Magnetic Sensor Rack System for Automated Cigarette Pack Counting
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Solution Overview
Problem
Current inventory tracking methods for store shelves are labor-intensive, prone to errors, and lead to underutilization of shelf space and revenue loss due to inaccurate counting of products.
Innovation Solution
A system utilizing magnetic sensors integrated into a rack design that automatically counts items by detecting a magnet's position along the rack, allowing for real-time and accurate tracking of product quantities, and includes a master controller to detect theft by monitoring data interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection and counting methods are used, then labor intensity and time consumption are high, but the system complexity and cost are low
Solution Approach 1:
The patent replaces manual mechanical counting with an automated sensor-based detection system. Magnetic sensors detect the position of a magnet on the shoe to determine item count, eliminating the need for manual inspection and significantly improving inventory tracking efficiency while reducing labor intensity.
Solution Approach 2:
The rack system performs self-counting through integrated sensors and a magnet mechanism. As items are loaded or removed, the shoe moves automatically, carrying the magnet to different positions that trigger sensor detections, enabling the system to track inventory autonomously without external intervention.
2Measurement precision
If manual counting is performed, then human errors occur, but the measurement precision requirement is low
Solution Approach 1:
The patent replaces error-prone manual counting with automated magnetic sensor detection. The sensors objectively detect magnet position and calculate item counts without human intervention, eliminating counting errors and improving measurement precision while maintaining relatively simple system architecture.
Solution Approach 2:
The system uses a magnet as a physical copy or representation of the shoe's position. The magnet's position on the shoe creates a detectable signal pattern that accurately represents the actual item count, enabling precise measurement through indirect detection rather than direct visual counting.
3Reliability
If frequent manual inspection is conducted, then accurate inventory data is obtained, but loss of time and labor increase
Solution Approach 1:
The patent implements continuous automated monitoring through sensors that detect magnet position in real-time as items are loaded or removed. The system continuously tracks inventory levels without interruption, eliminating the need for periodic manual inspections and providing reliable data without time loss.
Solution Approach 2:
The system provides immediate feedback through sensor detections that automatically update inventory counts. When the shoe moves to a new position, sensors detect the change and recalculate the item count, providing real-time feedback on inventory status without requiring manual verification or inspection cycles.
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 system provides efficient, accurate, and precise monitoring of inventory, preventing underutilization of shelf space and reducing losses by automating the counting process and quickly detecting potential theft.
Implementation Method 1
The circuit board includes an array of sensors along the length of the rack, wherein each sensor generates a voltage value based on a position of the magnet in relation to the sensor
Data Source
AI summary
A system includes a longitudinal rack storing a plurality of packs of cigarettes, a shoe movably attached to the rack, a magnet coupled to the shoe and a circuit board arranged along the length of the rack. The circuit board includes a plurality of sensors along the length of the rack. Each sensor generates a voltage value and an angular measurement depending on a position of the magnet in relation to the sensor. The circuit board further includes a processor configured to determine a position of the shoe/magnet based on the voltage values and the angular measurements generated by the sensors and determines a pack count of the packs based on the position of the shoe/magnet.