Image-Based Tool Inventory Control to Reduce Sensor Complexity
Find Innovative SolutionsGenerate Solutions
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 errors and inefficiencies due to reliance on sensors and manual methods.
Innovation Solution
An automated tool control system utilizing image sensing devices to capture and process images of storage locations, applying visual contrast elements to identify missing or incorrectly placed tools, and integrating with networked systems for secure data transfer and user authentication, enabling efficient tracking and management of tool inventory across multiple locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are disposed in numerous storage locations to detect tool presence, then inventory tracking capability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent uses digital images as copies of the physical storage locations to track tool presence. Instead of placing sensors in each storage location, the system captures images of the storage locations and processes them to determine whether tools are present, replacing numerous physical sensors with a single imaging system.
Solution Approach 2:
The patent replaces the mechanical sensor-based detection system with an optical imaging and image processing system. The image processing system analyzes digital images to detect tool presence, substituting the mechanical contact sensors, magnetic sensors, or infrared sensors with a non-contact optical approach.
2Device complexity
If manual inventory checks are performed to track tool location, then system complexity is reduced, but loss of time and productivity decrease
Solution Approach 1:
The system performs automated self-monitoring of tool inventory by capturing images and processing them to determine tool presence and location. The inventory control system automatically tracks tool movements and generates alerts without requiring manual intervention, enabling the system to monitor itself continuously.
Solution Approach 2:
The imaging system enables continuous monitoring of storage locations, capturing images at relevant times (when drawers are opened or closed) to track tool movements continuously rather than through periodic manual checks, eliminating gaps in monitoring while maintaining reasonable system complexity.
3Ease of manufacture
If traditional sensor-based inventory systems are used, then implementation cost is reduced, but reliability and accuracy of tool tracking deteriorate
Solution Approach 1:
The system creates digital copies (images) of storage locations and tool positions, enabling accurate visual verification of tool presence and identity. This image-based approach provides reliable evidence of tool location and condition without the susceptibility to sensor malfunction or false readings that plagues traditional sensor systems.
Solution Approach 2:
The patent introduces an image processing system as an intermediary between the physical storage locations and the inventory control database. This intermediary captures and processes visual information, providing a reliable bridge that accurately translates physical tool positions into digital inventory data without the errors associated with direct sensor contact.
4Measurement precision
If imaging technology is integrated into the inventory control system, then measurement precision and tracking accuracy are improved, but device complexity increases
Solution Approach 1:
The imaging system serves multiple functions: it captures storage location images, identifies tool presence and position, verifies tool identity, and provides audit trails. This multi-functional approach consolidates what would otherwise require separate sensing, identification, and monitoring systems into a single universal imaging platform.
Solution Approach 2:
The image processing system acts as a versatile intermediary that handles multiple inventory control tasks through a single integrated platform, managing the complexity by providing a unified interface between the imaging hardware and the inventory database while supporting various tracking and verification functions.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
The invention relates to a system comprising: a plurality of object storage devices (1030, 1510) each including a plurality of drawers and/or shelves for storing objects and each having an access control device (1006) operative to limit access to the object storage device; and a data processor configured to: establish a first group (1710) including a first subset of the plurality of object storage devices (1712), a first subset of all users (1714) of the plurality of object storage devices, and a first subset of all work locations (1716) associated with the plurality of object storage devices; establish a second group (1720) including a second subset of the plurality of object storage devices, a second subset of all users (1724) of the plurality of object storage devices (1722), and a second subset of all work locations (1726) associated with the plurality of object storage devices; receive from a user a request to access at least one object storage device of the system; when the user is associated with the first group, control the access control device of at least one object storage device of the plurality of object storage devices to grant the user access to the first subset of the plurality of object storage devices in the first group and at the first subset of all the work locations; and when the user is associated with the second group, control the access control device of at least one object storage device of the plurality of object storage devices to grant the user access to the second subset of the plurality of object storage devices in the second group and at the second subset of all work locations.