Merchandise inventory data collection for shelf systems using light sensors
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Solution Overview
Problem
Current methods for real-time inventory measurement in retail environments are inaccurate, costly, and not suitable for low-margin items or varying merchandise sizes/weights, often resulting in significant 'shrinkage' and inefficiencies in restocking.
Innovation Solution
The use of light sensors integrated into shelving systems to detect the presence or absence of merchandise, providing accurate real-time data through a signal generated by changes in light reception, which can be combined with bar code scanners and image recognition for precise inventory tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If RFID tags are placed on each product to capture real-time inventory data, then real-time inventory tracking is achieved, but the cost becomes prohibitively high for low-margin items
Solution Approach 1:
The patent replaces expensive RFID tags with inexpensive light sensors that detect inventory levels optically. The light sensors are positioned to receive light from LEDs placed behind the shelf, and the absence or presence of light indicates inventory status. This disposable, low-cost optical detection method eliminates the need for expensive electronic tags on each product while maintaining real-time tracking capability.
Solution Approach 2:
The patent substitutes electronic RFID detection with an optical detection system using light sensors and LEDs. Instead of using electromagnetic fields and electronic tags, the system uses simple optical principles where light blocks by products indicate their presence. This mechanical/optical substitution dramatically reduces costs while achieving the same inventory monitoring function.
2Measurement precision
If weight sensors are used on shelves to measure inventory, then real-time data is obtained, but the system cannot accurately measure merchandise with differing weights and sizes
Solution Approach 1:
The patent changes the measurement parameter from weight to light blockage. Instead of measuring the weight of different products, the system measures how much light is blocked by products on the shelf. This parameter change makes the system adaptable to products of any weight, size, or shape, as long as they block light. The light sensor detects inventory presence based on optical properties rather than physical mass.
3Measurement precision
If ultrasonic devices are deployed for inventory detection, then real-time measurement is achieved, but the devices occupy too much space at the back of and beneath the shelves
Solution Approach 1:
The patent extracts the detection function from bulky ultrasonic devices and implements it using compact light sensors and LEDs. The light sensing components can be mounted in thin profiles behind or beneath the shelf surface, eliminating the need for large ultrasonic transducers. This extraction of the core detection function to smaller components solves the space problem while maintaining detection accuracy.
Solution Approach 2:
The optical detection system can be implemented using thin film or flexible circuit board mounting for the light sensors and LEDs. These thin-profile components can be integrated into the shelf structure without requiring the bulky housings needed for ultrasonic devices, allowing installation in confined spaces behind and beneath shelves.
4Measurement precision
If infrared sensors are used in open spaces for inventory measurement, then detection capability is improved, but the sensors become harmful to the human eye
Solution Approach 1:
The patent changes the wavelength parameter from infrared to visible light. Instead of using infrared sensors that emit invisible radiation potentially harmful to eyes, the system uses visible light LEDs and matching light sensors. This parameter change to the visible spectrum eliminates eye safety concerns while maintaining the optical detection capability for inventory measurement.
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
This solution offers 95-100% accuracy in inventory measurement, is cost-effective, and can be retrofitted to existing shelving systems, reducing 'shrinkage' and enhancing inventory management efficiency.
Implementation Method 1
a plurality of light sensors disposed beneath or adjacent the inventory, wherein, when inventory is on the shelf, a first amount of light is received by at least one light sensor, wherein, when inventory is removed from the shelf, a second amount of light is received by the at least one light sensor
Data Source
AI summary
Disclosed is a system for real-time measurement of inventory on shelves. The system uses light sensors placed in association with the inventory and the shelves to measure in real-time the removal/replacement of inventory from the shelves. When inventory is on the shelves, less light reaches the light sensors. As inventory is removed from shelves, the light sensors receive more light. The difference in light received generates as signal that can be measured, thereby allowing for determining inventory levels on each shelf. The system may be retro-fitted to existing shelving systems, thereby avoiding the cost of purchasing new shelving systems. The system can work on any shelving system, including gravity-feed roller shelf (GRS), flat shelves, and spring loaded pusher shelves, and is unaffected by usual temperatures found in retail establishments and can thus work in both refrigerated and unrefrigerated systems. Also disclosed are related methods.