"integrated system for customized pallet assembly and tracking"

Abstract

An integrated system for customized pallet assembly and tracking (100) is disclosed, including bins (104), pallet members (108), a first sensor (112), a second 5 sensor (116), a Pallet Composition Engine (PCE) (120), a pallet database (124), an input unit (128), and a control unit (132) Each bin contains members (108) categorized by parameters such as dimension, weight, material, color, and identifiers. A first identifier is assigned to each bin and a second identifier to each member, enabling efficient scanning via first sensor. The PCE generates assembly and disassembly outputs and encodes a third identifier for each customized pallet. The system tracks each pallet throughout its lifecycle assembly, transit, usage, and disassembly; logging all data into pallet database, enabling full traceability, reuse monitoring, and optimized pallet management across industrial and logistics environments.

Description

[0001] “INTEGRATED SYSTEM FOR CUSTOMIZED PALLET ASSEMBLY

[0002] AND TRACKING”

[0003] FIELD OF THE INVENTION:

[0004] The present invention relates to an integrated pallet system for the streamlined creation of custom pallets, and more particularly the present invention relates to an integrated pallet system for creation of custom pallets that are customized and tracked.

[0005] BACKGROUND OF THE INVENTION:

[0006] In the manufacturing industry, the utilization of pallets plays a pivotal role in the storage and transportation of goods. Pallets, often designed as frame-like structures, provide a standardized and efficient method for organizing and moving materials within a manufacturing facility. Typically constructed with either three or four members, these pallets serve as a foundation for goods to be securely stacked and stored. In a manufacturing setting, raw materials, components, or finished products are systematically arranged on pallets, ensuring an organized and accessible inventory. This method not only facilitates efficient space utilization within warehouses but also streamlines the handling and movement of goods during various stages of production. Once goods are assembled or manufactured, the palletized items are then transported to their destination, be it within the facility for further processing or to external distribution centres for shipping. The use of pallets in manufacturing not only enhances logistical operations but also aligns with the broader goal of optimizing supply chain processes for increased productivity and effectiveness.

[0007] In the dynamic world of storage and transportation of goods, the manual customisation of pallets has been a prevailing practice. Businesses across various industries have relied on the traditional approach of manually assembling pallets tailored to specific requirements. However, this conventional method presents formidable challenges, especially in the absence of a comprehensive tracking system. The crux of the issue lies in the susceptibility of custom pallets to loss during transportation or at customer sites, exacerbated by the inherent lack of efficient monitoring.

[0008] The manual customization of pallets, while deeply ingrained in industry practices, is not without its shortcomings. This approach, characterized by its timeconsuming nature and susceptibility to errors, underscores the pressing need for a transformative solution. Such a solution must go beyond merely streamlining the pallet assembly process; it must address the overarching concern of tracking and traceability in the entire pallet supply chain.

[0009] One of the primary challenges faced by businesses relying on manual pallet customisation is the potential loss of custom pallets during transportation. The lack of a robust tracking system leaves these pallets vulnerable to misplacement, theft, or inadvertent mishandling. This not only poses a financial risk to businesses but also jeopardizes the timely and secure delivery of goods to end-users. In an era where efficiency, precision, and accountability are paramount, the current limitations of manual pallet customization become increasingly apparent. Moreover, the manual assembly of pallets is inherently time-consuming. The intricate process of selecting, arranging, and securing specific components requires a significant investment of time and resources. The inefficiencies introduced by this approach may impede the overall logistics chain, resulting in delays and increased operational costs. The need for a streamlined, automated solution becomes apparent as businesses seek to enhance their operational efficiency and stay competitive in the ever-evolving market landscape.

[0010] The manual customization of pallets is also prone to errors, ranging from misalignments in the assembly process to inaccuracies in the selection of components. These errors not only compromise the structural integrity of the pallets but can also lead to further complications in the supply chain. An automated pallet system that minimizes human intervention and ensures precision in the assembly process becomes crucial to mitigating such risks and optimizing the overall logistics workflow.

[0011] The patent JP2005050407, credited to Ishida Masato, discloses a storing system for managing articles stored within a drawer. The system incorporates an ID reader positioned to read the IDs of articles positioned in front of, above, or below the drawer. This reading area is situated to intersect with the trajectory of articles as the drawer undergoes the process of opening or closing. The synchronized operation of the ID reader and identification means provides real-time insights into the contents of the drawer.

[0012] A person skilled in the art will appreciate that the system of this patent to Ishida Masato does not address the broader context of tracking pallets or their components as they move through a facility or during transportation. Instead, it provides a solution for the targeted management and identification of articles within a specific storage unit, namely a drawer, offering a more localized and specialized approach to inventory control.

[0013] JP2004350201, attributed to Ishida Masato, introduces a system applicable to automatic warehouses. The key feature of this system involves stations equipped with transfer devices designed to move articles individually between trays and buckets. Notably, the hands of these transfer devices are equipped with both an ID tag reader and a writer. The primary functionalities outlined in this patent include the ability to grasp the ID of the article stored in the bucket, inspect delivered products, and write data corresponding to each article onto the ID tag. This invention is tailored for automated warehouses, optimizing the transfer of individual articles between trays and buckets, while it fails to address challenges related to the creation and tracking of customized pallets.

[0014] There is a need of integrated pallet system for customized pallet assembly for goods storage and transport. There is also a need of integrated pallet system for customised pallets that can track the pallet movement from assembly to end-user delivery to disassembly of respective pallets.

[0015] SUMMARY OF THE INVENTION:

[0016] The present invention relates to an integrated system 100 for customized pallet assembly and tracking. The system 100 includes a plurality of bins 104, a plurality of identifiers, a first sensor 112, a second sensor 116, an input unit 128, a pallet composition engine (PCE) 120, a pallet database 124 and a control unit 132. Each of the bins 104 have a plurality of pallet members 108 of similar or varying dimensions. The identifiers include a first identifier assigned to each bin, a second identifier assigned to each pallet member, and a third identifier generated with the first and second identifier for a customized pallet. The first sensor 112 scans the first and second identifiers and detects bin 104 and pallet member 108 information, and the second sensor reads a third identifier assigned to a customized pallet. An input unit 128 receives pallet configuration requirements from a user.

[0017] The pallet composition engine (PCE) 120 is configured to interface with the input unit 128, the first sensor 112, and the second sensor 116, and to generate digital outputs and the third identifier. The pallet database stores data including pallet identifiers, member identifiers, bin identifiers, tracking records, and lifecycle data of pallet members. The control unit 132 receives input and sensor data, and directs pallet assembly and disassembly operations through the digital outputs while enabling full traceability of pallet members.

[0018] The pallet composition engine (PCE) 120 generates a first digital output that defines instructions for selecting and assembling a customized pallet based on the user input and inventory data. The pallet composition engine (PCE) 120 generates a second digital output that defines disassembly instructions for returning members to storage. The pallet composition engine (PCE) 120 creates the third identifier for the assembled pallet. The third identifier is derived from at least the first identifier and second identifiers. The first and second identifiers include RFID tags, QR codes, barcodes, or unique alphanumeric strings. The third identifier includes an encoded or hashed string generated by combining the first identifier, second identifiers, and session metadata. The pallet database 124 includes usage frequency data for each pallet member and a timestamp of each assembly and disassembly. The second sensor 116 is installed on a transport vehicle or warehouse station for tracking pallet movement during transit. The control unit 132 provides visual dashboards and lifecycle reports for pallet members and customized pallets. The input unit 128 accepts parameters such as pallet dimensions, shape, material type, and weight-bearing requirements.

[0019] The present invention further discloses a method for managing the lifecycle of customized pallets using an integrated pallet system 100. The method includes receiving a pallet specification input from a user through an input unit 128; identifying one or more bins 104 using a first identifier associated with each bin 104; identifying pallet members 108 within the bins 104 using second identifiers; selecting appropriate pallet members 108 based on the specification input and inventory; assembling a customized pallet using the selected members 108; generating a first digital output that includes instructions for pallet assembly; generating a third identifier for the assembled pallet by encoding the associated first and second identifiers; associating the third identifier with the assembled pallet; logging all identifiers and assembly data into a pallet database 124; tracking the movement and location of the pallet through a second sensor 116 by reading the third identifier; receiving disassembly instructions through the input unit 128; generating a second digital output that includes instructions for disassembly; and returning the disassembled pallet members 108 to designated bins 104 while updating the pallet database 124 with lifecycle and location information.

[0020] In this method, the third identifier is generated using a hash function that includes a timestamp, session ID, and the member identifiers. The tracking includes reading the third identifier at entry and exit gates, warehouse docks, and onboard transport devices. The method generates a usage report for each pallet member 108 based on accumulated lifecycle data. The method includes updating the pallet database 124 in real-time upon each scan event, location change, or status update. The method includes issuing alerts or notifications if a pallet member 108 exceeds a predefined lifecycle count or transport duration threshold. The method further evaluates the structural condition or reuse eligibility of each pallet member 108 based on usage metrics stored in the database.

[0021] BRIEF DESCRIPTION OF DRAWINGS:

[0022] The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,

[0023] FIG.l shows a schematic of an integrated pallet system 100 for customized pallet assembly and tracking in accordance with the present invention, and

[0024] FIG. 2 shows a flow chart of the method executed by a Pallet Composition Engine (PCE) 120 for managing the lifecycle of customized pallets within the integrated pallet system 100 in accordance with the present invention.

[0025] DESCRIPTION OF THE INVENTION: References in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0026] References in the specification to “preferred embodiment” means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.

[0027] The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching.

[0028] The present invention discloses an integrated pallet system for customized pallet assembly and tracking 100, hereinafter referred as the pallet system 100, including a plurality of bins 104, a plurality of pallet members 108 having similar or different dimensions, a first sensor 112, a second sensor 116, a Pallet Composition Engine (PCE) 120, a pallet data base 124, an input unit 128, and a control unit 132. The pallet system 100 also includes a memory 136 and an output device 140. The system 100 also includes a plurality of identifiers for identifying bins 104, members 108, and customized pallets. The system 100 receives inputs from a user regarding the need of the custom pallets and provides the user with a digital output. Customized pallets are configured and disassembled as per the digital outputs. It is noted that the digital outputs provide instructions for collection of members, choice of bin 104, assembly of the members 108, sequence of assembly, the unique identifier of the respective customized pallet, and instructions to disassemble the pallets, etc.

[0029] In accordance with the present invention, each of the bins 104 include members 108 of specific dimensions. The members 108 are of different types and the type is decided based on the parameter such as dimensions, weight, material, identifiers, colour, and the like. These members 108 are utilized to configure pallets of the present invention. In an embodiment, for example, there are four bins 104 such that each bin 104 includes members 108 of predefined identical dimensions. A typical pallet of 1250 mm by 2500 mm requires three member of cross member of 1254 mm and three member of long member of 2550 mm.

[0030] In accordance with the present invention, each bin 104 is assigned with a unique identifier that is a first identifier. The primary identifier, for example is a unique code, unique number, RFID tag, digital identifier, QR code, or like that. This identifier is graphically representable. It is noted, however, that each bin 104 preferably includes a plurality of members 108 that have approximately identical dimensions. Similarly, each of the members 108, in each of the bin 104 includes a unique identifier i.e. a second identifier. For example, the second identifier includes an RFID tag, a digital tag, QR code, unique code, unique number or the like which is a recognizable identifier that is associated with the respective member and that identifies the respective member 108. The identifier may identify the member by various parameters such as length, breadth, height, section, shape, configuration, weight, material, colour or the like.

[0031] In accordance with an alternate embodiment of the present invention, the identifiers are identified by GPS technologies.

[0032] The first sensor 112 identifies the bins 104 and the members 108 in the bins 104. In other words, the first sensor 112 identifies the first identifier and / or second identifier associated with respective bin 104 or the member 108. In accordance with the present invention, the identification of the identifier is preferably done by scanning the respective identifier on the member 108.

[0033] The system 100 of the present invention receives inputs from one or more users. This input is nothing but the need of customized pallets for a predefined requirement such as size, shape, strength, shape, material, nature of goods to be shipped, etc. Based on this input, the system 100 generates digital output for the user such that the output directs the user with set of instruction to select, assemble one or more pallets that suits the users’ requirement and also generates identifier that is to be assigned to each of the respective pallet.

[0034] The first sensor 112 provides inputs to the controller 132 of the pallet system 100. Accordingly, the pallet system of the present invention includes data associated with a first identifier that identifies a bin 104, and data associated with the pallet’s second identifier that identifies members 108 in the bins 104. The second sensor 116 identifies the pallets configured as per the first digital output, and provides the data related to the pallet to the Pallet Composition Engine 120. The second sensor 116 identifies the respective pallets by the third identifier. The third identifier is the identifier that identifies customized pallets configured as per the digital output of the system 100.

[0035] For example, for a pallet have two members 108 of long member and two members of cross member, as per the user instruction to the input unit 128, the first sensor 112 provides a first digital input to the controller of the pallet system 100. Accordingly, the pallet system 100 generates a first identifier that identifies a BIN A and BIN B. The second sensor 116 identifies the requirement for the pallets to be configured, and provides the data related to the pallet to the Pallet Composition Engine 120. The PCE 120 provides instructions to the user to obtain the long members Member 1 and Member 2 from BIN A and the cross members Member 3 and Member 4 from BIN B.

[0036] • Bin Identifiers (First Identifiers) o Bin A: BIN-A01 o Bin B: BIN-B02

[0037] • Selected Pallet Members and Their Identifiers (Second Identifiers) o From Bin A:

[0038] ■ Member 1 : MEM- A01-001

[0039] ■ Member 2: MEM-A01-002 o From Bin B:

[0040] ■ Member 3: MEM-B02-005

[0041] ■ Member 4: MEM-B 02-008 The PCE 120 generates the third identifiers by accessing the first and the second identifiers from the database 124. The PCE 120 retrieves the first identifiers assigned to each bin 104 from which the pallet members 108 are selected. Then the PCE 120 retrieves the second identifier associated with each selected member 108. Now the PCE 120 generates third identifier in a predefined sequence by encoding the first and second identifiers. For example, the third identifier may include a bin identifier prefix, a hashed combination of member identifiers, a time stamp, a session identifier, etc.

[0042] The third identifier construction is a concatenated string that is encoded by encoding methods such as hashed function, alphanumeric coding, etc. This creates a unique and machine readable third identifier for the customized pallet. The third identifier is digitally assigned to the assembled pallet and preferably mechanically positioned on the same pallet. The PCE 120 stores the third identifier in the pallet database. The third identifier is used by the system 100 to track the life cycle of the pallet. It also links the pallet to specific members 108 being used in that particular pallet and the bins 104 from they originated.

[0043] In accordance with the present invention, the Pallet Composition Engine (PCE) 120 is configured to receive inputs from the input unit 128, the first sensor 112, the second sensor 116 and to provide a digital output directing the pallet system 100 to define one or more pallets as per the first digital output and the second digital output.

[0044] The first digital output includes a plurality of instructions to define a desired pallet. The second digital output includes a plurality of instructions to disassemble a desired pallet. In accordance with the present invention, each digital output generates a second identifier i.e. a pallet identifier that is assigned to the pallet configured as per the inputs from the user. It is noted that one member 108 may become part of various pallets that are configured during the life cycle of a member 108.

[0045] The pallet database 124 includes tracking data, location information of every member 108, location information of every pallet, member data, member identity information etc. The role of the pallet database 124 is not only storing information about the composition of pallets but also tracking their movement and maintaining location data.

[0046] The control unit 132 is configured to receive user inputs such as the type of the pallet, member identification information, pallet identifier etc. and with the use of the database 124, providing the digital output to define one or more pallets, tracking reports, member use reports, etc. Pallet system 100 of the present invention seamlessly guides users through both assembly and disassembly cycles, maintaining a comprehensive record of each step, from the initial configuration to the final disassembly, contributing to a dynamic and sustainable pallet management system. It is noted that the assembly cycle is executed as per the first digital output and the disassembly cycle is executed as per the second digital output.

[0047] The Pallet Composition Engine (PCE) 120 is configured to interface with the input unit 128, the first sensor 112, and a second sensor 116. It is configured to process these inputs and subsequently generate the two digital outputs, guiding system users through the definition or disassembly of one or more pallets in the first assembly cycle and second disassembly cycle. This digital output is bifurcated into a first digital output, which furnishes a set of instructions for defining a desired pallet, and a second digital output, including instructions for disassembling a desired pallet.

[0048] Now the assembly cycle of the pallet is described. This assembly cycle is executed as per the first digital output. The assembly cycle of the pallet system 100 begins with user inputs detailing the desired specifications, such as shape, quantity, and material of the pallets to be configured.

[0049] The pallet system 100 processes these inputs and generates a first digital output, providing the user with instructions to assemble one or multiple pallets. Following these detailed instructions, the user collects individual members 108 from designated bins 104 and assembles the pallet. During this process, each scanned member 108 is recorded in the pallet system database 124, establishing a comprehensive log of the assembly. The pallet system 100 systematically records both the individual members 108 and the completed pallets, rendering them ready for immediate use.

[0050] Upon completion, goods are strategically placed on the pallet within the warehouse, and the entire pallet, laden with goods, is securely wrapped for shipment. In another embodiment, each transport vehicle is equipped with a secondary scanning device, recording the members 108 and, consequently, the assembled pallet. During transit from the origin to the destination, the pallet's journey is tracked and logged by the pallet system 100. Upon arrival at the designated location, the pallet is put to use for a defined period. When the need arises to unload the goods, the user initiates the disassembly process. In one assembly cycle, a pallet of four members 108 was assembled as per the first digital output in 120 seconds.

[0051] Now the disassembly cycle of the pallet system 100 is described. To disassemble the pallet, the user interacts with the pallet system 100, providing disassembly inputs and scanning each individual member 108. In response, the pallet system 100 generates a second digital output, guiding the user through the disassembly process and instructing them to position the disassembled members in predefined bins 104 at the location. The disassembly cycle ensures that each member 108 is systematically returned to its designated storage i.e. bin / s 104, ready to become part of another pallet in the future. In one disassembly cycle, a pallet of four members 108 was disassembled as per the second digital output in 60 seconds and the members 108 were scanned, positioned in the respective bins 104.

[0052] Both of the digital outputs yield a unique identifier, known as the third identifier. This third identifier is assigned to the pallet configured based on the user's inputs, effectively labeling and distinguishing each pallet within the pallet system 100. It is important to note that a single member 108 may contribute to the formation of multiple pallets throughout its life cycle, exemplifying the versatile and reusable nature of the pallet system's 100 components. This capability ensures that the third identifier serves as a comprehensive record of each pallet's origin and the individual members involved, facilitating efficient tracking and management across the entirety of the pallet's life cycle. Now, referring to FIG. 2, the operation of the Pallet Composition Engine (PCE) 120 for managing the lifecycle of customized pallets within an integrated pallet system is described. Upon initiation, the PCE receives user-defined pallet specifications via an input unit 128, including dimensional, material, and structural requirements. The PCE 120 interfaces with a pallet database 124 to retrieve inventory metadata comprising bin identifiers (first identifiers), member identifiers (second identifiers), and location data. It analyzes available bins 104 and pallet members 108, mapping them against the received specifications. Based on this analysis, the PCE 120 generates a first digital output comprising assembly instructions for selection and arrangement of specific members 108 sourced from designated bins 104 and assigns a unique third identifier to the resulting customized pallet. This identifier is derived from a structured combination of first and second identifiers along with session metadata, enabling traceability. The digital output, along with the third identifier, is communicated to the user for execution.

[0053] Upon completion of the pallet’s functional cycle, the PCE 120 receives disassembly input, generates a second digital output containing reverse instructions for systematic deconstruction, and guides the reintegration of each scanned member 108 into its designated bin 104. The pallet database 124 is dynamically updated with member status, location data, and lifecycle records, thereby maintaining a closed-loop system for pallet composition, usage tracking, and disassembly, ensuring efficient, traceable, and reusable pallet management.

[0054] Now a preferred method for monitoring the lifecycle of customized pallets using an integrated pallet system 100 is described. The system includes bins 104, pallet members 108, sensors, a Pallet Composition Engine (PCE) 120, a database 124, input / output units, and a control unit 132. Each component is uniquely identified using machine -readable identifiers such as QR codes, RFID tags, or digital tags. The method begins with receiving a user input via an input unit 128. The user specifies requirements such as pallet size, shape, strength, and material. Based on the input, the Pallet Composition Engine (PCE) 120 processes the data and generates a first digital output. This output contains a set of assembly instructions. It also assigns a unique third identifier to the pallet to be assembled.

[0055] Each bin 104 is assigned a first identifier. Each pallet member 108 stored in the bins is assigned a second identifier. A first sensor 112 scans these identifiers to identify and verify the location and type of members 108 required. The members 108 are selected based on parameters like dimension, weight, colour, and material. The user collects the identified pallet members 108 from the respective bins 104. The members 108 are assembled to form a customized pallet as per the first digital output. During assembly, each member 108 is scanned and its usage is recorded in a pallet database 124. The assembled pallet is tagged with the third identifier generated earlier.

[0056] Once assembled, the pallet may be loaded with goods. It is tracked during storage, transit, and use. A second sensor 116, installed in transport vehicles or warehouse stations, reads the third identifier. The system logs the movement, location, and time-stamped usage data of the pallet. All tracking data is stored in the pallet database 124. Upon delivery or completion of use, the user initiates the disassembly process. The system receives a disassembly input from the user. The PCE 120 generates a second digital output containing disassembly instructions. Each member 108 is scanned again, and the system guides the user to return them to designated bins 104. Each step is logged into the database 124.

[0057] The pallet database 124 advantageously stores and manages tracking data. It maintains records of each member’s use history, each pallet’s composition, and all location updates. The control unit 132 uses this database to generate reports, including tracking reports and member lifecycle reports. Each member 108 can be reused multiple times. The system ensures accurate tracking of every reuse instance. The control unit 132 of the system facilitates monitoring of the pallets. The lifecycle of each pallet is thereby recorded from assembly to disassembly.

[0058] Now a method of monitoring the customized pallets in accordance with the present invention is described.

[0059] 1) Receiving User Input: First a user input is received via the input unit 128, detailing the desired specifications, such as shape, quantity, and material of the pallets to be configured.

[0060] 2) Component identification and selection: Based on the user input, PCE 120 generates a first digital output. The first digital output provides instructions to the user for collecting individual members 108 from the designated bins 104; and the assembling sequence of the pallet. ) Pallet assembly and recording: The pallet database 124 records the bin ID and the member ID based on the data associated with a first identifier and the second identifier.

[0061] The user follows the instructions of the first digital output and assembles the pallet based on the assembling sequence of the pallet. Each member 108 scanned by the first scanner is entered into the pallet database 124. Each member’s pallet ID and the time of assembly is recorded. A unique and machine readable third identifier is generated for the customized pallet.

[0062] The third identifier is digitally assigned to the assembled pallet and the PCE 120 stores the third identifier in the pallet database 124. The third identifier is used by the system 100 to track the life cycle of the pallet. ) Tracking during use and transportation: The pallet is tracked during storage and shipment by a second sensor 116. The second sensor 116, installed in transport vehicles, warehouse stations, or on plant in gate and out gate, reads the third identifier. The system logs the movement, location, and time-stamped usage data of the pallet. All tracking data is stored in the pallet database 124. ) Second digital output generation: The PCE 120 generates a second digital output containing disassembly instructions. The second digital output guides the user through the disassembly process. Each member 108 is scanned again, and the system guides the user to position the disassembled members 108 in predefined bins 104 at the location. ) Reuse of member and next life cycle tracking: As per the new user input is received via the input unit 128, the member 108 is reused for next pallet assembly as per a new first digital output forming a part of the next pallet life cycle.

[0063] 7) Database updating and management: The pallet database 124 has a real time update of the record of the date and location of the pallet. Further the status of each member 108, status of each pallet is recorded and tracked.

[0064] 8) Continued monitoring: The control unit 132 continuously tracks and updates the status of each member 108 and pallet. The pallet database 124 generates a report of the number of uses of a member 108.

[0065] Within the scope of the present invention, the pallet database 124 assumes a multifaceted role, encompassing not only the storage of crucial information regarding the composition of pallets but also playing a pivotal role in tracking their dynamic movement and preserving essential location data. The comprehensive functionality of the pallet database 124 includes the tracking data, precise location information for each individual member 108, location details pertaining to every pallet, member- specific data, and distinct member identity information.

[0066] The pallet database 124 of the pallet system 100 catalogues the location information of each pallet, providing an organized repository of their current positions and historical movements. This dual capacity of tracking both members and pallets contribute to a robust system that not only assembles and disassembles pallets but also monitors their spatial dynamics. The inclusion of member data and identity information further enhances the database's utility, creating a centralized hub for effective pallet management and tracking. The tracking data within the database 124 serves to record and log the intricate details of each pallet's journey, facilitating a comprehensive and real-time overview of their movement within the pallet system 100. Concurrently, the location information for every member is advantageously maintained, ensuring a systematic record of the whereabouts of each component throughout its life cycle.

[0067] In accordance with the present invention, the control unit 132 serves as a key interface, adept at receiving diverse user inputs, including but not limited to pallet types, member identification information, and pallet identifiers. Leveraging the data stored in the pallet database 124, the control unit 132 efficiently processes these inputs and generates digital outputs customized to the user's requirements. These outputs include instructions for defining one or more pallets, dissembling pallets, tracking reports, member use reports, and other pertinent information.

[0068] This integration of user inputs and database analytics allows the control unit 132 to guide users through both the assembly and disassembly cycles of the pallet system 100. By maintaining a real-time connection with the database 124, the control unit 132 ensures the provision of accurate and up-to-date information, contributing to the creation of a dynamic and sustainable pallet management system 100. The pallet system's 100 inherent ability to record and manage each step, from the initial configuration of pallets to their final disassembly, establishes a robust framework for efficient pallet utilization and tracking. The comprehensive recordkeeping facilitated by the control unit 132 enhances user experience, operational transparency, and the overall effectiveness of the pallet system. The integrated pallet system 100 for customized pallet assembly and tracking of the present invention brings together a myriad of components, including specialized bins 104, sensors 112, 116, a Pallet Composition Engine 120, a robust database 124, an intuitive input unit 128, and an efficient control unit 132. Users provide the pallet specifications, such as shape and material, and receive precise digital outputs guiding them through the assembly process. The pallet system's prowess extends beyond assembly, as it tracks each member's location and maintains a comprehensive database of pallet movements. From initial assembly to eventual disassembly, the pallet system 100 leaves an indelible mark on pallet management, providing a dynamic and sustainable solution for industries reliant on efficient logistics and inventory control.

[0069] In another embodiment of the present invention, the Pallet Composition Engine (PCE) 120 is implemented as a software -based logic module comprising algorithmic routines and functional sequences that interact with the system components including the input unit 128, first sensor 112, second sensor 116, control unit 132, and pallet database 124. The PCE 120 is configured to carry out three primary functions such as generating digital outputs, encoding unique pallet identifiers, and monitoring the lifecycle of customized pallets. The internal logic of the PCE 120 is executed as discussed below. A first step is of receiving and processing the user inputs. The process begins with the PCE 120 receiving structured input data from a user via the input unit 128. This input includes pallet configuration parameters such as required dimensions, material type, shape, weight tolerance, and quantity of pallets. The PCE 120 parses this input and temporarily stores the input parameters for further processing.

[0070] In a second step includes inventory analysis and member selection. Based on the parsed specifications, the PCE 120 queries the pallet database 124 to retrieve metadata for all available bins 104 and pallet members 108. Each bin 104 is identified by a first identifier, and each member 108 within the bin 104 is identified by a second identifier. The PCE 120 filters pallet members by matching their stored specifications such as size, material, and weight to the user-defined criteria. A list of suitable pallet members 108 is selected for assembly, ensuring that all required parts are identified for one or more pallets.

[0071] Generation of First Digital Output is done in a third step. Once the members are selected, the PCE 120 generates a first digital output containing step-by-step assembly instructions. These include identifiers of the bins 104 from which members 108 are to be picked, the sequence of member assembly, and any constraints or guidelines for configuration. The first digital output is transmitted to the control unit or output device for display or execution.

[0072] Generation of Third Identifier (Encoding Logic) is included in the fourth step. In parallel, the PCE 120 generates a unique third identifier for the customized pallet being assembled. This identifier is encoded by combining:

[0073] • the first identifiers of the bins 104 used,

[0074] • the second identifiers of the selected pallet members 108,

[0075] • session metadata such as user session ID and timestamp. The concatenated string is further processed using a deterministic encoding method such as SHA-256 hashing, CRC encoding, or alphanumeric compression, to produce a unique, machine-readable third identifier. This third identifier is digitally associated with the customized pallet and is stored in the pallet database.

[0076] A fifth step includes assembly logging and tracking initiation. During physical pallet assembly, the first sensor 112 continuously scans each selected member 108, and the scanned data is relayed back to the PCE 120. This data is cross-referenced against the selected members 108 to verify accuracy. As the pallet is assembled, the PCE 120 logs each scan event with a timestamp, member ID, and bin origin, thereby forming a complete composition log for the pallet.

[0077] A sixth step includes lifecycle monitoring. After assembly, the PCE 120 enters lifecycle monitoring mode. The second sensor 116, located on warehouse gates, transport vehicles, or storage zones, continuously scans the third identifier of the pallet as it moves through logistics stages. Each detection event is timestamped and stored in the pallet database. The PCE 120 tracks the location, usage time, status (in-transit, stored, in-use), and event history of each pallet in real-time.

[0078] A seventh step includes generation of second digital output. When the user initiates the disassembly phase, the PCE 120 retrieves the stored composition log and generates a second digital output containing reverse instructions. This includes identification of each member 108 used in the pallet, instructions to scan each member 108, and bin allocation for storage. The second output is displayed to the user, and each disassembly step is logged. A next step includes reuse and initiating next lifecycle. Once disassembled, the pallet members 108 are returned to respective bins 104 and updated in the database 124 as “available.” These members 108 are now eligible to participate in a new pallet assembly cycle. The PCE 120 tracks each reuse, enabling cumulative lifecycle tracking of individual members.

[0079] A last step includes report generation and alerts. At regular intervals or on demand, the PCE 120 generates reports summarizing: number of uses per member 108, total pallets assembled / disassembled, exceptions or mismatches during scanning, members reaching lifecycle limits. The PCE 120 may also trigger alerts if a pallet remains in one location beyond a threshold period or if a member exceeds a pre-defined reuse count.

[0080] Accordingly, by automating the processes of pallet configuration, identifier encoding, and lifecycle monitoring, the system substantially reduces the possibility of human error, enhances operational accuracy, and improves traceability of each pallet and its constituent members throughout the supply chain. The generation of digital outputs for assembly and disassembly ensures standardized workflows, while the encoding of a unique third identifier using deterministic algorithms enables reliable identification and reuse tracking. Furthermore, the real-time monitoring capability facilitated by continuous sensor interaction and dynamic database updates offers increased transparency and control over pallet logistics. A person skilled in the art will appreciate that these advantages collectively contribute to improved efficiency, data-driven decision-making, and a scalable, software- integrated pallet management system suitable for industrial, warehousing, and transportation environments.

[0081] The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0082] It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

CLAIMS:

1. An integrated system for customized pallet assembly and tracking 100, comprising: a plurality of bins 104, each having a plurality of pallet members 108 of similar or varying dimensions; a plurality of identifiers including a first identifier assigned to each bin 104, a second identifier assigned to each pallet member 108, and a third identifier generated with the first and second identifier for a customised pallet; a first sensor 112 scanning the first and second identifiers and detecting bin and pallet member information; a second sensor 116 reading a third identifier assigned to a customized pallet; an input unit 128 receiving pallet configuration requirements from a user; a pallet composition engine (PCE) 120 configured for interfacing with the input unit 128, the first sensor 112, and the second sensor 116, and generating digital outputs and the third identifier; a pallet database 124 storing data including pallet identifiers, member identifiers, bin identifiers, tracking records, and lifecycle data of pallet members 108; and a control unit 132 receiving input and sensor data, and directing pallet assembly and disassembly operations through the digital outputs while enabling full traceability of pallet members 108.

2. The system 100 of claim 1, wherein the pallet composition engine (PCE) 120 generating a first digital output defining instructions for selecting and assembling a customized pallet based on the user input and inventory data.

3. The system 100 of claim 1, wherein the pallet composition engine (PCE) 120 generating a second digital output defining disassembly instructions for returning members 108 to storage.

4. The system 100 of claim 1, wherein the pallet composition engine (PCE) 120 creating the third identifier for the assembled pallet, the third identifier being derived from at least the first identifier and second identifiers.

5. The system 100 of claim 1 , wherein the first and second identifiers including RFID tags, QR codes, barcodes, or unique alphanumeric strings.

6. The system 100 of claim 1 , wherein the third identifier including an encoded or hashed string generated by combining the first identifier, second identifiers, and session metadata.

7. The system 100 of claim 1, wherein the pallet database 124 including usage frequency data for each pallet member 108 and a timestamp of each assembly and disassembly.

8. The system 100 of claim 1, wherein the second sensor 116 being installed on a transport vehicle or warehouse station for tracking pallet movement during transit.

9. The system 100 of claim 1, wherein the control unit 132 providing visual dashboards and lifecycle reports for pallet members 108 and customized pallets.

10. The system of claim 1, wherein the input unit 128 accepting parameters such as pallet dimensions, shape, material type, and weight-bearing requirements.

11. A method for managing the lifecycle of customized pallets using an integrated pallet system 100, comprising: a. receiving a pallet specification input from a user through an input unit 128; b. identifying one or more bins 104 using a first identifier associated with each bin 104; c. identifying pallet members 108 within the bins using second identifiers; d. selecting appropriate pallet members 108 based on the specification input and inventory; e. assembling a customized pallet using the selected members 108; f. generating a first digital output that includes instructions for pallet assembly; g. generating a third identifier for the assembled pallet by encoding the associated first and second identifiers; h. associating the third identifier with the assembled pallet; i. logging all identifiers and assembly data into a pallet database 124; j. tracking the movement and location of the pallet through a second sensor 116 by reading the third identifier;k. receiving disassembly instructions through the input unit 128; generating a second digital output that includes instructions for disassembly; and l. returning the disassembled pallet members 108 to designated bins 104 while updating the pallet database 124 with lifecycle and location information.

12. The method of claim 11, wherein the third identifier being generated using a hash function that includes a timestamp, session ID, and the member identifiers.

13. The method of claim 11, wherein the tracking including reading the third identifier at entry and exit gates, warehouse docks, and onboard transport devices.

14. The method of claim 11 including generating a usage report for each pallet member 108 based on accumulated lifecycle data.

15. The method of claim 11 including updating the pallet database 124 in realtime upon each scan event, location change, or status update.

16. The method of claim 11 including issuing alerts or notifications if a pallet member 108 exceeds a predefined lifecycle count or transport duration threshold.

17. The method of claim 11 including evaluating the structural condition or reuse eligibility of each pallet member 108 based on usage metrics stored in the database 124.

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