RFID Enabled Pallet Mover with RTLS Tracking
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Solution Overview
Problem
Current inventory tracking systems in shipping warehouses using barcodes are time-consuming and prone to errors, as workers may forget to scan barcodes or scan the wrong ones, leading to inaccurate pallet location tracking due to large areas covering multiple pallets.
Innovation Solution
A location-aware, RFID-enabled pallet mover equipped with an RFID system and a real-time location system (RTLS) that uses antennas and a controller to detect and track RFID tags on pallets, providing accurate location tracking and feedback to operators, ensuring correct pallet movement and drop-off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If barcode scanning is used for inventory tracking, then workers can manually track pallet locations, but the process is time-consuming and error-prone
Solution Approach 1:
The patent replaces the manual barcode scanning system with an automated RFID-based tracking system. RFID tags on pallets communicate their location automatically to readers in the warehouse, eliminating the need for workers to manually scan barcodes. This substitution of mechanical/manual processes with automated electromagnetic field-based systems directly addresses both productivity and reliability issues.
Solution Approach 2:
The RFID system enables pallets to self-track their own location without human intervention. The RFID tags automatically transmit their identity and location information to readers as pallets move through the warehouse, making the tracking process autonomous and eliminating dependency on worker attention and accuracy.
2Reliability
If barcode scanning is used, then inventory location can be tracked, but workers may forget to scan or scan the wrong barcode
Solution Approach 1:
The RFID system eliminates the need for worker intervention by enabling automatic, passive tracking. Pallets with RFID tags automatically communicate their location to readers without requiring workers to actively scan or check barcodes, removing the human error factors of forgetting to scan or scanning the wrong barcode.
Solution Approach 2:
The system provides continuous automatic feedback on pallet location through RFID readers that constantly monitor the warehouse environment. This real-time feedback mechanism ensures accurate tracking without relying on worker memory or attention, as the system automatically records and reports pallet positions throughout their movement.
3Measurement precision
If barcode scanning is used, then pallet location can be identified, but large staging areas with multiple pallets make accurate location tracking difficult
Solution Approach 1:
The patent divides the large staging area into multiple zones with individual RFID readers positioned throughout. Each reader independently tracks pallets in its local area, enabling precise location identification even within large spaces. This segmentation of the monitoring system allows accurate tracking without requiring the entire large area to be monitored by a single system.
Solution Approach 2:
The system replaces manual barcode scanning with automated RFID electromagnetic field-based detection. RFID readers can passively detect and identify pallets at any location within their reading range, providing precise location data without the limitations of manual scanning processes that struggle in large, cluttered areas.
4Reliability
If RFID system is implemented, then real-time accurate tracking is achieved, but device complexity increases
Solution Approach 1:
The RFID tags are passive and automatically respond to readers without requiring power sources or active components on the pallets themselves. This self-service capability maintains simplicity on the moving objects while enabling sophisticated tracking, as the complexity is distributed to the stationary reader infrastructure rather than being embedded in each pallet.
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 ensures real-time, accurate tracking of inventory location throughout the transport cycle, reducing errors and improving efficiency by providing operators with precise location feedback and correcting mistakes in pallet movement and destination.
Implementation Method 1
RFID tags, which can be passive or active, are disposed on the inventory (e.g., individual packages or pallets) in the warehouse and are programmed with information identifying the associated inventory. The identifying information is read from the RFID tags by RFID readers.
Implementation Method 2
the pallet mover includes a real-time location system (RTLS) tag that can be used to determine a location of the pallet mover
Data Source
AI summary
Embodiments presented herein describe a location aware, RFID-enabled pallet mover for tracking inventory moving in a warehouse. The pallet mover includes a RFID system for detecting a pallet currently loaded on the pallet mover and a real-time location system (RTLS) tag for identifying a location of the pallet mover in the warehouse. In one embodiment, the RFID system includes an antenna and an RFID reader for detecting RFID tags in order to track inventory such as a pallet or packages. The RFID reader can communicate with the RFID tags in the environment to identify which pallet is currently loaded on the mover. In one embodiment, the RFID system waits until the pallet mover is moving before activating the RFID reader and monitoring a received signal strength indicator (RSSI) of an RFID tag to determine whether the corresponding pallet is currently loaded onto the pallet mover.