further, each of the RFID interrogators may be configured to read a unique identifier of an RFID tag associated with each of the plurality of items within a defined boundary of at least one scan zone generated by the respective RFID interrogator, and subsequently communicate to the processing system a unique identifier of each scanned RFID tag identified within each scan zone of the respective RFID interrogator.

[0017] Thus, in operation, at least one memory of the processing system can be configured to store program instructions that, when executed, selectively configure defined boundaries for each scanning zone for each RFID interrogator to provide a user desired level of fidelity and / or resolution for the generated unique identifiers of each scanned RFID tag within a defined space of the material handling equipment.

[0018] In an optional aspect, the defined boundaries for each scan zone for each RFID interrogator can be configured such that the boundaries of each RFID interrogator do not overlap, or alternatively or in combination, the defined boundaries for each scan zone for each RFID interrogator are user configurable such that at least a portion of the defined boundary of each RFID interrogator overlaps with at least an adjacent or selected RFID interrogator to define at least one overlapping scan zone. In this aspect, each overlapping scan zone and associated RFID identifier data therefrom are generated from RFID identifier data received from each scan of each scan zone of each selected RFID interrogator, and the RFID identifier data of each scanned RFID tag identified within the overlapping scan zone is communicated to a processing system.

[0019] It is further envisioned that in operation, the scan zones projected by each RFID interrogator may be selectively configured to provide a user desired level of fidelity and / or resolution through the use of one or more configurable program options to include at least one of: modifying the number of RFID interrogators to modify the number of scan zones projected by the RFID interrogators in the defined space of the material handling equipment; modifying the use of overlapping scan zones projected by the RFID interrogators in the defined space of the material handling equipment; modifying the use of signal strength or phase shift modality in each scan zone projected by the RFID interrogators in the defined space of the material handling equipment; modifying the use of steerable antenna technology in each RFID interrogator to generate multiple spaced apart scan zones emanating from each of the RFID interrogators in the defined space of the material handling equipment; or modifying the use of steerable antenna technology in the RFID interrogators in the defined space of the material handling equipment to generate multiple overlapping scan zones from each of the RFID interrogators.

[0020] Accordingly, as described herein, it is envisioned that a user's desired level of fidelity and / or resolution may be selectively increased through the use of one or more configurable program options to include at least one of increasing the number of RFID interrogators and increasing the number of scan zones projected by the RFID interrogators within the defined space of the material handling equipment; increasing the use of overlapping scan zones projected by the RFID interrogators within the defined space of the material handling equipment; increasing the use of signal strength or phase shift modalities within each scan zone projected by the RFID interrogators within the defined space of the material handling equipment; increasing the use of steerable antenna technology in each RFID interrogator and increasing the number of multiple spaced apart scan zones generated from each of the RFID interrogators within the defined space of the material handling equipment; or increasing the use of steerable antenna technology in the RFID interrogators within the defined space of the material handling equipment and increasing the number of multiple overlapping scan zones generated from each of the RFID interrogators.

[0021] Further aspects, embodiments, and advantages of these exemplary aspects and embodiments are discussed in detail below. Moreover, it should be understood that both the foregoing information and the following detailed description are merely illustrative examples of the various aspects and embodiments, and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed aspects and embodiments. Thus, these and other objects, together with the advantages and features of the invention disclosed herein, will become apparent through the following description and reference to the accompanying drawings. Moreover, it should be understood that the features of the various embodiments described herein are not mutually exclusive and may exist in various combinations and permutations. [Brief description of the drawings]

[0022] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, and together with the detailed description, illustrate embodiments of the present disclosure, and serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of the present disclosure in more detail than may be necessary for a basic understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced therein. In accordance with common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced in order to more clearly illustrate the embodiments of the present disclosure.

[0023] [Figure 1] FIG. 1 diagrammatically illustrates one example of a warehouse inventory control system.

[0024] [Diagram 2] FIG. 2 diagrammatically illustrates an example of an RFID interrogator subsystem and a global inventory database subsystem of a warehouse inventory control system.

[0025] [Diagram 3] FIG. 3 diagrammatically illustrates one example of a warehouse inventory control system, showing a number of conventional warehouse racks or H-racks positioned in an array on the floor of a facility or warehouse.

[0026] [Figure 4] FIG. 4 diagrammatically illustrates a first embodiment of a fixed RFID interrogator positioned within a conventional warehouse H-rack.

[0027] [Diagram 5] FIG. 5 is an expanded schematic diagram of the fixed RFID interrogator of FIG. 4 positioned within a conventional warehouse rack.

[0028] [Figure 6] FIG. 6 diagrammatically illustrates multiple fixed RFID interrogators of FIG. 4 positioned within a conventional warehouse H-rack.

[0029] [Figure 7] FIG. 7 diagrammatically illustrates a plurality of fixed RFID interrogators and a plurality of rack-mounted RFID tags of FIG. 6 positioned within a conventional warehouse rack.

[0030] [Figure 8] FIG. 8 diagrammatically illustrates a second exemplary embodiment of a fixed RFID interrogator positioned within a conventional warehouse H-rack.

[0031] [Figure 9] FIG. 9 is an expanded schematic diagram of the fixed RFID interrogator of FIG. 8 positioned within a conventional warehouse rack.

[0032] [Figure 10] FIG. 10 is an expanded schematic diagram of the fixed RFID interrogator of FIG. 9 positioned within a conventional warehouse rack, with a portion of the cover removed to reveal a portion of the antenna.

[0033] [Figure 11] FIG. 11 diagrammatically illustrates multiple fixed RFID interrogators of FIG. 8 positioned within a conventional warehouse H-rack.

[0034] [Figure 12] FIG. 12 diagrammatically illustrates the fixed RFID interrogators of FIG. 8 coupled in a daisy chain fashion and in communication with serially powered fixed RFID interrogators, showing a plurality of electrically coupled fixed RFID interrogators further electrically coupled to a source of mains and / or battery power.

[0035] [Figure 13] FIG. 13 diagrammatically illustrates one example of a fixed RFID interrogator.

[0036] [Figure 14]FIG. 14 illustrates an example warehouse floor plan.

[0037] [Figure 15] FIG. 15 illustrates an example scanning zone within the example warehouse of FIG.

[0038] [Figure 16] FIG. 16 illustrates four RFID interrogators mounted on a racking unit that would scan individual compartments or shelves in one embodiment.

[0039] [Figure 17] FIG. 17 illustrates the process flow in one embodiment.

[0040] [Figure 18] FIG. 18 illustrates an exemplary RFID interrogator (reader) / hub system.

[0041] [Figure 19] FIG. 19 illustrates the structure of a database system in one embodiment.

[0042] [Figure 20] FIG. 20 illustrates the process flow in one embodiment.

[0043] [Figure 21] FIG. 21 illustrates an example of a base system architecture with two zones, one hub, and four assets.

[0044] [Figure 22] FIG. 22 illustrates a process flow for the system of FIG. 21 in one embodiment.

[0045] [Figure 23] FIG. 23 illustrates an example of a base system schematic for an RFID interrogator in an embodiment.

[0046] [Figure 24] FIG. 24 illustrates an example of the basics of a low-to-high fidelity system in one embodiment.

[0047] [Diagram 25] FIG. 25 illustrates an example setup for a warehouse shelf with multiple RFID interrogators.

[0048] [Figure 26] FIG. 26 illustrates multiple zones that may be achieved through placement of RFID interrogators by varying the quantity of RFID interrogators, by varying the signal strength of each RFID interrogator, and / or by varying the azimuth orientation of the RFID interrogators.

[0049] [Figure 27] 27 and 28 illustrate one embodiment of a mobile RFID interrogator device mounted on an upper surface of a vehicle, such as an exemplary forklift, showing a housing that includes an operational side of the mobile RFID interrogator device operably coupled to multiple antennas configured or otherwise positioned to scan within different zones. As exemplary shown, the multiple antennas may comprise at least two separate pairs of antennas that may be positioned on either side of the vehicle and laterally relative to the axis of movement of the vehicle. [Figure 28] 27 and 28 illustrate one embodiment of a mobile RFID interrogator device mounted on an upper surface of a vehicle, such as an exemplary forklift, showing a housing that includes an operational side of the mobile RFID interrogator device operably coupled to multiple antennas configured or otherwise positioned to scan within different zones. As exemplary shown, the multiple antennas may comprise at least two separate pairs of antennas that may be positioned on either side of the vehicle and laterally relative to the axis of movement of the vehicle.

[0050] [Figure 29]29 and 30 diagrammatically illustrate side and top views of one of the antenna pairs of FIGS. 27 and 28, each of which comprises a first and a second antenna. The first antenna is positioned such that the first antenna is selectively angled with respect to the Earth's surface such that the azimuthal axis of operation of the first antenna has an orientation that faces upward, and the second antenna is positioned such that the second antenna is substantially transverse to the Earth's surface such that the azimuthal axis of operation of the second antenna is substantially horizontal. Exemplary scan zones for each of the first and second antennas about their respective azimuthal axes of operation ( FIG. 29 , side view) and exemplary scan zones relative to the axes of motion ( FIG. 30 , top view) are also shown. [Diagram 30] 29 and 30 diagrammatically illustrate side and top views of one of the antenna pairs of FIGS. 27 and 28, each of which comprises a first and a second antenna. The first antenna is positioned such that the first antenna is selectively angled with respect to the Earth's surface such that the azimuthal axis of operation of the first antenna has an orientation that faces upward, and the second antenna is positioned such that the second antenna is substantially transverse to the Earth's surface such that the azimuthal axis of operation of the second antenna is substantially horizontal. Exemplary scan zones for each of the first and second antennas about their respective azimuthal axes of operation ( FIG. 29 , side view) and exemplary scan zones relative to the axes of motion ( FIG. 30 , top view) are also shown.

[0051] [Diagram 31]31 and 32 illustrate one embodiment of a mobile RFID interrogator device configured to be mounted on a vehicle, such as the top surface of an exemplary forklift, showing a housing including an operational side of the mobile RFID interrogator device operably coupled to multiple antennas configured or otherwise positioned to scan within different zones. As exemplary illustrated, and further shown in FIG. 32 with the housing cover removed, the housing of the mobile RFID interrogator device defines opposing pairs of planar surfaces behind which multiple antennas are operably positioned within the housing. In this aspect, the multiple antennas comprise two separate pairs of antennas that may be operably positioned underlying respective opposing pairs of planar surfaces that may be transverse to an axis of movement of the vehicle. [Diagram 32] 31 and 32 illustrate one embodiment of a mobile RFID interrogator device configured to be mounted on a vehicle, such as the top surface of an exemplary forklift, showing a housing including an operational side of the mobile RFID interrogator device operably coupled to multiple antennas configured or otherwise positioned to scan within different zones. As exemplary illustrated, and further shown in FIG. 32 with the housing cover removed, the housing of the mobile RFID interrogator device defines opposing pairs of planar surfaces behind which multiple antennas are operably positioned within the housing. In this aspect, the multiple antennas comprise two separate pairs of antennas that may be operably positioned underlying respective opposing pairs of planar surfaces that may be transverse to an axis of movement of the vehicle.

[0052] [Diagram 33]Fig. 33 diagrammatically illustrates a front view of the housing of the mobile RFID interrogator device of Figs. 31 and 32 showing an exemplary pair of antennas, each of the antenna pairs comprising a first and a second antenna. In this side, the first antenna is positioned such that the first antenna is angled with respect to the Earth's surface, whereby the azimuthal axis of operation of the first antenna has an orientation facing upward, and the second antenna is positioned such that the second antenna is substantially transverse to the Earth's surface, whereby the azimuthal axis of operation of the second antenna is substantially horizontal. Exemplary side scan zones for each of the first and second antennas about their respective azimuthal axes of operation are also shown.

[0053] [Diagram 34] FIG. 34 diagrammatically illustrates a top view of the housing of the mobile RFID interrogator device of FIGS. 31 and 32 showing a top view of exemplary scanning zones for those about their respective azimuthal axes of operation of their respective first and second antennas.

[0054] [Diagram 35] 35 and 36 illustrate one embodiment of a mobile RFID interrogator device configured to be mounted on a vehicle, such as the top surface of an exemplary forklift, showing a housing including an operational side of the mobile RFID interrogator device operably coupled to a pair of antennas configured or otherwise positioned to scan within different zones. As exemplary shown, the housing of the mobile RFID interrogator device defines a surface behind which the pair of antennas are operably positioned. In this side, the pair of antennas are operably coupled together to selectively move each antenna through an angular sweep in a selected plane, which plane may be transverse to an axis of movement of the vehicle, such that the angular sweep provides selective rotation between an upwardly facing sweep limit and a downwardly facing sweep limit. [Diagram 36]35 and 36 illustrate one embodiment of a mobile RFID interrogator device configured to be mounted on a vehicle, such as the top surface of an exemplary forklift, showing a housing including an operational side of the mobile RFID interrogator device operably coupled to a pair of antennas configured or otherwise positioned to scan within different zones. As exemplary shown, the housing of the mobile RFID interrogator device defines a surface behind which the pair of antennas are operably positioned. In this side, the pair of antennas are operably coupled together to selectively move each antenna through an angular sweep in a selected plane, which plane may be transverse to an axis of movement of the vehicle, such that the angular sweep provides selective rotation between an upwardly facing sweep limit and a downwardly facing sweep limit.

[0055] [Figure 37] FIG. 37 diagrammatically illustrates a front partial perspective elevation view of the mobile RFID interrogator device of FIGS. 33 and 34.

[0056] [Figure 38] Fig. 38 diagrammatically illustrates a front view of the mobile RFID interrogator device of Figs. 35 and 36 (without housing) showing an exemplary pair of antennas comprising rotatably mounted first and second antennas. In this side, the first and second antennas are operatively coupled together such that each first and second antenna may sweep through a scan range that may be selected to extend between an upward position where each antenna is angled with respect to the earth's surface, whereby the antenna's azimuth axis of operation in the upward position has an orientation facing upward, and a downward position where each antenna is angled with respect to the earth's surface, whereby the antenna's azimuth axis of operation in the downward position has an orientation facing downward. Exemplary side scan zones for each first and second antenna through the angular sweep of the antenna in the selected plane are also shown.

[0057] [Figure 39]FIG. 39 diagrammatically illustrates a top view of the housing of the mobile RFID interrogator device of FIGS. 35 and 36 showing a top view of exemplary scanning zones for the respective first and second antennas about their respective azimuthal axes of operation.

[0058] [Diagram 40] 40 and 41 illustrate an embodiment of a mobile or optionally fixed RFID interrogator device that can be mounted on casters or optionally fixed within a geographic location showing an operational aspect of the mobile or fixed RFID interrogator device housing that is operably coupled to multiple antennas configured or otherwise positioned to scan within different zones. As exemplarily illustrated, the housing of the mobile RFID interrogator device defines an opposing pair of planar surfaces behind which multiple antennas are operably positioned within the housing. In this aspect, the multiple antennas comprise two separate pairs of antennas that can be operably positioned on respective opposing pairs of planar surfaces that can be lateral to the ground surface. [Diagram 41] 40 and 41 illustrate an embodiment of a mobile or optionally fixed RFID interrogator device that can be mounted on casters or optionally fixed within a geographic location showing an operational aspect of the mobile or fixed RFID interrogator device housing that is operably coupled to multiple antennas configured or otherwise positioned to scan within different zones. As exemplarily illustrated, the housing of the mobile RFID interrogator device defines an opposing pair of planar surfaces behind which multiple antennas are operably positioned within the housing. In this aspect, the multiple antennas comprise two separate pairs of antennas that can be operably positioned on respective opposing pairs of planar surfaces that can be lateral to the ground surface.

[0059] [Diagram 42]FIG. 42 diagrammatically illustrates a top view of the housing of FIGS. 40 and 41 showing the angular relationship of opposing pairs of planar surfaces, where each corner of a pair is a planar surface positioned in a plane that is approximately 70-120 degrees relative to one another behind which two separate pairs of antennas are positioned, respectively. In this exemplary aspect, each pair of antennas comprises a first and a second antenna. The first antennas are positioned such that each of the first antennas is angled relative to the planar surface such that an operational azimuth axis of the first antenna extends substantially parallel to the Earth's surface, and the second antennas are positioned such that each of the second antennas is angled relative to the planar surface such that an operational azimuth axis of the second antenna extends substantially parallel to the Earth's surface. In this aspect, the operational azimuth axis of the first antenna is positioned at an operational angle ranging from approximately 70-120 degrees relative to an operational azimuth axis of the second antenna. Exemplary scan zones for each of the first and second antennas of each pair of antennas about their respective azimuthal axes of operation are also shown. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0060] The present invention can be more readily understood by reference to the following detailed description, examples, drawings, and claims, as well as the preceding and following descriptions thereof. However, before the present device, system, and / or method are disclosed and described, it should be understood that the present invention is not limited to the specific device, system, and / or method disclosed, unless otherwise specified, and therefore may, of course, vary. It should also be understood that the terminology used herein is for the purpose of describing certain aspects only, and is not intended to be limiting.

[0061] The following description of the invention is provided as an enabling teaching of the invention in its best currently known embodiment. To this end, those skilled in the art will recognize and appreciate that many changes can be made to various aspects of the invention described herein and still obtain the beneficial results of the invention. It will also be apparent that some of the desired benefits of the invention can be obtained by selecting some of the features of the invention without utilizing other features. Thus, those skilled in the art will recognize that many modifications and adaptations to the invention are possible and even desirable in certain circumstances and are a part of the invention. Thus, the following description is provided as an illustration of the principles of the invention, and not as a limitation thereon.

[0062] As used throughout, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a "fixed RFID interrogator" can include two or more such fixed RFID interrogators unless the context dictates otherwise.

[0063] Ranges can be expressed herein as from "about" one particular value, and / or to "about" another particular value. When such a range is expressed, the other aspect includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms the other aspect. It will be further understood that each of the endpoints of a range is significant both in relation to the other endpoint, and independently of the other endpoint.

[0064] As used herein, the term "optional" or "optionally" means that the event or circumstance described subsequently may or may not occur, and that the description includes instances in which the event or circumstance occurs and instances in which it does not occur.

[0065] The word "or" as used herein means any one member of a particular list and also includes any combination of members of that list. Furthermore, it should be noted that conditional language such as "can," "could," "might," or "can," among others, is generally intended to convey that certain aspects include certain features, elements, and / or steps while other aspects do not, unless specifically stated otherwise or understood otherwise within the context as used. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are required in any manner for one or more particular aspects, or that one or more particular aspects necessarily include logic for determining whether those features, elements, and / or steps are to be included or implemented in any particular embodiment, with or without user input or prompting.

[0066] The phraseology and terminology used herein are for purposes of description and should not be regarded as limiting. As used herein, the term "plurality" refers to two or more items or components. The terms "comprising," "including," "carrying," "having," "containing," and "involving," whether in the written description or in the claims, are open-ended terms, i.e., mean "including but not limited to." Thus, use of such terms is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. The transitional phrases "consisting of" and "consisting essentially Only "consisting essentially of" is a closed or semi-closed transitional phrase, respectively, for any claim. The use of ordinal terms such as "first," "second," "third," etc. in the claims to modify claim elements does not, in itself, imply any priority, precedence, or order in which the method acts are performed within a claim element relative to another or the chronological order in which the method acts are performed therein, but is merely used as a marker to distinguish one claim element having a certain name from another element having the same name (except for the use of the ordinal terms) and to distinguish the claim elements.

[0067] Components that can be used to implement the disclosed methods and systems are disclosed. These and other components are disclosed herein, and when combinations, subsets, interactions, groups, etc. of these components are disclosed, it is understood that specific references to each of the various individual and collective combinations and permutations thereof may not be explicitly disclosed, but each is specifically contemplated and described herein with respect to all methods and systems. This applies to all aspects of this application, including, but not limited to, steps in the disclosed methods. Thus, if there are various additional steps that can be implemented, it is understood that each of these additional steps can be implemented with any specific embodiment or combination of embodiments of the disclosed methods.

[0068] The methods and systems may be more readily understood by reference to the following detailed description of the preferred embodiments and the examples contained therein, and to the figures and their preceding and following descriptions.

[0069] With respect to the adaptive inventory management system described herein, two definitions are established for the respective terms "fidelity" and "resolution". Fidelity as defined herein refers to the respective granularity and selective granularity regarding the results on the number and / or identification of RFID tags detected within a particular scanned zone or a particular defined space. In a warehouse inventory management system, "fidelity" answers the basic question of "RFID tagged items present within the scanned area", more specifically, "the number of items and the particular items present within the scanned zone or a defined space (according to the associated RFID tag)". Resolution as defined herein refers to the respective geospatial location and selective geospatial location of RFID tags detected within a particular scanned zone or a particular defined space. In a warehouse inventory management system, "resolution" answers the basic question of "the location of RFID tagged items physically located within the scanned area", more specifically, "the zone or defined space in which a particular item is physically located (according to the associated RFID tag)".

[0070] Radio Frequency Identification (RFID) systems utilize RFID reader / writer devices, also known as RFID interrogators, and RFID tags. Such systems can be used to locate and identify items to which the tags are attached, and tags are particularly useful in product-related industries to track inventory items through manufacturing, distribution, and sale. RFID tags can be affixed to individual products, their packaging, or containers for multiple products or packages.

[0071] RFID tags typically include an antenna section, a radio section, a power management section, and frequently, a non-volatile memory. Some RFID tags include an energy storage device, such as a battery. It is expected that RFID tags used within warehousing facilities will be conventionally constructed and thus will typically be passive tags that are powered only by the RF signals they receive and will not include an energy storage device (e.g., a battery).

[0072] Conventional RFID inventory control techniques utilize an RFID interrogator to inventory one or more items having RFID tags, inventorying involving at least singulating the tag and receiving a unique identifier from the tag. As used herein, "singulating" is defined as the RFID interrogator picking out one tag, potentially among multiple tags, and "identifier" is defined as a number that identifies the tag or the item to which the tag is attached, such as a tag identifier (TID) or electronic product code (EPC). Conventionally, an RFID interrogator can transmit modulated RF commands, receive tag replies, and, if desired, transmit an RF acknowledgement signal in response to the tag replies. A tag that senses an interrogating RF wave responds by sending back another RF wave, and the tag either generates a transmitted RF wave or reflects back a portion of the interrogating RF wave in a process known as backscattering. The reflected RF wave can encode data stored within the tag, such as an EPC. For example, the response can be decoded by an RFID interrogator to thereby identify, count, or otherwise interact with the associated item. In one aspect, the decoded data can indicate the geospatial location, or other desired attribute or status, of the item to which the RFID tag is attached. Systems and methods described hereinafter utilize such data to improve the operation and use of a warehouse inventory control system.

[0073] In various embodiments, a warehouse inventory management system for a warehouse has a plurality of racks positioned in an array on the warehouse floor. The warehouse inventory management system has a global inventory database subsystem for inventorying a plurality of inventory items, each item identified by at least a unique identification code and a physical location within the warehouse, and a radio frequency identification (RFID) interrogator subsystem operative to read an RFID tag associated with each of the plurality of inventory items. The RFID interrogator system includes a plurality of fixed RFID interrogators mounted on a portion of each rack within the warehouse, the RFID interrogators configured to communicate at least location and identification data to the global inventory database subsystem for determination of geospatial locations of the inventory items within the warehouse.

[0074] 1-3, an exemplary warehouse inventory control system is shown that includes an RFID interrogator subsystem 10 for use in a warehouse and a global inventory database subsystem 20. As one skilled in the art would understand, the global inventory database subsystem 20 (alternatively referred to herein as a "server") can be local or remote, and the remote location can be dedicated or cloud-based.

[0075] The RFID interrogator subsystem 10 can include a plurality of fixed RFID interrogators 12. Each fixed RFID interrogator has an interface to the global inventory database subsystem 20, and the interface for the fixed RFID interrogators can be configured to be wired, wireless, or at least partially wireless (e.g., to a local router, a Wi-Fi router). As will be described more fully hereinafter, it is also envisioned that the RFID interrogators can also include a direct wireless connection for sharing certain data. Such a connection can be, for example, a Bluetooth® wireless connection. In operation, the RFID interrogators are configured to selectively interact with RFID tags included on the items (note that it is envisioned that RFID tags can be associated on individual items, on boxes of items, etc.). Optionally, individual items or boxes of items with RFID tags can also be within a container with their own respective RFID tags. Optionally, the plurality of fixed RFID interrogators can include at least one handheld RFID interrogator, each operative to share data associated with scanned items with the global inventory database subsystem.

[0076] As shown in FIG. 2, the global inventory database subsystem 20 can include a processing system having at least one processor 22 and at least one memory 23, which can be coupled to a non-volatile memory including a database 24 for inventorying information related to a plurality of inventory items, the memory including instructions that, when executed by the processor, operate to perform the essential, recommended and / or optional functions of various embodiments of the global inventory database subsystem described herein.

[0077] As illustrated in Figures 4-6 and 8-12, the exemplary RFID interrogator subsystem 10 may include a plurality of fixed RFID interrogators 12 mounted on a portion of each rack 40 located within the warehouse. The exemplary rack 40 includes a conventional H-rack as illustrated, but is not intended to be limited to such an H-rack. Rather, any conventional geospatial fixed location rack 40 may be utilized in this warehouse inventory management system. As will be appreciated, it is envisioned that the warehouse will include a plurality of racks positioned in an array throughout the warehouse floor space, as illustrated in Figure 3. The geospatial location of each of the plurality of fixed RFID interrogators 12 for each rack has a known geospatial relationship stored within the global inventory database subsystem 20. Thus, the global inventory database subsystem knows the relative position of each of the plurality of fixed RFID interrogators 12 for each rack 40, and therefore also knows the relative position of each of the plurality of fixed RFID interrogators 12 for all racks 40 located within the warehouse. The exemplary RFID interrogator subsystem 10 may further include at least one hub configured to act as a network node, the hub configured to relay information from each individual fixed RFID interrogator device 12 to and from the global inventory database subsystem 20. In one exemplary aspect, the fixed RFID interrogator devices 12 may wirelessly communicate with the hub, which may then communicate to the global inventory database subsystem 20 by either Ethernet, Wi-Fi, cellular, etc.

[0078] It is envisioned that each fixed RFID interrogator device 12 (e.g., the RFID interrogator device shown in FIG. 13) of the RFID interrogator subsystem 10 may individually have a processing system having at least one processor 14 and at least one memory 16, a baseband circuit 17 with a transmitter TX and a receiver RX, and an RF circuit 15 with a circulator, which are coupled to an antenna 18 for interacting with an RFID tag affixed to an item, box, or container. Optionally, the antenna 18 may be configured to be replaceable or replaceable to enable operator-selected scanning zones for each fixed RFID interrogator device 12. It is further envisioned that the memory 16 may include instructions, which when executed by the processor 14, operate to perform the essential and optional functions of the RFID interrogator 12 described herein.

[0079] Optionally, each fixed RFID interrogator device 12 can be configured to further include circuitry or components, such as a phase shifter, configured to modify the inductance of antenna 18, thereby causing the phase of the electromagnetic field emitted by antenna 18 to vary across the length of antenna 18. Because the strength of an RFID signal emitted by an RFID tag in the presence of an electromagnetic field typically depends on the strength of the electromagnetic field, varying the phase of the electromagnetic field at various time intervals (e.g., by up to ninety degrees (90°) or one hundred and eighty degrees (180°) of phase angle in either direction across the length of antenna 18 at predetermined intervals) increases the likelihood that an RFID signal of sufficient strength will be transmitted by an RFID tag held by each of the items positioned on respective racks in the warehouse within a predefined range of antenna 18, regardless of where the RFID tag is located.

[0080] For example, shifting the phase of the rectified standing wave of the electromagnetic field back and forth relative to the length of the antenna 18 can cause the peak and minimum amplitude points (e.g., peaks and valleys) of the rectified standing wave to move along the length of the antenna 18, ensuring that the points where the strength of the electromagnetic field is at a minimum, e.g., the minimum amplitude points of the rectified standing wave, never remain on a rack in the same geographic location for a long duration, ensuring that all RFID tags located on respective racks in a warehouse within a predefined range of the antenna 18 experience a sufficiently strong electromagnetic field, thereby emitting an RFID signal. Thus, if the strength of the RFID signal transmitted by an RFID tag to the antenna 18 remains above a threshold or limit for a predetermined period of time, it can be determined that an item bearing an RFID tag is located on a rack provided within a predefined range of the antenna 18. Varying the phase of the electromagnetic field can also allow a user-selectable level of fidelity and / or resolution for an item bearing an RFID tag on a support bar or arm to be determined or predicted based on the strength of the RFID signal received from the RFID tag.

[0081] Optionally, each fixed RFID interrogator device 12 can be configured to further include circuitry or components, such as an antenna azimuth shifter, configured to change the relative scanned angular orientation or azimuth of the antenna 18, thereby causing the electromagnetic field emitted by the antenna 18 to propagate along a changed azimuth axis of the antenna. Varying the azimuth of the electromagnetic field may also allow a user-selectable level of fidelity and / or resolution for an item bearing an RFID tag on a support bar or arm to be determined or predicted based on the RFID signal received from the RFID tag from the use of repeated azimuth readings received from a single RFID interrogator.

[0082] In various aspects, each fixed RFID interrogator device 12 of the RFID interrogator subsystem 10 can further include a frame configured to support an antenna 18 and an associated processing system. Such a frame can be housed within a durable plastic housing 19 for protection and RF transparency. Additionally, as illustrated in FIGS. 4-6, each fixed RFID interrogator can further include a rail system 50 coupled to the frame and configured to selectively couple to deerdrop openings present in opposing vertical risers of a conventional industrial rack system, for example. As will be appreciated, it is envisioned that the rail system can be secured to a conventional rack via mechanical connections that would fit various brands of racks and their openings. Additionally, different length arms or adjustable arms for different depth racking or systems can be mounted to one vertical riser of a conventional industrial rack system, as shown in FIGS. 8-12.

[0083] In an optional aspect not shown herein, the fixed RFID interrogator devices 12 can be mounted under the wire decking of a conventional rack system to allow for a "look up" or "look down" orientation of the interrogator antenna 18. For example, in this aspect, the fixed RFID interrogator devices 12 can be mounted under the wire decking in spaced apart spaces defined between the cross beams of the rack such that the mounted fixed RFID interrogator devices 12 do not interfere with stored inventory.

[0084] It is envisioned that each fixed RFID interrogator device 12 can be configured to operate from battery power or optional standard wall outlet power, which allows for the possibility of use of the system in remote locations where standard power is not available. As will be appreciated, the battery-operated RFID interrogator devices make power down unnecessary, and the envisioned use of Wi-Fi, Bluetooth, and cellular technologies eliminates cable runs, which allows for simple installation and reconfiguration of the system. In one optional aspect shown in FIG. 12, multiple fixed RFID interrogators mounted on one vertical riser of a conventional industrial rack can be electrically coupled in a daisy-chain fashion to allow for serial communication of power to the mounted fixed RFID interrogators. As further exemplary shown, the multiple electrically coupled fixed RFID interrogators can be further configured to be electrically coupled to a source of mains and / or battery power.

[0085] Optionally, it is envisioned that the warehouse inventory management system may further include a plurality of RFID tags positioned on each respective rack within the warehouse, as shown in Figure 7. The rack-mounted RFID tags are not intended to be associated with respective inventory items, but rather are positioned on each of the respective racks in a known location array stored within the global inventory database subsystem. It is envisioned that the combination of the known location of each fixed RFID interrogator on each rack and the known location of each rack-mounted RFID tag on each rack will help to positionally fix and / or increase the fidelity of the geospatial location of inventory items within the warehouse environment.

[0086] In a warehouse (also called a "distribution center"), an inventory control system must perform many functions, including receiving, delivery audits, sorting processes, pack audits, and shipment confirmation. Upon receiving a shipment, an RFID interrogator reads the RFID tag on each container or the RFID tag of each item in a container to be checked against an Advanced Shipping Notice ("SN"), and any discrepancies between what was received and the SN can be reported to the inventory control system.

[0087] As explained above, the Global Inventory Database Subsystem 20 inventories all inventory items in the warehouse and generates a SN, which identifies one or more items (each by a unique identification code). The RFID Interrogator Subsystem 10 is then used to scan the RFID tags of items contained within the warehouse or a desired selected portion of the warehouse. Following scanning of the items, a report is sent to the Global Inventory Database System, which may identify the items identified / counted and the physical location of each item within the warehouse.

[0088] In various aspects, the fixed RFID interrogators can share data associated with scanned items, either directly or indirectly. The direct wireless connection can be, for example, a Bluetooth® wireless connection. Alternatively, or in addition, each fixed RFID interrogator can share data indirectly through the global inventory database subsystem 20 by real-time reporting of each scanned item, which can then be pushed to or pulled by another fixed RFID interrogator. The shared data includes at least a unique identification code for each scanned item and geospatial location data associated with each scanned item, including the date and time of the scan event, so that the warehouse inventory management system can synchronize data associated with each inventory item received from different fixed RFID interrogators. For example, the global inventory database subsystem 20 should maintain at least the immediate location along with the date and time, and in some embodiments, maintaining a record of data from all scan events can be useful for inventory control or determining reasons for discrepancies. Those skilled in the art will appreciate that maintaining a time-based record of scanned items can be used to generate a history of the items' movement through the warehouse, which can be used to handle inventory bottlenecks, identify spoilage or perishable inventory, alert operators to stolen items, etc.

[0089] The warehouse inventory management system 10 may further include a motion detection subsystem (e.g., an infrared sensor, a microwave sensor, an ultrasonic sensor, or a video camera sensor, etc.) in communication with the global inventory database subsystem 20. In one aspect, it is contemplated that the motion detection subsystem may be mountable within at least one of the fixed RFID interrogators mounted on racks within the warehouse. Optionally, the motion detection subsystem may be mountable as desired within the warehouse space (e.g., proximate a door entrance, etc.). In operation, the motion detection subsystem may be configured to detect movement within an area between a first physical zone and a second physical zone; in response to detecting the movement, enable the RFID interrogator subsystem to identify inventory items moving from the first physical zone to the second physical zone; and report the identity of each identified inventory item to the global inventory database subsystem, whereby the global inventory database system may update the physical location of each item from the first physical zone to the second physical zone. As used herein, "enabled" or "enabling" means either activating an RFID interrogator subsystem (generally, if deactivated) or enabling an RFID tag to be interrogated (generally, if activated). Once activated or otherwise enabled to interrogate RFID tags, the RFID interrogator subsystem identifies inventory items moving from a first physical zone to a second physical zone, and the identification of such items is then reported to the Global Inventory Database Subsystem, which can then update the location of each inventory item moved between physical zones.

[0090] As will be described, the global inventory database subsystem 20 can be configured to activate scanning or prevent scanning depending on need and / or events triggered by the motion detection subsystem. In various examples, and not meant to be limiting, motion detected at a back door proximate to a motion detection sensor can trigger a scan for theft, or general movement within the warehouse sensed by the motion detection subsystem may suggest that items are being moved.

[0091] It is also envisioned that the global inventory database subsystem 20 may be configured to use timers to trigger scans, to push commands from a user, or other such combinations.

[0092] It is envisioned that, optionally, fixed RFID interrogators 12 positioned within warehouse racks may be positioned such that their associated read zones do not overlap, e.g., such that the read zone of a first fixed RFID interrogator in a first rack does not overlap with the read zone of a second fixed RFID interrogator in a second neighboring rack. In this operational scenario, movement of an item from a first physical zone in proximity to a first fixed RFID interrogator to a second physical zone in proximity to a second fixed RFID interrogator is indicated if the first fixed RFID interrogator reads the item's RFID tag before the second fixed RFID interrogator, and movement from the second physical zone to the first physical zone is indicated if the second fixed RFID interrogator reads the item's RFID tag before the first fixed RFID interrogator.

[0093] Still further, it is envisioned that, optionally, fixed RFID interrogators 12 positioned within a warehouse rack may be positioned such that their associated read zones intentionally overlap, e.g., multiple fixed RFID interrogators are configured to have overlapping read zones. In this example, if an item is self-marked in all three of the overlapping read zones, the item will be within a very precise geospatial region. However, if the item is self-marked in only two of the three overlapping read zones, the item will be within a different, but specific, geospatial region, and if the item is self-marked in only one of the three overlapping read zones, the item will be within yet another different, but specific, geospatial region.

[0094] The exemplary warehouse inventory control system can be configured to accommodate multiple types of businesses. As will be appreciated, every business has slightly different needs and prospects, and the warehouse inventory control system is configured to be adaptable to accommodate the needs and prospects of each business as they change over time.

[0095] An exemplary methodology for configuring a warehouse inventory control system to meet user requirements may include the initial step of completing a site assessment. At this stage, the user may identify the expected performance of the warehouse inventory control system and consider at least one of business, technical, IT, facilities, and HR factors. This site assessment step may involve the development of a customer installation plan that may identify critical factors, describe installation requirements, and / or provide a material bill for ordering hardware.

[0096] In the site assessment step, it is desirable to identify details of the items the business desires to be tagged and tracked. In one non-limiting example, knowing at least one of the quantity, density, migration rate, physical composition, and environmental context of the intended tracked items can aid in determining the appropriate RDID tags to affix to the items.

[0097] Further, in the site assessment step, it is desirable to identify the intended monitored spaces. Identifying the intended monitored spaces allows for the determination of the physical and radio frequency (RF) characteristics of the spaces to be monitored (to include determining potential RF interference so that background noise levels that may interfere with RF technology scanning may be identified) in addition to at least one user-defined zone within each space. In this aspect, a zone is a location that the warehouse inventory control system will report as a location for an item. As will be appreciated, the number and size of the various zones can determine the amount of RFID interrogators 12 and hubs that will be required to build a warehouse inventory control system and meet the operational needs of each business.

[0098] In this on-site assessment step, the warehouse inventory control system may also determine users and their profiles. The warehouse inventory control system may be configured to allow controlled access to data, which may be set up with authorization roles for different users, which allows different users to have different visibility / access within the warehouse inventory control system 10.

[0099] In a subsequent installation step, the required hardware, i.e., devices and systems supporting the exemplary RFID interrogator subsystem 10 and the global inventory database subsystem 20, are installed at the facility location according to the customer installation plan. For example, fixed RFID interrogator devices 12 and hubs can be positioned at the desired location along with the facility with the intent of having the exemplary RFID interrogator subsystem 10 present low visibility and minimal impact. This can allow for mitigation of damage to system components and help eliminate potential equipment interference with the normal functioning of the business.

[0100] Further, in the installation step, the exemplary RFID interrogator subsystem 10 and the global inventory database subsystem 20 are configured and the hardware is brought online. All of the fixed RFID interrogator devices 12 and hubs are configured and operationally tested. In one non-limiting aspect, it is envisioned that the exemplary warehouse inventory control system will be a browser-based application, and thus the warehouse inventory control system will not require device level installation.

[0101] In a subsequent user configuration step, a client or site can be created in the warehouse inventory control system and then subsequent users can be created to provide access to the data. In this user configuration step, it is assumed that the user logs into the warehouse inventory control system, identifies the product / item / asset category, and the warehouse inventory control system automatically provides a naming template (which may be user customizable). In operation, the user provides the necessary information, inputs the template, and once the data entry is complete and verified for accuracy, the warehouse inventory control system will generate an Electronic Product Code (EPC) and associate all data entries with this EPC in a secure database. It is further assumed that the printer can then be used to print an RF-enabled tag with the EPC coded into its internal circuitry. It is further assumed that, optionally, additional human-readable item information (optional barcode) can be printed on the sign. Conventional RF printers can not only print ink-based data onto RF-enabled tags for users to read, but can also overwrite RF-enabled tags with custom data.

[0102] In the tracking substep of the user configuration step, the user applies an indicator to an item, and then when the indicatored item is positioned within at least one of the warehouse inventory control system zones and a scan is initiated, the warehouse inventory control system will report back the item's location and timestamp. In various exemplary aspects, indicators can be integrated into containers, pouches, etc., and can be reused and re-coded, and active tags can be used by the warehouse inventory control system depending on the range and tracking resolution required.

[0103] Optionally, in a system functionality step, scanning zones can be created or otherwise configured to distinguish between ambient and cold storage. Illustratively, RFID interrogator devices 12 can be installed above and / or to the sides of entry / exit points to track items entering or exiting the building / facility. Optionally, RFID interrogator devices 12 can be motion or event activated. It is further envisioned that the warehouse inventory management system can be configured to enable administration of scans based on a recurring or otherwise identified timeline or schedule.

[0104] In a further optional aspect, in a system functionality step, scan zones can be generated by the exemplary RFID interrogator subsystem 10 and the global inventory database subsystem 20. As described herein, it is envisioned that the scan zones can be configured to be user customizable. For example, scan zones can be generated or otherwise configured for a desired fidelity and / or resolution through the use of one or more configurable options to include at least one of the following: increasing / decreasing the number of RFID interrogator devices 12 within a defined warehouse space; increasing / decreasing the use of multiple scan zones and / or multiple overlapping scan zones; increasing / decreasing the use of signal strength or phase shift modalities within each scan zone; and / or increasing / decreasing the use of steerable antenna technology within the RFID interrogator devices 12 to generate multiple scan zones from each of the RFID interrogator devices 12.

[0105] As explained above, it is envisioned that the resolution and fidelity of the warehouse inventory control system may be modified and / or upgraded as desired by the user. The addition of additional RFID interrogator devices 12 and / or the use of overlapping zones (which allow for sensing of items by more than one RFID interrogator device 12 within a user-configured warehouse inventory control system) can allow for user-entered increases in the fidelity and / or resolution of a particular identified item.

[0106] In one additional optional aspect, it is envisioned that a user may modify the configuration settings of the system to achieve a desired degree of fidelity and / or resolution for a given warehouse space and a given fixed number of RFID interrogator devices 12.

[0107] In one aspect, the warehouse inventory management system, and more specifically, the global inventory database subsystem 20, includes a system operating process ("SOP") 25, described in detail below using both intended and optional systems. Various system and process embodiments of the SOP 25 using various combinations of the features described above and below are considered within the scope of the present disclosure.

[0108] The intent of SOP 25 in the Global Inventory Database Subsystem 20 is to provide a means to track, locate, aggregate, and communicate inventory, assets, or objects within some defined space. There are many intended users for such a process 25, and SOP 25 provides a user-selectable and customizable solution as a company's warehouse supplies require changes over time.

[0109] The SOP process, in one embodiment, begins with defining the area or site that needs to be monitored. In one exemplary case, the area or site may be a warehouse. However, the area or site may also be a barn, lumber yard, airport, retail space, manufacturing facility, laboratory, hospital, truck, etc. This definition step typically involves generating a map or floor plan of the space. Figure 14 shows an exemplary warehouse floor plan.

[0110] As shown, the warehouse 60 illustratively has a racking unit 62, an assembly room 64, and a building exit 66. The next step is to divide the site into zones. A zone is a location or area within a site that can be named and identified. The zones and locations within the zones can be as granular as needed. If the user's need is to provide very precise locations, more zones will be created, optionally, as described herein. Zones can also overlap, if needed, to eliminate dead spots or increase the desired level of fidelity and / or resolution of the system. In the illustrated example, the warehouse 60 has several warehouse storage racking units 62, with multiple shelves on each rack, the warehouse 60 has an exit 66, and has an assembly room 54, all of which need to be zoned.

[0111] 15 illustrates exemplary intended zones 70 (shown as dashed lines) defined for locations and fixtures within warehouse 60. At this point, in one embodiment process, the zones can be named with user friendly names or anything meaningful to the user, and this information is loaded into the global inventory database subsystem 20 software application.

[0112] As shown by way of example, the warehouse space has a zone 70 or multiple zones 70 for each racking unit 52, an entrance to an assembly room 64, an assembly room 64 with two overlapping zones 70, and an exit 66 with an interior and exterior zone 70. Having a zone 70 at the entrance allows for monitoring of items entering and exiting through the entrance doorway. In this aspect, having two zones 70 at the entrance can be used to monitor the direction of travel of an RFID-identified object (e.g., did the item leave the warehouse or enter the warehouse?). This is a simplified exemplary aspect, but the system can be selectively configured to be much more granular in its analysis to provide higher resolution and / or fidelity, as desired. For example, each racking unit can have several shelves (each with an individual zone 70), zones 70 with multiple resolvable locations within the zone 70, or more than one zone 70 per shelf. The zones can also be somewhat defined in size and shape by antenna power and design, with lower power equivalent to smaller zones. Additionally, RF blocking can be selectively utilized to terminate particular zones 70. By configuring each overlap zone 70, if an item appears in more than one zone, the location must be within the overlap area shared by the overlap zones, so that the location itself can be defined as a zone or a location within a zone, in some embodiments, with higher fidelity and resolution.

[0113] The next process step is to install the RFID interrogator devices 12 so that the intended zone 70 may be scanned. It is envisioned that the zone 70 may consist of multiple RFID interrogator devices 12 to achieve the appropriate degree of fidelity and / or resolution where product density is high or where the nature of the warehouse and materials involved in the scanning is challenging. It is further envisioned that the zone 70 may consist of one or more RFID interrogator devices 12, with each RFID interrogator device 12 configured to scan at least one zone or at least a portion of two or more zones (for a user to configure the global inventory database subsystem 20 for a desired resolution and / or fidelity of the system output to the user).

[0114] In one non-limiting example, Figure 16 shows four RFID interrogator devices 12 mounted on a racking unit that may be configured to scan individual bays or shelves. However, it is also envisioned that the RFID interrogator devices 12 may be mounted and provided in many form factors (drones or ROVs (remotely operated vehicles), wall or ceiling mounted lighting fixtures, railroad cars or railcars, etc.).

[0115] Figure 16 illustrates an example arrangement 72 of four RFID interrogators 12 (see also Figure 6) as readers in fixed locations. As already explained, increasing or decreasing the number of four RFID interrogators 12 can be used to change the desired resolution and / or fidelity of the system in combination with other optional processes described herein.

[0116] The next step in the process is to identify the items or assets to be tracked and "tag" them. Assets can be many things which will define the required level of tagging at each time. In the exemplary warehouse, each box of goods gets a unique tag. The tags are RFID transponders which can be of many form factors and types. Some are for tagging metal objects, some are for implantation in animals, some are inexpensive paper tags while some are rugged ones designed to withstand extreme environments. The tags are encoded with a unique identifier called an EPC (Electronic Product Code). However, the tags can also be programmed with a user specific code if required. The tags are then printed or programmed and registered within the Global Inventory Database Subsystem 20 software application. They can also have a barcode or other user data on the tag if required. The Global Inventory Database Subsystem 20 software application can also pull from other ERP (Enterprise Resource Planning) or accounting / inventory management software. For example, when a user purchases an item through their accounting software, a tag can be automatically generated and integrated into the Venatrust software application. Within the application software database, the tag is registered and the EPC code on the tag is similarly tied to a user friendly name. For example, a particular EPC (not user friendly) can be tied or associated in the database with "red jackets" (user friendly). In this way, users can see how many "red jackets" they have, as opposed to a list of arbitrary EPCs. Figure 17 shows the general process flow.

[0117] FIG. 17 illustrates an example process flow involving zones, RFID tags, and RFID interrogators 12, which in various embodiments are suitable for use in the field and involve a system as described herein. Action 74 is zone creation, where various zones are identified and RFID interrogators are installed to define the zones (and possibly locations within the zones). Action 76 is tag registration, where ERP data 78 and user-generated data 80 are associated with the RFID tags and involves appropriate entry of information into database 82 (e.g., through a database system). Action 86 is tag application to products, where each RFID tag is associated with a corresponding product (e.g., an item of inventory to be tracked by the system), for example, by attaching the RFID tag to the product, product packaging, or container holding the product. Action 88 is product placement in zones, where products with RFID tags applied in action 86 are placed within the various zones created in action 74.

[0118] In action 92, where the tag is scanned by a reader, the RFID interrogator 12 scans the RFID tag and the system reports the scan information and a determination of the RFID tag's location according to zone and possibly location within the zone to the database 82. Action 92 is repeated with occurrences of action 90 as the product moves around the site, whereby the product location and product movement as determined by the system are represented in records in the database 82 with appropriate fidelity and resolution (which may be flexible and vary with location, physical setup, system and / or user defined parameters, etc.). Action 84, where data is communicated to a user, involves access to the database 82 and may be implemented through various communication protocols and with various system analyses as appropriate to the particular implementation.

[0119] The next aspect of the process is the hub. The hub is a device that communicates locally with the array of readers. The RFID interrogators 12 are designed to communicate through either a wired or wireless connection to the hub, which then communicates to the database and application software. Methods of communication from the reader / hub include wired cable, Wi-Fi, Xbee / Zigbee, Bluetooth, and similar data stream connectivity methods. The hubs act as the link to the traffic controller and the database and application software. They are also responsible for issuing scan commands to their respective arrays when a command is triggered from the system. A complete system can consist of many readers and hubs, all linked to a specific customer or site, or even multiple customer sites. The hub can consist of an array of communication options including Xbee / Zigbee, Wi-Fi, cellular modem, BLE, LoRa, LAN router, etc. The hub also includes an SBC (single board computer) and an HMI (human machine interface). An on-board computer and touch screen allows for configuration and diagnostics of the system. It can monitor reader and battery health, connectivity, and other related functions. Figure 18 shows an exemplary schematic of an RFID interrogator / hub system.

[0120] In FIG. 18, tags 94 (i.e., RFID tags) are shown in various zones adjacent to readers 96 (i.e., RFID interrogators). The RFID interrogators 12 are connected to a power supply 95 for power, and they communicate to a hub 97. The dashed lines indicate wired or wireless communication from the readers 96 to the hub 97. In this example, the tags 94 are outside of the scan zones 93 and therefore would be "missing" from the system. This could indicate an item that was misplaced, lost, vandalized, sold, or stolen. Tags 94 in overlapping zones 93 would have higher location resolution and product resolution because they would appear to be in multiple zones 93 at once.

[0121] The hub 97 communicates to the database and server through various means. This could be a wired or Wi-Fi connection to a local network, a cellular connection to the cloud, or other means of system connectivity. The hub 97 is also registered within the software application with an identifier to aid in diagnostic and location functions.

[0122] One further aspect to the system is, in one embodiment, the server, database, and application software. The database can reside in the cloud or locally at the user's site, for example, in cloud or network data storage 98. The user can access the database through user interface software 99. In one embodiment, the database stores all relevant data, historical and current, including EPC, name, timestamp, zone location, etc. (see also database embodiment in FIG. 17). FIG. 19 illustrates the structure of one such database system, with the subsystems shown. For end users to communicate and view the data, the UI can be through a web browser or mobile / desktop applications. Alternative and additional database systems may also be suitable.

[0123] FIG. 19 illustrates a schematic diagram of a database system called Vespy, which forms part of the global inventory database subsystem 20. The various components of the Vespy database system can be implemented in software (e.g., running on a processing device), hardware, firmware, and various combinations thereof, in various embodiments. In the Vespy database system, a user can access the database system through, for example, but not limited to, a web browser 108, a user interface Vespy-UI 101, etc. In one embodiment, Vespy-UI 101 is a reactive single-page application that provides user interaction, configuration, and display. Vespy-UI 101 allows for adjustment of reader overlap (zones), scanning frequency, and display of current information regarding the status of inventory assets.

[0124] Vespy-Central 102, an aspect of the Vespy database system, provides information to the UI (e.g., for queries) and handles configuration commands. Vespy-Central 102 processes multiple asset events from Vespy-IoT 103 and translates machine level data through algorithms that provide user tailored location information at the area (zone) or detailed location (e.g., from RFID reader / interrogator rssi and / or RFID sensing overlap) level, providing intelligent information for humans. Vespy-Central 102 handles configuration for monitoring volume and frequency.

[0125] Vespy-IoT 103, an aspect of the Vespy database system, converts bulk machine data from devices in the field into useful events (e.g. frex:tags change zones). Vespy-Central 103 performs filtering of repetitive scan information, reducing the usage of downstream components.

[0126] An additional aspect of the Vespy database system, the VenaEventStore 104, stores a continuous stream of all events from update sources. The VenaEventStore 104 allows the system to detect the status of a tag at any point during system operation. The VenaEventStore 104 allows evaluation of a tag's complete life cycle over the duration of the tag's journey through the system. The historical trace of tag movement can be replayed at any point for forensic purposes. The VenaEventStore 104 allows the processing of a large number of events without collisions.

[0127] Azure Storage (Field Images) 105, an aspect of the Vespy database system, provides the storage solution for user field images.

[0128] Active Directory 106, an aspect of the Vespy database system, provides industry standard identity management.

[0129] An aspect of the Vespy database system, the IoT Event Hub 107, is the focal point for device events. The system is configured to leverage the Azure IoT Event Hub 107 to process incoming device messages at scale.

[0130] In the Vespy database system, a web browser 108 provides users with access to the database system. In various embodiments, users can access the application as a web app.

[0131] An aspect of the Vespy database system is the IoT hub 109, which is an Azure device registry for communication.

[0132] FIG. 20 illustrates an SOP process flow within an application, including events, command issuance, and queries. The various components illustrated in the process flow are implemented in software, hardware, firmware, and combinations thereof, in various embodiments. Commands and queries are issued by external services 122, including Vena Chassis. Commands proceed through command gateway 124, which may have a queue, command sorter, command combiner, or other command front-end handling, to command dispatcher 132, which may have one or more command handlers (e.g., two command handlers are shown). Queries proceed through query gateway 126, which may have a queue, query sorter, query combiner, or other query front-end handling, to query executor 134, which may have one or more query handlers (e.g., two query handlers are shown).

[0133] The event bus 130 passes domain events from the command dispatcher 132 to the appropriate component, e.g., an RFID interrogator, which also sends the domain events to the event store 128, e.g., a database. Events are also passed from the event bus 130 to the event dispatcher 140, which has one or more event receivers (e.g., two event receivers are shown), a synchronization entity, and a projector. The synchronization entity sends applications to an entity 136, e.g., a database called Mongo (which may mean large amounts of memory). The projector sends projections to a projection 138, e.g., another database also called Mongo (e.g., large amounts of memory). The entity 136 provides queries to a query executor 134.

[0134] The software application closes the loop and communicates to the user the current status and health of the systems and assets as a result of the scan, as well as historical data from the system. It can also communicate back to an ERP or POS (point of sale) system. For example, if items are sold and they are scanned exiting the front door, they can be removed from the system. Stolen, lost, or misplaced items can also be reported and then reconciled. If a user wants to locate a specific asset in the field, this can be accomplished with spontaneous scanning for a specific item by name or EPC. Historical data can also be reported for tracking and analysis. For example, in a manufacturing facility, bottlenecks can be identified with historical data that shows that an asset tagged as "Raw Material Cart A" was scanned entering the "Assembly Room" zone at a particular time and then scanned exiting it at a subsequent time. With user levels and access permissions, different tasks and reporting can be assigned to different personnel in the facility. Using a map generated at the start of the process, the software application can visually show assets, asset quantities, their progress history through their respective locations or zones, time spent at a location, last seen location and time, etc. The application software is intended to be customizable to account for specific customer needs.

[0135] FIG. 21 shows an exemplary schematic of a system architecture having two zones 70, referred to as Zone "A" and Zone "B", one hub 97, referred to as Hub "A", and four assets 150, referred to as Asset 1, Asset 2, Asset 3, and Asset 4. A reader 96, referred to as Reader "A", monitors the zone 70, referred to as Zone "A", and scans the assets 150, referred to as Asset 1 and Asset 2. A reader 96, referred to as Reader "B", monitors the zone 70, referred to as Zone "B", and scans the assets 150, referred to as Asset 3 and Asset 4. The reader 96 communicates through the hub 97, referred to as Hub "A", with a server 152, which communicates with a database 154 and a tag printer 156. The server 152 also runs ERP / POS software 158 and application software 160, and generates custom reports 164 according to user permissions 162.

[0136] FIG. 22 illustrates one of many possible process flows for the system of FIG. 21 (or variations thereof) based on the need for loss prevention of high-value assets. For system setup, there are actions of zone creation 174: for example, identification of zones, installation of RFID readers or interrogators, and system parameter association of the RFID interrogators with the zone and possibly a location within the zone, tag registration 176, asset tagging 178, and asset installation 180 within the zone. Zone scanning 172 is initiated by a scan trigger 170 in response to a timer, user trigger, motion sensor, or other trigger, and may determine asset movement 182. Zone scanning 172 performs an action 184 of sending data to a server.

[0137] In response to the data being sent to the server at send data to server action 184, flow proceeds to decision action 186. At decision action 186, the system determines if the tag is showing up in the scan. If the tag is not showing up in the scan, the system generates an alert 188 to alert the user of the missing asset along with a timestamp. If the tag is showing up in the scan, flow proceeds to decision action 190. At decision action 190, the system determines if the tag is showing up in the "correct" zone. If the tag is not showing up in the correct zone, the system generates an alert 192 to alert the user that the asset is in a "wrong" or unexpected zone. If the tag is showing up in the correct zone, the system generates an alert 194 to alert the user of the current location and timestamp of the RFID identification tag / object.

[0138] The RFID interrogator, as exemplarily shown in one embodiment in Figure 23, may include at least the following: a microcontroller 200 that runs firmware and is configurable or otherwise capable of handling local commands and GPIO; a reader IC 208 that operates an RFID antenna 214 and transmits and receives RFID signals; an RFID antenna 214 that transmits and receives RF energy to and from an RFID tag; sensors and triggers (such as a motion sensor 212 and / or other triggers) that may provide feedback to the microcontroller 200 to trigger a scan or to report a state or condition; in addition to the motion sensor 212, other sensors 210 may include temperature, humidity, door sensors, shock, inertia, vibration, etc.; Xbee 206, WIFI 204, and other wireless communication 202 modules and methods. This may be one or more of many methods used in tandem or as redundancy programs to send / receive data to the hub and antenna 214 as required for their respective communication protocols.

[0139] As will be appreciated, the system can be configured to handle a wide range of tag densities through user adjustment of the system's respective fidelity / resolution level. In one aspect, greater fidelity to the granularity of the number of RFID tags of items that can be detected at a location can be determined through the ability to detect multiple RFID tags at a location (e.g., by multiple RFID interrogators 12, each capable of detecting multiple RFID tags). To provide an example of the end of such an environment, one may consider an area of ​​5 feet by 5 feet by 10 feet, i.e., 250 feet. 3 In one scenario, there may be only one tagged container in the shelf. At the other extreme, there may be four containers, each containing 100 tagged shirts. 3 From one tag per 250 feet 3 Variations up to 400 tags per second are possible for such fidelity. In higher density tag environments, the system may optionally involve one or more RFID interrogators 12 penetrating the target space from different angles. This provides a higher degree of resolution and / or fidelity of the target space being scanned. This is also useful for assets such as liquids and metal objects that are RF unfriendly. Figure 24 shows one illustrative example of a low to high fidelity system.

[0140] 24 depicts a low fidelity warehouse shelf 220 with an arrangement of RFID interrogators 12 appropriate for targeted fidelity, and a high fidelity warehouse shelf 222. The low fidelity warehouse shelf 220 has two readers 96, referred to as Reader A and Reader B, in an arrangement suitable for detecting one tagged container 224. The high fidelity warehouse shelf 222 has eight readers 96, referred to as Reader A, Reader B, Reader C, Reader D, Reader E, Reader F, Reader G, and Reader H, in an arrangement suitable for detecting four groups of 100 tagged assets each, with appropriate fidelity and resolution.

[0141] In the case of resolution, the system can be user customized to provide a desired level of fidelity and / or resolution for each tag geospatial location. In one aspect, lower resolution of an item's RFID tag may be based on a single RFID interrogator detecting an RFID tag at a location, and higher resolution of an item's RFID tag's physical location may be based on multiple RFID interrogators detecting the same RFID tag in determining the tag's physical location (e.g., RFID interrogators with overlapping sensing areas). For example, a user may determine that a tag is within an exemplary 250 ft. 3 A shelf may only require knowing if a tag is on a shelf. Thus, the shelf is a single zone with multiple RFID interrogators in the system software (e.g., parameter associations of zone, resolution, and RFID interrogators). The system only needs to identify that a tag is somewhere on the shelf. However, if a user has changes needs and they require much higher resolution, the system can be modified to meet their needs (e.g., changing the parameter associations of zone, resolution, and RFID interrogators, and / or changing the physical placement of the readers).

[0142] In one aspect, system customization, as described herein, provides multiple paths to meet evolving user needs without the need to add additional RFID interrogators after the initial installation in the warehouse space. With a system toolbox approach, there are many tools to employ to meet those needs. It is the combination and tuning of these tools that allows the system to perform optimally.

[0143] One such tool is envisioned to be RFID interrogator placement. RFID interrogators can be placed logically within the environment or site such that they do not interfere with the normal functioning of the user and such that they will likely not be moved or damaged. RFID interrogators can also be positioned within the warehouse space in such a way that all space intended to be covered is covered and therefore there are no dead spots.

[0144] Another such tool is scan management. Scan management refers to how and when the system triggers a scan. This can be as simple as a timer set in the system software, or even user-triggered scanning. If the user requires that certain zones be scanned more frequently than others, the user can set the system to implement various automatic scan routines. Optionally, the user can trigger a spontaneous scan if the user needs to identify whether a particular RFID-tagged asset is currently located. Optionally, it is envisioned that other scan triggers can be sensor-based. For example, if the need identified for a particular zone is loss prevention, the RFID interrogator can be triggered as a result of input received from an integrated motion sensor and a door trigger. In this exemplary aspect, the system would trigger whenever someone enters the area or opens the door. Thus, for this solution, it would not be necessary to have the scanner active all the time, since one or both of the actions that would trigger a scan of the area for any asset exiting a particular area would be identified.

[0145] Zone definitions can provide another user-configurable aspect of the system. In operation, a user has the ability to customize the scanning zones and RFID interrogator relationships in the software (e.g., system and / or user defined parameters) to represent a space as one or more zones, even though it may have a fixed or variable number of RFID interrogators. In the example described above, a warehouse shelf is set up as one zone, but in reality may have eight readers all scanning the desired identified space from different angles, thereby effectively creating eight read sub-zones in this example, as shown in FIG.

[0146] In this example warehouse shelf 230 in FIG. 25, eight readers 96, called Reader A, Reader B, Reader C, Reader D, Reader E, Reader F, Reader G, and Reader H, scan the shelf, but the user can then customize how this works and reports within the system software. For example, this zone may be named "Shelf 1." All of the readers 96 would report the current tag as residing within "Shelf 1," and thus the system would report 400 individual assets within "Shelf 1." This is an example of higher fidelity rather than lower resolution. Once the user resolution / fidelity requires a change and the need shifts to knowing "where individual tags are located within Shelf 1." In one aspect, the system can be configured to subdivide the location "Shelf 1" into sub-locations. As will be appreciated, the system allows for user-defined creation of highly complex sub-zones that allow the system to identify, with a high degree of resolution.

[0147] In FIG. 26 below, a schematic diagram of three readers 96 and the multiple zones 232 that can be achieved can be seen. If an RFID tag appears on more than one reader 96 (RFID interrogator 12) as determined by the overlap of the respective zones, the system can provide a high degree of resolution or asset location. Zone definitions are practically an infinite combination of zone / subzone groupings and definitions. By defining the zones 232 with user-friendly names or locations within the software, the system has the ability to report the location of a particular asset within a very small space. Generally, there is a practical limit to the system's compatible spatial resolution. More readers may mean higher resolution, so a streamlined system that can locate an asset within one cubic foot would likely solve the needs of most users.

[0148] Another optional system process that is useful in monitoring / configuring the desired resolution is the use of RSSI (Received Signal Strength Indicator). RSSI is a value placed on the return signal from the tag that represents the strength of the signal. In various embodiments, the RFID interrogator or processing device determines the RSSI while reading the RFID tag. The RSSI value can be used by the system to determine the distance from the scanning antenna RFID interrogator to the RFID tag. There are many factors that can affect the RSSI, but once the system is set up and establishes a range of RSSI values, monitoring the RSSI value can be a useful tool for approximate ranging in the system. In this aspect, when an RFID tag is scanned and responds to the RFID interrogator, not only is the EPC code or ID sent to the server, but the RSSI and timestamp are tied to the data record.

[0149] Optionally, the system and process can provide the user with the ability to configure RF blockers to create barriers to RF scanning, thus defining a customizable definitive end of one zone and / or the beginning of another. For example, RF blockers can be installed on warehouse racking systems or on walls to prevent the scanner from detecting tags in other areas that are not intended to be read.

[0150] In a further optional aspect, the system and process can configure the scanning power and scanning duration of each RFID interrogator 12. The system and process can provide user-customized adjustable settings from within the software system that can help define the fidelity and / or resolution of the system. It is envisioned that each individual RFID interrogator 12 has its own adjustable value. For example, but not limited to, the higher the output power, the longer the range of interrogation signal strength generated and / or the stronger the strength. Similarly, the longer the scanning cycle of the interrogation signal generated, the more chances there are to pick up all RFID tags within a defined scanning space. It is further envisioned that the system and process can provide user-selectable time frames for the application of higher power signals and interrogations, i.e., the application of higher power signals and interrogations can be limited to time frames and / or zones where, for example, personnel are not currently present.

[0151] In another optional aspect, the system and process can provide system site mapping, which is a visual tool that allows a user to understand the various data outputs of the system in a graphical display. It is envisioned that such system site applications in the software system would be customizable to floor plans, sites, or areas within the scannable space. For example, colors and graphical elements can be used to display and report tag locations, quantities, asset progress history, last seen location, etc.

[0152] As already explained, the RFID tags themselves can form another customizable aspect of the systems and processes. Traditionally, RFID tags can be provided as extremely small packages or large robust units. Some RFID tags are active, transmit over long distances, and can also transmit sensor data such as temperature or humidity. Some RFID tags can be configured to be used with metal assets, and some RFID tags are configured to be embedded. RFID tag variability gives the system more flexibility and the ability to meet and customize the system to fit specific fidelity and / or resolution needs.

[0153] In yet further optional aspects, the systems and processes contemplate the use of at least one RFID interrogator having at least one antenna or multiple antennas, the antennas being configurable for movement about the azimuthal axis of the RFID interrogator. Optionally, it is also contemplated that each of multiple RFID interrogators in a system setup may have at least one antenna or multiple antennas that are configurable for movement about the azimuthal axis of the respective RFID interrogator.

[0154] In this exemplary aspect, the use of movable antennas in the RFID interrogators allows for additional customizable increases / decreases in selecting system fidelity and / or resolution. Through the use of antennas that can be moved via motorized actuators such as servo motors or stepper motors, the antennas in each RFID interrogator can be directed to a specific and predefined space along a varying and selected signal generation azimuth angle. By knowing parameters such as azimuth angle, rotation angle, etc., the system can effectively increase the number of zones in a given defined space being interrogated (e.g., each "azimuth zone" interrogated along a selected azimuth angle defines a single zone within which multiple tags are potentially identified, and it is envisioned that as incremental movements of the RFID interrogator antenna move through a user-selected azimuth angle range, the respective azimuth zones, such as adjacent azimuth zones, will overlap to some degree, such degree being user definable). Thus, the system's fidelity and / or resolution can be further defined to a desired level of granularity.

[0155] As explained above, as the antenna of an RFID interrogator scans, the signal emission axis of each RFID interrogator moves relative to the fixed space being interrogated. As an RFID tag appears and then disappears through the scanning process, that particular RFID tag may be assumed to be within that angle of movement. In one additional optional aspect, by correlating the RSSI data in memory, it may be assumed that when the RSSI is strongest, the angle or azimuth of the antenna should be pointing directly at the RFID tag.

[0156] As already mentioned, it is envisioned that similar results can be achieved by using multiple antennas in a single RFID interrogator. In this aspect, depending on the settings, the system and process can record the azimuth direction of each antenna in the single RFID interrogator. The microcontroller can then selectively switch between the internal antennas and signal to the system as to the respective azimuth angle of the RFID tag relative to each selected antenna of the RFID interrogator based on which antenna is "active" when the tag appears. When multiple RFID interrogators scan the RFID tag, each with a common azimuth angle, tag fidelity and / or resolution can be predicted and reported to the user.

[0157] A further feature for a customized system is, in some embodiments, the antenna type and form factor. RFID interrogators and their respective antennas can be packaged in various forms for different environments or applications. Antenna designs offer different dispersion cones, ranges, and penetration parameters. Some antennas are designed to be longer and narrower dispersed, while others are the opposite. Antennas can also have motorized poles or planes, giving the user a software controlled method to vary the antenna design. In other words, by modifying the structure of the antenna, the tuning can be changed. This can in turn modify the range and dispersion cone of the scan / read zone of the particular RFID interrogator used in the system.

[0158] As described in detail herein, an adaptive inventory control system for use in a material handling facility can include a plurality of bins, a global inventory control system, and an RFID interrogator subsystem. In this aspect, the plurality of bins, such as the illustrated racks, can be configured to receive one or more of a plurality of items, each of which is associated with a radio frequency identification (RFID) tag. In this aspect, each RFID tag is envisioned to store a unique identifier, as described herein.

[0159] In this aspect, the global inventory database subsystem has a processing system having at least one memory of the processing system configured to store program instructions. It is envisioned that the RFID interrogator subsystem includes a plurality of RFID interrogators, at least one of which may be mounted within a fixed geospatial location within the material handling equipment. Further, each of the RFID interrogators may be configured to read a unique identifier of an RFID tag associated with each of the plurality of items within a defined boundary of at least one scan zone generated by the respective RFID interrogator, and thereafter communicate to the processing system a unique identifier of each scanned RFID tag identified within each scan zone of the respective RFID interrogator.

[0160] Thus, in operation, at least one memory of the processing system is configured to store program instructions that, when executed, cause defined boundaries for each scanning zone for each RFID interrogator to be selectively configured to provide a user desired level of fidelity and / or resolution for the generated unique identifiers of each scanned RFID tag within a defined space of the material handling equipment.

[0161] In an optional aspect, the defined boundaries for each scan zone for each RFID interrogator can be configured such that the boundaries of each RFID interrogator do not overlap, or alternatively or in combination, the defined boundaries for each scan zone for each RFID interrogator are user configurable such that at least a portion of the defined boundary of each RFID interrogator overlaps with at least an adjacent or otherwise selected RFID interrogator such that at least one overlapping scan zone is defined. In this aspect, each overlapping scan zone and associated RFID identifier data therefrom are generated from RFID identifier data received from each scan of each scan zone of each selected RFID interrogator, and the RFID identifier data of each scanned RFID tag identified within the overlapping scan zone is communicated to a processing system.

[0162] It is further envisioned that, in operation, the scan zones projected by each RFID interrogator may be selectively configured to provide a user desired level of fidelity and / or resolution through the use of one or more configurable program options to include at least one of the following: modifying the number of RFID interrogators and modifying the number of scan zones projected by RFID interrogators within the defined space of the material handling equipment; modifying the use of overlapping scan zones projected by RFID interrogators within the defined space of the material handling equipment; modifying the use of signal strength or phase shift modality within each scan zone projected by RFID interrogators within the defined space of the material handling equipment; modifying the use of steerable antenna technology in each RFID interrogator to generate multiple spaced apart scan zones emanating from each of the RFID interrogators within the defined space of the material handling equipment; or modifying the use of steerable antenna technology in RFID interrogators within the defined space of the material handling equipment to generate multiple overlapping scan zones from each of the RFID interrogators.

[0163] Thus, a user's desired level of fidelity and / or resolution can be selectively increased through the use of one or more configurable program options to include at least one of the following: increasing the number of RFID interrogators and increasing the number of scan zones projected by the RFID interrogators within the defined space of the material handling equipment; increasing the use of overlapping scan zones projected by the RFID interrogators within the defined space of the material handling equipment; increasing the use of signal strength or phase shift modality within each scan zone projected by the RFID interrogators within the defined space of the material handling equipment; increasing the use of steerable antenna technology in each RFID interrogator and increasing the number of multiple spaced apart scan zones generated from each of the RFID interrogators within the defined space of the material handling equipment; or increasing the use of steerable antenna technology in the RFID interrogators within the defined space of the material handling equipment and increasing the number of multiple overlapping scan zones generated from each of the RFID interrogators.

[0164] It is further envisioned that a user's desired level of fidelity and / or resolution may be selectively reduced through the use of one or more configurable program options to include at least one of the following: reducing the number of RFID interrogators and reducing the number of scan zones projected by the RFID interrogators within the defined space of the material handling equipment; reducing the use of overlapping scan zones projected by the RFID interrogators within the defined space of the material handling equipment; reducing the use of signal strength or phase shift modalities within each scan zone projected by the RFID interrogators within the defined space of the material handling equipment; reducing the use of steerable antenna technology in each RFID interrogator and reducing the number of multiple spaced apart scan zones generated from each of the RFID interrogators within the defined space of the material handling equipment; or reducing the use of steerable antenna technology in the RFID interrogators within the defined space of the material handling equipment and reducing the number of multiple overlapping scan zones generated from each of the RFID interrogators.

[0165] It is contemplated that optionally, the geospatial location of each of the plurality of bins may be stored within at least one memory of the processing system. Optionally, the geospatial location of at least one of the RFID interrogators mounted within a fixed geospatial location within the material handling equipment may be stored within at least one memory of the processing system.

[0166] In a further aspect, at least one of the RFID interrogators can be a mobile RFID interrogator that can be configured to be operated or otherwise controlled by the RFID interrogator subsystem and / or a mobile agent of the material handling equipment. In this aspect, with respect to systems in which zones or scan areas are created by installing a plurality of geospatially fixed RFID interrogators within a defined volume of the material handling equipment, it may be desirable to selectively increase a user desired level of fidelity and / or resolution by introducing mobile RFID interrogators into user selectable locations within the material handling equipment. It will be appreciated that adding one or more mobile RFID interrogators within a material handling equipment, thereby within a user selected location within a zone or scanning area of ​​at least one of a plurality of geospatially fixed RFID interrogators, will increase a user's desired level of fidelity and / or resolution through one or more of the following: an increased number of RFID interrogators to increase the number of scanning zones projected by the (fixed and mobile) RFID interrogators within the defined space of the material handling equipment in which the mobile RFID interrogators are introduced; increased use of overlapping scanning zones projected by the (fixed and mobile) RFID interrogators within the defined space of the material handling equipment in which the mobile RFID interrogators are introduced; and / or increased use of signal strength or phase shift modality within each scanning zone projected by the (fixed and mobile) RFID interrogators within the defined space of the material handling equipment in which the mobile RFID interrogators are introduced.

[0167] The mobile RFID interrogator device can be configured to be handheld or otherwise moved to an operator-desired defined space of the material handling equipment in which the mobile RFID interrogator is installed.

[0168] Optionally, the mobile RFID interrogator devices may comprise self-powered robotic devices configured to move freely around the material handling equipment. In a further optional aspect, as described in more detail below, the mobile RFID interrogator devices may be operably mounted on an upper surface of a vehicle, such as an illustrated forklift, for movement around the material handling equipment. In these aspects, it is contemplated that each mobile RFID interrogator device may be configured to operably communicate with at least one of the RFID interrogator subsystem 10 and / or the global inventory database subsystem 20 such that the mobile RFID interrogator device may be moved or otherwise positioned as desired within a selected location within the material handling equipment. Once positioned at a desired location, the geospatial location of the mobile RFID interrogator may be communicated to the RFID interrogator subsystem 10. Additionally, the RFID interrogator subsystem 10 may be used to instruct the mobile RFID interrogator device to perform an interrogation process within a particular scan zone or follow other interrogation methods and processes described herein.

[0169] The RFID interrogator subsystem 10 can use any form of communication to instruct the mobile RFID interrogator device. In one aspect, the RFID interrogator subsystem 10 and the mobile RFID interrogator device are configured to communicate using wireless technology, such as a wireless local area network (WLAN). As one optional exemplary aspect, some embodiments of the mobile RFID interrogator devices can communicate with the RFID interrogator subsystem 10 and / or each other using Wi-Fi (IEEE 802.11), Bluetooth (IEEE 802.15), Infrared Data Communications Association standard, or any other suitable wireless communication protocol.

[0170] It is envisioned that each mobile RFID interrogator device of the RFID interrogator subsystem 10 may individually have a processing system having at least one processor 14 and at least one memory 16; a baseband circuit 17 with a transmitter TX and a receiver RX; and an RF circuit 15 with a circulator coupled to at least one antenna 18 for interacting with an RFID tag affixed to an item, box, or container. Optionally, the antenna 18 may be replaceable or replaceable and configured to enable operator-selected scanning zones for each mobile RFID interrogator device. It is further envisioned that the memory 16 may include instructions which, when executed by the processor 14, operate to perform the essential and optional functions of the mobile RFID interrogator described herein.

[0171] Optionally, each mobile RFID interrogator device can be further configured to include circuitry or components, e.g., a phase shifter, configured to modify the inductance of antenna 18, thereby varying the phase of the electromagnetic field emitted by antenna 18 over its length. Because the strength of an RFID signal emitted by an RFID tag in the presence of an electromagnetic field typically depends on the strength of the electromagnetic field, varying the phase of the electromagnetic field at various time intervals (e.g., by up to ninety degrees (90°) or one hundred and eighty degrees (180°) of phase angle in either direction over the length of antenna 18 at predetermined intervals) increases the likelihood that an RFID signal of sufficient strength will be transmitted by an RFID tag held by each of the items positioned on the respective racks in the warehouse within a predefined range of antenna 18, regardless of where the RFID tag is located.

[0172] Optionally, each mobile RFID interrogator device can be further configured to include circuitry or components, e.g., an antenna azimuth shifter, configured to change the relative scanned angular orientation or azimuth of the antenna 18, thereby causing the electromagnetic field emitted by the antenna 18 to propagate along a changed azimuth axis of the antenna. Varying the azimuth angle of the electromagnetic field may also allow a user-selectable level of fidelity and / or resolution for an item bearing an RFID tag on a support bar or arm to be determined or predicted based on the RFID signal received from the RFID tag from the use of repeated azimuth readings received from a single RFID interrogator.

[0173] In various aspects, each mobile RFID interrogator device 12 of the RFID interrogator subsystem 10 may further include a housing configured to support the antenna 18 and associated processing system. Such a frame may be housed within a durable plastic housing for protection and RF transparency. Additionally, each mobile RFID interrogator may optionally further comprise means for operatively moving the housing to a desired location within the facility.

[0174] In one exemplary aspect, the self-powered robotic mobile RFID interrogator device can include at least one drive wheel mounted to the housing. In this aspect, the at least one drive wheel would be in communication with a power source, such as, for example, but not limited to, an electric motor and a coupled battery. Optionally, the self-powered robotic mobile RFID interrogator device can also include at least one stabilizer wheel. In a further optional aspect, the self-powered robotic mobile RFID interrogator device can be configured to move along a track, rail, cable, or other inductive element that traverses the material handling equipment. In such an aspect, the self-powered robotic mobile RFID interrogator device can receive power through a connection to an inductive element, such as a powered rail.

[0175] It is envisioned that each fixed and mobile interrogator device 12 may be configured to operate from battery power. As will be appreciated, a battery-operated mobile RFID interrogator device would make power down unnecessary, and the envisioned use of Wi-Fi, Bluetooth, and cellular technologies would allow for simple installation and reconfiguration of the system.

[0176] In an exemplary scenario, the mobile RFID interrogator device 12 may be mounted on a vehicle, such as the illustrated forklift (powered via connection to the vehicle's battery or electrical system), or designed or configured as a mobile lightweight backpack unit worn by a user. In these exemplary aspects, the mobile RFID interrogator device may include multiple antennas 18 facing a desired direction or orientation, one or more reader modules, a method for wirelessly communicating to a cloud or software system, and a rechargeable battery pack. Each mobile RFID interrogator device may be configured to communicate with a specific RFID transponder ("tag") that is geospatially fixed within each scanning zone and registered as a "location" tag in at least one of the RFID interrogator subsystem 10 and / or global inventory database subsystem 20.

[0177] 27 and 28, an exemplary mobile RFID interrogator device is shown mounted to a surface of a vehicle, such as the illustrated top surface of a forklift (powered via communication to the vehicle's battery or electrical system, or optionally by an internal battery). In this example, the mobile RFID interrogator device 12 includes multiple antennas 18 that may be configured or otherwise positioned to scan in different zones. As illustratively shown, the multiple antennas may comprise at least two separate pairs of antennas 180 that may be positioned on either side of the vehicle, transverse to the axis of vehicle movement.

[0178] Optionally, with reference to FIG. 28, each of the antenna pairs 180 can further comprise first and second spaced apart antennas as exemplarily illustrated. Now with reference to FIGS. 30 and 31, the first antenna 182 can be positioned such that the first antenna is selectively angled relative to the Earth's surface, whereby the operational azimuth axis of the first antenna has an upwardly facing orientation. Further, in this exemplary aspect, the second antenna 184 can be positioned such that the second antenna is transverse to the Earth's surface, whereby the operational azimuth axis of the second antenna is substantially horizontal. In a further optional aspect, each of the antenna pairs 180 can be further configured to include circuitry or components (e.g., antenna azimuth shifters) configured to change the relative scanned angular orientation or azimuth of the antennas 18, thereby propagating the electromagnetic field emitted by the antennas 18 along the changed azimuth axis of the antennas. For example, referring to Figures 29 and 30, exemplary zones for each of the first and second antennas about their respective azimuthal axes of operation (Figure 29, side view) and exemplary zones relative to the axes of motion (Figure 30, top view) are illustrated.

[0179] 31 and 32, an alternative embodiment of a mobile RFID interrogator device is configured to be mounted on a vehicle (powered via communication to the vehicle's battery or electrical system, or optionally by an internal battery), such as the top surface of a forklift as illustrated. In this example, the mobile RFID interrogator device has a housing that includes the operational aspects of the mobile RFID interrogator device, and the mobile RFID interrogator device is operably coupled to a number of antennas 180 configured or positioned to scan within different zones. As illustratively illustrated, and further shown in FIG. 32 with the housing cover removed, the housing of the mobile RFID interrogator device defines a pair of opposing planar surfaces 190, and the multiple antennas 180 are operably positioned within the housing behind the planar surfaces 190. In this aspect, the plurality of antennas 180 comprises two separate pairs of antennas 180', 180" that may be operatively positioned on respective opposing pairs of planar surfaces that may be transverse to an axis of motion of the vehicle.

[0180] Each of the antenna pairs 180 can further comprise first and second spaced apart antennas. Now referring to FIGS. 32-34, in one aspect, the first antenna 182 is positioned such that the first antenna is angled relative to the Earth's surface such that the operational azimuth axis of the first antenna has an upward facing orientation, and the second antenna 184 is positioned such that the second antenna is transverse to the Earth's surface such that the operational azimuth axis of the second antenna is substantially horizontal. In a further optional aspect, each of the antenna pairs 180 can be further configured to include circuitry or components (e.g., antenna azimuth shifters) configured to change the relative scanned angular orientation or azimuth of the antennas 18, thereby causing the electromagnetic field emitted by the antennas 18 to propagate along the changed azimuth axis of the antennas.

[0181] For purposes of illustration, Figure 33 diagrammatically illustrates exemplary side scan zones for the respective first and second antennas about their respective azimuthal axes of operation. Similarly, Figure 34 diagrammatically illustrates a top view of the housing of the mobile RFID interrogator device of Figures 31 and 32 showing a top view of exemplary scan zones for the respective first and second antennas about their respective azimuthal axes of operation.

[0182] 35 and 36, an alternative embodiment of a mobile RFID interrogator device 12 is configured to be mounted on a vehicle (powered via communication to the vehicle's battery or electrical system, or optionally by an internal battery), such as the top surface of a forklift as illustrated. In this example, the mobile RFID interrogator device 12 has a housing including an operational side of the mobile RFID interrogator device operably coupled to a pair of antennas 180 configured or otherwise positioned to scan within different zones. As illustrated exemplarily, the housing of the mobile RFID interrogator device defines a surface behind which the pair of antennas are operably positioned. In this aspect, the pair of antennas are operably coupled together to selectively move each antenna through an angular sweep in a selected plane, which may be transverse to both axes of movement, whereby the angular sweep provides selective rotation between an upwardly facing sweep limit and a downwardly facing sweep limit.

[0183] Figures 35 and 36 diagrammatically illustrate the mobile RFID interrogator device of Figure 33 showing an exemplary pair of antennas 180, with rotatably mounted first and second antennas. In this aspect, the first antenna 182 and the second antenna 184 are operatively coupled together such that the respective first and second antennas may sweep through a scan range angle that may be selected to span between an upward position where each antenna is angled with respect to the earth's surface such that the antenna's operational azimuth axis in the upward position has an orientation that faces upward, and a downward position where each antenna is angled with respect to the earth's surface such that the antenna's operational azimuth axis in the downward position has an orientation that faces downward. In a further optional aspect, each of the pair of antennas 180 can be configured to further include circuitry or components (e.g., antenna azimuth shifters) configured to change the relative scanned angular orientation or azimuth of the antennas 18, thereby causing the electromagnetic fields emitted by the antennas 18 to propagate along the changed azimuth axes of the antennas.

[0184] For purposes of illustration, Figure 37 diagrammatically illustrates exemplary scan zones for the respective first and second antennas about their respective azimuthal axes of operation. Similarly, Figure 38 diagrammatically illustrates a top view of the housing of the mobile RFID interrogator device of Figures 35 and 36 showing a top view of exemplary scan zones for the respective first and second antennas about their respective azimuthal axes of operation.

[0185] In this aspect, it is contemplated that each of the first and second antennas 182, 184 may be configured to be selectively moved through a scan range angle in a selected plane such that the angular sweep may provide selective rotation between an upwardly facing sweep limit and a downwardly facing sweep limit. In various aspects, it is contemplated that the rate of sweep angle and the amount of angular sweep of the respective first and second antennas may be selectively selected by an operator.

[0186] 37, in this aspect, the housing defines an interior cavity through which a post 200 extends substantially vertically. The post further defines a first pivot mount 202 and an opposing second pivot mount 204, both of which extend outwardly from the mounting post in a common plane. In this aspect, the housing is assumed to be mounted to an underlying vehicle such that the common plane is positioned transverse to the axis of motion of the underlying vehicle, and such that the "horizontal" directional axes of operation of the respective first and second antennas are substantially horizontal. Each pivot mount defines a bore 206, which extends substantially transverse to the common plane through a distal end of the pivot mount.

[0187] Further, in this aspect, each of the respective first and second antennas 182, 184 is mounted to a support plate 208 having a mounting post 210 extending outwardly therefrom. As shown, the antenna mounting post 210 is configured to be operably received within a respective pivot mount and rotatably secured to the pivot mount by operative reception of a shaft 212. As further shown, each mounting post has an ear 220 extending outwardly from an exterior surface of the post in a common plane. In this aspect, the ears 220 of each mounting post are oppositely positioned, with each ear defining an elongated track 222 having an axis.

[0188] The post 200 further defines a pair of spaced brackets 230 to which an opposing pair of spaced sleeves 232 are mounted. As shown, the pair of drive shafts 234 are configured to move axially along a common axis positioned in a common plane through a bore 233 defined in each of the sleeves 232. A proximal end of each drive shaft is configured to be slidably received within a respective elongated tract 22 of the ear 220 of the mounting post 210. A respective distal end of each drive shaft is configured to be mounted to opposing edges of a drive member 236 configured for axial movement along the common axis. In this example, the drive member 236 defines an elongated track 238 positioned in a common plane and having an axis of motion that is transverse to the common axis of the drive shafts 234.

[0189] As further shown, the mobile RFID interrogator device includes a drive gear member 240 that is selectively controlled to rotate at a desired speed and configured to simultaneously selectively control the rate of sweep of the respective first and second antennas 182, 184. In this aspect, the drive gear member 240 has a bushing 242 mounted towards a peripheral edge of the drive gear member, the bushing rotating about an axis of the drive gear member in a conventional manner. As will be appreciated, the bushing 242 is configured for operative slidable reception therein of the elongated track 238 of the drive member 236, such that rotational movement of the drive gear member 240 via a conventional electric motor and subsequent axial movement of the coupled bushing 242 within the elongated track 238 of the drive member 236 results in axial movement of the respective drive shafts which, in turn, results in rotational movement of the mounted antennas.

[0190] 40 and 41, an alternative embodiment of an RFID interrogator device is shown. As shown, this embodiment of an RFID interrogator device can be configured to be optionally mobile or optionally fixed (powered via communication to an internal battery) within a geographic location. In this example, the mobile or fixed RFID interrogator device has a housing including an operational aspect of the mobile or fixed RFID interrogator device operably coupled to a plurality of antennas 180 configured or otherwise positioned to scan within different zones. As exemplarily illustrated, the housing of the mobile RFID interrogator device defines an opposing pair of planar surfaces, with a plurality of antennas operably positioned within the housing behind the opposing pair of planar surfaces. In this aspect, the plurality of antennas comprises two separate pairs of antennas, which may be operably positioned on respective opposing pairs of planar surfaces, which may be lateral to the earth's surface.

[0191] Optionally, with reference to Figures 41 and 42, each of the pairs of antennas 180 can further comprise first and second spaced apart antennas 182, 184. The angular relationship of the opposing pairs of planar surfaces is also shown diagrammatically, with each angular surface of one pair being a planar surface positioned in a plane that is approximately 70-120 degrees relative to each other, behind which each of the two separate pairs of antennas is positioned.

[0192] In this aspect, the first antenna 182 is positioned such that each of the first antennas is angled relative to the planar surface such that the operational azimuth axis of the first antenna extends substantially parallel to the Earth's surface, and the second antenna 184 is positioned such that each of the second antennas is angled relative to the planar surface such that the operational azimuth axis of the second antenna extends substantially parallel to the Earth's surface. In this aspect, the operational azimuth axis of the first antenna is positioned at an operational angle ranging from about 70 to 120 degrees relative to the operational azimuth axis of the second antenna. For illustration, referring to FIG. 42, exemplary scan zones for each first and second antenna of each pair of antennas are about their respective operational azimuth axes.

[0193] Those skilled in the art will appreciate that while the mobile RFID interrogator device is optionally shown mounted on a vehicle, such as a conventional forklift as illustrated, it is contemplated that the mobile RFID interrogator device may be mounted on any mobile platform, such as a sweeper unit, etc. It is further contemplated that the mobile platform may include a harness configured or suitable for selectable receipt of the mobile RFID interrogator device such that the mobile RFID interrogator device may be attached to different mobile RFID interrogator devices at the operator's discretion.

[0194] In operation, as the mobile RFID interrogator devices move about the warehouse and perform their normal functions, their attached scanning systems will scan. When a particular zone is approached, not only is the "location" tag scanned, but all of the tagged assets within that zone are also scanned. As described herein, the RFID interrogator subsystem 10 and / or the global inventory database subsystem 20 are programmed to receive and process the data and correlate asset tags with location tags.

[0195] In a further aspect, each RFID interrogator can have an interface to the global inventory database subsystem, and the interface can be configured to be wired, wireless, or at least partially wireless.

[0196] In a further aspect, the RFID interrogator subsystem can further comprise at least one hub configured to act as a network node, the network node configured to relay information from each RFID interrogator to and from the global inventory database subsystem.

[0197] In a further aspect, at least one of the RFID interrogators mounted within the fixed geospatial location within the material handling equipment can comprise a plurality of fixed RFID interrogators mounted within the fixed geospatial location within the material handling equipment, in this aspect, each of the plurality of fixed RFID interrogators are spaced apart from one another, and the geospatial locations of the plurality of fixed RFID interrogators are stored within at least one memory of the processing system. In this aspect, it is contemplated that the plurality of fixed RFID interrogators can include direct wireless connections between each of the plurality of RFID interrogators for sharing of certain data.

[0198] In another aspect, each of the multiple bins can be associated with an RFID tag that stores a unique geospatial location identifier. In this aspect, it is envisioned that the geospatial location identifiers of each of the multiple bins are stored within at least one memory of the processing system, whereby a combination of the known locations of each of the multiple fixed RFID interrogators and the known geospatial locations of each bin's on-board RFID tag helps to increase the fidelity of the geospatial locations of inventory items within the material handling equipment.

[0199] In a further aspect, as further described herein, the unique identifier of each scanned RFID tag comprises at least one of a unique identification code for each scanned item or geospatial location identifier data associated with each scanned item, including the date and time of the scan event, thereby enabling the warehouse inventory management system to synchronize data associated with each inventory item received from different RFID interrogators.

[0200] As described in further detail herein, the management system may further comprise a motion detection subsystem that may be configured to detect movement within a defined area between a first physical zone and a second physical zone. In this aspect, in response to detecting the movement, the processing system instructs the RFID interrogator subsystem to identify inventory items moving from the first physical zone to the second physical zone and subsequently report the item movement to the global inventory database subsystem, the identification of each item identified as having moved enabling the system of the global inventory database subsystem to update the physical location of each item transitioning from the first physical zone to the second physical zone. It is also envisioned that the global inventory database subsystem may be configured to activate scanning or prevent scanning in response to needs and / or events triggered by the motion detection subsystem.

[0201] In a further aspect, the global inventory database subsystem can be configured to activate scanning or prevent scanning based on a recurring or otherwise identified timeline or schedule.

[0202] As described in detail herein, an adaptive inventory management system for use in a material handling facility may include a plurality of items positioned within a defined space of the material handling facility, each of the plurality of items being associated with a radio frequency identification (RFID) tag, each RFID tag storing a unique identifier, a global inventory database subsystem, and an RFID interrogator subsystem.

[0203] In this aspect, the global inventory database subsystem has a processing system having at least one memory of the processing system configured to store program instructions. It is envisioned that the RFID interrogator subsystem includes a plurality of RFID interrogators, at least one of which may be mounted within a fixed geospatial location within the material handling equipment. Further, each of the RFID interrogators may be configured to read a unique identifier of an RFID tag associated with each of the plurality of items within a defined boundary of at least one scan zone generated by the respective RFID interrogator, and subsequently communicate to the processing system a unique identifier of each scanned RFID tag identified within each scan zone of the respective RFID interrogator.

[0204] Thus, in operation, at least one memory of the processing system is configured to store program instructions that, when executed, cause the defined boundaries of each scanning zone for each RFID interrogator to be selectively configured to provide a user desired level of fidelity and / or resolution for the generated unique identifier of each scanned RFID tag within the defined space of the material handling equipment.

[0205] In an optional aspect, the defined boundaries of each scan zone for each RFID interrogator can be configured such that the boundaries of the respective RFID interrogators do not overlap, or alternatively, or in combination, the defined boundaries of each scan zone for each RFID interrogator are user configurable such that at least a portion of the defined boundaries of the respective RFID interrogators overlaps with at least an adjacent or otherwise selected RFID interrogator to define at least one overlapping scan zone. In this aspect, each overlapping scan zone and associated RFID identifier data therefrom are generated from RFID identifier data received from each scan of the respective scan zone of the respective selected RFID interrogator, and the RFID identifier data of each scanned RFID tag identified within the overlapping scan zone is communicated to a processing system.

[0206] It is further envisioned that in operation, the scan zones projected by each RFID interrogator may be selectively configured to provide a user desired level of fidelity and / or resolution through the use of one or more configurable program options to include at least one of: modifying the number of RFID interrogators to modify the number of scan zones projected by the RFID interrogators in the defined space of the material handling equipment; modifying the use of overlapping scan zones projected by the RFID interrogators in the defined space of the material handling equipment; modifying the use of signal strength or phase shift modality in each scan zone projected by the RFID interrogators in the defined space of the material handling equipment; modifying the use of steerable antenna technology in each RFID interrogator to generate multiple spaced apart scan zones emanating from each of the RFID interrogators in the defined space of the material handling equipment; or modifying the use of steerable antenna technology in the RFID interrogators in the defined space of the material handling equipment to generate multiple overlapping scan zones from each of the RFID interrogators.

[0207] In this aspect, as further described herein, the unique identifier of each scanned RFID tag comprises at least one of a unique identification code for each scanned item or geospatial location identifier data associated with each scanned item, including the date and time of the scan event, thereby enabling the warehouse inventory management system to synchronize data associated with each inventory item received from different RFID interrogators.

[0208] The foregoing describes various embodiments of a warehouse inventory control system and method of operation thereof, particularly a system that utilizes RFID interrogators. The disclosed systems and methods are provided to illustrate essential and optional features and functions, and those skilled in the art may envision alternatives or modifications that do not depart from the principles of the invention, as encompassed by the appended claims, and such alternatives or modifications may be functional equivalents.

Claims

1. 1. An adaptive inventory control system for use in a material handling facility, the adaptive inventory control system comprising: a plurality of items, each of the plurality of items being associated with a radio frequency identification (RFID) tag, each RFID tag storing a unique identifier; a global inventory database subsystem having a processing system, at least one memory of the processing system configured to store program instructions; an RFID interrogator subsystem; Equipped with The RFID interrogator subsystem includes: a plurality of fixed RFID interrogators mounted within respective fixed geospatial locations within said material handling equipment, each of said plurality of fixed RFID interrogators being spaced apart from one another, said geospatial locations of said plurality of fixed RFID interrogators being stored within said at least one memory of said processing system, said plurality of fixed RFID interrogators including a direct wireless connection between respective RFID interrogators for sharing of certain data, each of said RFID interrogators being configured to read the unique identifier of the RFID tag associated with each of said plurality of items within a defined boundary of at least one scan zone generated by said respective RFID interrogator, and to communicate to said processing system the unique identifier of each scanned RFID tag identified within each scan zone of said respective RFID interrogator; at least one mobile RFID interrogator; Equipped with each RFID interrogator is locatable within a user selectable geospatial location within said material handling equipment and is mounted within a respective fixed geospatial location within said material handling equipment, said geospatial location of each mobile RFID interrogator is stored within at least one memory of said processing system, each of said mobile RFID interrogators is configured to read the unique identifier of the RFID tag associated with each of said plurality of items that is within a defined boundary of at least one scan zone generated by said respective mobile RFID interrogator, and to communicate to said processing system the unique identifier of each scanned RFID tag identified within each scan zone of said respective RFID interrogator; An adaptive inventory management system, wherein the at least one memory of the processing system is configured to store program instructions that, when executed, cause the defined boundaries for each scanning zone for each RFID interrogator to be selectively configured to provide a user desired level of fidelity and / or resolution for the generated unique identifier of each scanned RFID tag within a defined space of the material handling equipment.

2. The adaptive inventory management system of claim 1 , wherein the defined boundaries for each of the scan zones for each of the fixed RFID interrogators are configured such that the boundaries of the respective RFID interrogators do not overlap.

3. 2. The adaptive inventory management system of claim 1, wherein the defined boundary for each scan zone for each RFID interrogator is user configurable such that at least a portion of the defined boundary of the respective RFID interrogator overlaps with at least an adjacent or selected RFID interrogator to define at least one overlapping scan zone, each overlapping scan zone and the associated RFID identifier data therefrom are generated from RFID identifier data received from each scan of the respective scan zone of the respective selected RFID interrogator, and the RFID identifier data of each scanned RFID tag identified within the overlapping scan zone is communicated to the processing system.

4. 2. The adaptive inventory management system of claim 1, wherein the scan zones projected by each RFID interrogator are selectively configured to provide a user desired level of fidelity and / or resolution through use of one or more configurable program options to include at least one of: varying a number of RFID interrogators and varying a number of scan zones projected by the RFID interrogators in the defined space of the material handling equipment; varying the use of overlapping scan zones projected by the RFID interrogators in the defined space of the material handling equipment; varying the use of signal strength or phase shift modality in each scan zone projected by the RFID interrogators in the defined space of the material handling equipment; varying the use of steerable antenna technology in each RFID interrogator and generating a plurality of spaced apart scan zones emanating from each of the RFID interrogators in the defined space of the material handling equipment; or varying the use of steerable antenna technology in RFID interrogators in the defined space of the material handling equipment and generating a plurality of overlapping scan zones from each of the RFID interrogators.

5. 5. The adaptive inventory management system of claim 4, wherein a user's desired level of fidelity and / or resolution can be selectively increased through use of one or more configurable program options to include at least one of: increasing the number of said RFID interrogators and increasing the number of scan zones projected by said RFID interrogators within said defined space of said material handling equipment; increasing the use of overlapping scan zones projected by said RFID interrogators within said defined space of said material handling equipment; increasing the use of signal strength or phase shift modalities within each scan zone projected by said RFID interrogators within said defined space of said material handling equipment; increasing the use of steerable antenna technology in each RFID interrogator and increasing the number of multiple spaced apart scan zones generated from each of said RFID interrogators within said defined space of said material handling equipment; or increasing the use of steerable antenna technology in RFID interrogators within said defined space of said material handling equipment and increasing the number of multiple overlapping scan zones generated from each of said RFID interrogators.

6. 5. The adaptive inventory management system of claim 4, wherein a user's desired level of fidelity and / or resolution can be selectively reduced through use of one or more configurable program options to include at least one of: reducing the number of said RFID interrogators and reducing the number of said scan zones projected by said RFID interrogators in said defined space of said material handling equipment; reducing the use of overlapping scan zones projected by said RFID interrogators in said defined space of said material handling equipment; reducing the use of signal strength or phase shift modalities in each scan zone projected by said RFID interrogators in said defined space of said material handling equipment; reducing the use of steerable antenna technology in each RFID interrogator and reducing the number of said generated multiple spaced apart scan zones generated from each of said RFID interrogators in said defined space of said material handling equipment; or reducing the use of steerable antenna technology in said RFID interrogators in said defined space of said material handling equipment and reducing the number of multiple overlapping scan zones generated from each of said RFID interrogators.

7. 10. The adaptive inventory management system of claim 1, further comprising a plurality of bins configured to receive one or more of the plurality of items, the geospatial location of each of the plurality of bins being stored within at least one memory of the processing system.

8. The adaptive inventory management system of claim 1 , wherein the at least one mobile RFID interrogator is configured to be operated by a mobile agent of the material handling equipment.

9. The adaptive inventory management system of claim 1 , wherein the at least one mobile RFID interrogator is configured to be mounted on a vehicle of the material handling equipment.

10. The adaptive inventory management system of claim 9 , wherein said at least one mobile RFID interrogator is powered via communication with said vehicle's electrical system.

11. The adaptive inventory management system of claim 9 , wherein said at least one mobile RFID interrogator is powered via communication with an internal battery.

12. The adaptive inventory management system of claim 9 , wherein said at least one mobile RFID interrogator comprises multiple antennas positioned to face a desired direction or orientation.

13. The adaptive inventory management system of claim 12 , wherein the plurality of antennas comprises at least two separate pairs of antennas positionable laterally to an axis of motion of the vehicle on either side of the vehicle.

14. 14. The adaptive inventory management system of claim 13, wherein each of the pairs of antennas further comprises first and second spaced apart antennas.

15. 13. The adaptive inventory management system of claim 12, wherein the plurality of antennas comprises at least two separate pairs of oppositely positioned antennas configured to operatively scan laterally to an axis of motion of the vehicle.

16. 16. The adaptive inventory management system of claim 15, wherein each of the pairs of antennas further comprises first and second spaced apart antennas.

17. 16. The adaptive inventory management system of claim 15, wherein the first antenna is positioned such that the first antenna is angled relative to the ground surface whereby an azimuth axis of operation of the first antenna has an upwardly facing orientation, and the second antenna is positioned such that the second antenna is substantially transverse to the ground surface whereby an azimuth axis of operation of the second antenna is substantially horizontal.

18. 13. The adaptive inventory management system of claim 12, wherein the plurality of antennas can comprise a pair of oppositely positioned spaced apart antennas configured to operatively scan transversely to an axis of motion of the vehicle.

19. The adaptive inventory management system of claim 1 , wherein said at least one mobile RFID interrogator is configured to communicate a real-time geospatial location of said mobile RFID interrogator to said RFID interrogator subsystem.

20. 10. The adaptive inventory management system of claim 1, wherein the global inventory database subsystem is configured to activate scanning or prevent scanning based on a recurring or identified timeline or schedule.

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