An inventory control system having advanced functionalities
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Solution Overview
Problem
Current inventory control systems for tools in manufacturing and service environments face challenges in accurately tracking tool presence, type, and location, especially in aerospace industries, where tools must be precisely accounted for to prevent damage and theft, and existing systems are prone to false alarms, are costly, and lack efficient data processing and network compatibility.
Innovation Solution
An automated tool control system utilizing machine vision to identify inventory conditions by capturing and processing images of storage locations, applying visual contrast elements to indicate missing tools, and integrating with web services for network compatibility and secure data transfer, allowing for efficient tracking and reporting of tool usage and status changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact sensors, magnetic sensors or infrared sensors are disposed in or next to each tool storage location to detect tool presence, then the system can determine whether tools are missing, but the system becomes costly, tedious to implement, and prone to damages or malfunctions producing false alarms
Solution Approach 1:
The patent uses image capture devices to create visual copies (images) of tool storage locations instead of using physical sensors at each location. The image processing system analyzes these visual copies to detect tool presence, absence, and misplacement, eliminating the need for numerous physical sensors while maintaining detection accuracy.
Solution Approach 2:
The patent replaces the mechanical sensor-based detection system with an optical imaging and image processing system. Instead of using contact sensors, magnetic sensors, or infrared sensors that require physical placement at each storage location, the system uses cameras or image capture devices to optically detect tool conditions and processes images to determine tool status.
2Productivity
If sensors are disposed at each storage location to detect tool presence, then inventory conditions can be determined, but the system is tedious and costly to implement and maintain
Solution Approach 1:
The patent employs a single image capture device that serves multiple functions: detecting tool presence, identifying tool misplacement, monitoring storage location status, and providing visual records for audit purposes. This universal imaging system replaces numerous specialized sensors, reducing system complexity while maintaining or improving inventory check efficiency.
Solution Approach 2:
The system creates digital image copies of storage locations that can be processed and analyzed without requiring physical sensor installation at each location. These image copies enable comprehensive inventory monitoring while eliminating the tedious and costly sensor deployment and maintenance requirements.
3Extent of automation
If automated tool control systems capture and process images of storage locations, then inventory conditions can be determined efficiently, but the system may not fully utilize advancing electronic capabilities for tracking tool status changes and providing interactive feedback
Solution Approach 1:
The patent implements feedback mechanisms where the image processing system provides real-time or near-real-time information about tool status changes to users through displays or notifications. The system captures images, processes them to detect tool conditions, and feeds back this information to operators, enabling them to respond to misplacement or missing tools promptly. This feedback loop充分利用advancing electronic capabilities to enhance automation while maintaining complete tool status tracking.
4Reliability
If manual methods are used to review audit images and determine incorrect tool placement, then tool status can be tracked, but the process is time consuming and inefficient
Solution Approach 1:
The patent replaces manual review of audit images with automated image processing algorithms that rapidly analyze captured images to detect tool misplacement, absence, and status changes. The computer-based image processing system maintains the reliability of accurate tool status tracking while dramatically reducing the time required compared to manual image review, thereby eliminating the time loss associated with manual methods.
Data Source
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AI summary
An inventory control system is described that includes a tool storage device including a drawer or a tray providing a pallet, wherein the pallet includes storage locations for objects; a sensing device configured to form an image of the storage locations; and a data processor configured to determine presence or absence of the pallet and presence or absence of objects within the storage locations of the pallet using the information from the image.