Optical Code Detection on Storage Bins Using Tilted Support Structure
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Solution Overview
Problem
Traditional Kanban inventory management systems face issues with imaging-based solutions that fail to properly detect optical codes on bins due to misalignment, bin stacking, improper lighting, and camera settings, leading to ineffective replenishment signals.
Innovation Solution
An imaging-based inventory management system with cameras and processors that detect optical codes on bins, specifically designed to capture images of the top shelf replenishment area, ensuring proper alignment and focus, and generating notifications only when codes are correctly oriented within the camera's field of view, thus eliminating the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If imaging-based Kanban solutions are used to automatically detect bins on the top shelf, then manual labor is reduced, but detection reliability deteriorates when optical codes are not sufficiently visible due to misalignment, stacking, or hiding
Solution Approach 1:
A support structure with a tilted surface is introduced as an intermediary between the bin and the camera. This tilted surface positions the bin at an optimal angle relative to the camera's field of view, ensuring the optical code is always visible and properly oriented for reliable automated detection, regardless of how the bin is placed on the shelf
Solution Approach 2:
The support structure pre-positioned on the top shelf creates a predetermined optimal viewing angle for the optical code. This preliminary arrangement ensures that when a bin is placed on the support structure, the code is automatically oriented correctly for the camera, eliminating the need for manual alignment and ensuring reliable detection from the start
2Quantity of substance
If bins are stacked or placed in front of each other to maximize storage space, then storage density is improved, but optical code visibility deteriorates as codes become hidden or misaligned
Solution Approach 1:
Instead of arranging bins in a single horizontal plane where they can block each other, the support structure introduces a vertical/angular dimension by tilting the bin at an angle. This angular displacement ensures that even when bins are stacked or placed close together, their optical codes are oriented at different angles relative to the camera, preventing mutual obstruction and maintaining visibility
3Area of stationary object
If the camera's field of view is widened to capture the entire top shelf, then coverage area is improved, but image quality and code detection accuracy deteriorate due to improper focus or cropping
Solution Approach 1:
The support structure creates a localized optimal viewing zone by tilting bins to a specific angle that aligns with the camera's field of view. This ensures that within the camera's coverage area, the optical codes are consistently positioned and oriented for high-quality capture and accurate detection, while maintaining wide overall coverage
Data Source
AI summary
An apparatus for monitoring and replenishing an inventory of goods includes a shelving unit, a replenishment signaling area, a camera, and a processor. The shelving unit has storage shelves that hold storage bins, including a first bin that holds a first type of goods and has first optical code that identifies the first type of goods. The replenishment signaling area includes the uppermost shelf of the shelving unit, wherein the storage shelves are disposed below the uppermost shelf. The camera's field of view encompasses the replenishment signaling area, but not the storage shelves. The first bin is placed in the replenishment signaling area after its goods are depleted. The processor executes instructions to generate a replenishment notification based on detecting the first optical code within images generated by the camera. The replenishment notification indicates that the supply of the goods in the first bin needs to be replenished.