Monitoring removal and replacement of tools within an inventory control system
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Solution Overview
Problem
Current inventory control systems for tools in manufacturing and aerospace environments face challenges in accurately tracking tool presence, type, and location, leading to inefficiencies and potential tool misplacement or theft, especially in environments where high security and calibration status are critical.
Innovation Solution
An automated tool control system utilizing image sensing devices and data processors to capture and analyze images of storage locations, apply visual contrast elements, and integrate with networked systems for secure data transfer and user authentication, enabling efficient tracking and management of tools within tool storage devices.
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 toolbox can determine whether any tools are missing, but disposing sensors for numerous storage locations is tedious and costly and the large number of sensors is prone to damages or malfunctions which will produce false negative or positive alarms
Solution Approach 1:
The system divides the tool storage monitoring into two levels: individual storage location detection using simple presence sensors, and comprehensive inventory verification using image sensing devices. This segmentation allows the system to use simple sensors for basic detection while using image analysis for accurate identification, reducing the reliance on complex sensor arrays at each location.
Solution Approach 2:
The patent introduces image sensing devices as an intermediary mechanism that captures visual data of storage locations. This intermediary approach allows the system to verify tool presence and identity without relying solely on sensor signals, providing a backup and verification layer that reduces false alarms and improves accuracy.
2Productivity
If sensors detect that something is occupying a storage location, then the toolbox will determine that no tool is missing from that storage location, but the toolbox does not know whether the right kind of tool is indeed placed back in the toolbox or it is just some objects placed in the storage location to cheat the system
Solution Approach 1:
The patent replaces sensor-based detection with image sensing and optical recognition technology. Instead of relying on mechanical or magnetic sensors that can only detect presence, the system uses image cameras and pattern recognition algorithms to visually identify tools, their types, and their correct placement, thereby eliminating cheating possibilities.
Solution Approach 2:
The system creates visual copies (images) of the storage locations and tools within them. By capturing and analyzing images of the actual tools and their positions, the system can verify tool identity and placement accuracy without physical contact, enabling remote monitoring and verification of tool inventory.
3Loss of information
If automated tool control systems capture and process images of storage locations to determine inventory condition, then the system can identify tool presence and type, but the system may not fully take advantage of the capabilities of advancing electronic capabilities in today's automated tool control systems, especially those systems equipped with imaging capabilities
Solution Approach 1:
The patent implements a feedback mechanism where image sensing devices continuously monitor storage locations, and the data processor analyzes changes in tool presence and status. This feedback loop provides real-time information about tool inventory conditions, enabling automatic alerts and tracking of tool removals, returns, and misplacements, thereby fully utilizing automated imaging capabilities.
Solution Approach 2:
The system is designed to perform multiple functions using the same imaging infrastructure: identifying tool presence, verifying tool type, detecting tool removals, monitoring tool returns, and tracking storage location status. This multi-functional approach maximizes the utility of the imaging capabilities and reduces the need for separate specialized systems.
Data Source
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.