Stock Management Mat With Sensor Array And Partitions
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Solution Overview
Problem
Current stock management systems face challenges in accurately counting items of varying sizes on mats with sensors, as items larger than the sensing area can span multiple sensors, leading to discrepancies between detected positive sensing areas and actual item count.
Innovation Solution
A stock management system comprising a mat with sensors arranged in an array, partitions defining lanes, and a controller that processes sensing results to calculate the actual number of items by adjusting for the size of items and the position of sensors within lanes, ensuring accurate stock level calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If items larger than the sensing area are placed on the mat, then the sensing coverage increases, but the counting accuracy deteriorates because a single item spans multiple sensors
Solution Approach 1:
The mat is divided into multiple sensing areas with individual sensors, allowing the system to detect which specific sensors are activated. By segmenting the detection area and tracking which sensors are positive, the system can distinguish between multiple items even when they span across sensing areas, resolving the contradiction between coverage and counting accuracy
Solution Approach 2:
The system transitions from simple presence/absence detection to spatial distribution analysis by tracking which specific sensors are activated. This dimensional approach allows the controller to calculate item positions and distinguish between multiple items based on their spatial arrangement, improving counting accuracy while maintaining large sensing coverage
2Adaptability or versatility
If a single mat format is used for different types of items, then the system versatility improves, but the measurement accuracy deteriorates due to item size variations
Solution Approach 1:
The mat is designed with a universal format that can detect various types of items regardless of their size. The controller adapts its counting algorithm based on the activation pattern of sensors, allowing the same mat to accurately measure different item types from small to large, achieving both versatility and accuracy
Solution Approach 2:
The system changes the parameter of interest from fixed item size assumptions to dynamic sensor activation patterns. By analyzing which sensors are positive and their spatial distribution, the system adapts to different item sizes and shapes, maintaining measurement accuracy across diverse item types while using a single mat format
3Reliability
If the number of sensors increases to cover larger items, then the detection capability improves, but the device complexity increases
Solution Approach 1:
The detection area is segmented into multiple sensing areas with individual sensors. This segmentation provides the reliability needed to detect large items spanning multiple areas while keeping each sensor simple and the overall system manageable through modular architecture
Solution Approach 2:
Instead of using a single complex high-resolution sensor, the system uses multiple simpler sensors arranged in an array. Each sensor is a simple binary detector, but their collective arrangement provides the enhanced detection capability needed for large items, reducing individual component complexity while maintaining system reliability
Data Source
AI summary
A stock management method and system utilizes a mat that includes a plurality of sensors corresponding to a plurality of sensing areas, each of sensors is configured to sense an item placed on a certain sensing area. Partitions define a plurality of lanes on the mat. A controller receives sensing results of the plurality of the sensors and calculates a stock level of remained items on the mat based on the sensing results. One of the sensing areas is located in both of two lanes of the plurality of lanes.