Forklift-Mounted Tower Inventory System for Warehouse Tracking

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Solution Overview

Problem

Current warehouse inventory systems are inefficient and costly due to the need for complex navigation systems, multiple sensors, and mechanical components, which can lead to increased time and maintenance costs, especially when dealing with high shelves and densely packed storage areas.

Innovation Solution

A Tower Inventory System (TIS) using a 20-foot tall tower with multiple RFID antennas and readers mounted on a stable base, navigated by an existing forklift, which eliminates the need for complex navigation and collision avoidance systems, and provides software to determine the x, y, and z coordinates of goods within the warehouse, allowing for accurate inventory tracking and location identification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a mobile inventory robot with navigation systems and sensors is used, then automated inventory tracking is achieved, but device complexity and maintenance costs increase

Engineering Contradiction:

Improveautomated inventory trackingVSAvoidnavigation systems and sensors

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical navigation systems and sensor arrays with a simplified approach using existing forklift navigation capabilities combined with RFID technology. The forklift's existing navigation system is leveraged instead of implementing a new robot navigation system, significantly reducing device complexity while maintaining automated inventory tracking functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention utilizes the existing forklift as a multi-functional platform that serves both its traditional material handling role and the new inventory tracking role. By mounting RFID readers and antennas on the forklift, it performs dual functions without requiring a dedicated inventory robot, thereby reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Quantity of substance

If mechanical positioning systems are added to read items on higher shelves, then inventory coverage is improved, but reliability decreases due to increased mechanical failure risk

Engineering Contradiction:

Improveinventory coverageVSAvoidmechanical failure risk

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent eliminates mechanical positioning systems by using RFID technology that can read tags on all shelves without physical contact or mechanical movement. The RFID readers mounted on the forklift can detect tags at various heights through radio frequency signals, removing the need for mechanical lifting or positioning mechanisms and thereby improving reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

RFID tags and readers serve as an intermediary that enables inventory reading without direct mechanical interaction. The radio frequency signals act as a mediator between the forklift-based reading system and the goods on shelves, allowing inventory tracking without mechanical positioning systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If RFID tags are used for inventory tracking, then inventory accuracy is improved, but cost increases due to tagging all goods

Engineering Contradiction:

Improveinventory accuracyVSAvoidcost of tags

Core Design Contradiction:

Measurement precisionVSQuantity of substance

Solution Approach 1:

The patent implements RFID tracking selectively rather than universally. RFID tags are applied to high-value items, slow-moving items, or items that benefit most from precise tracking, while other items may use alternative tracking methods. This partial implementation achieves improved inventory accuracy for critical items without the prohibitive cost of tagging every single item in the warehouse.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The TIS enables efficient and accurate inventory tracking across multiple levels and densely packed storage areas, reducing time and maintenance costs by leveraging existing forklift navigation and RFID technology, while maintaining system stability and accuracy.

Implementation Method 1

The invention provides hardware that can be moved through a warehouse and reads the RFID products tags that are affixed to the goods stored in the warehouse

Methodology Applied

Scientific EffectRFID (Radio Frequency Identification): Electromagnetic Induction

Data Source

PatentUS10102499B2Tower inventory system

Publication Date: 2018.10.16 R F I D INVENTORY INC

AI summary

A movable Tower Inventory System which contains a number of RFID antennas mounted vertically along the tower. The Tower Inventory System is the moved along the front of storage racks to acquire information from RFID tags affixed to assets positioned on the storage rack. This information enables the determination of the x, y and z location values for each unique RFID number stored in the RFID tags.