Storage Cart Weight Sensor Item Placement Verification
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Solution Overview
Problem
Inefficient and time-consuming manual processes for stocking and replenishing items on shelves, where multiple bins or totes are used, often result in incorrect item placement and difficulty in locating items due to the lack of effective organization and verification systems.
Innovation Solution
A mobile item storage cart equipped with a control device, weight sensors, and a cart manager component that analyzes sensor data to verify correct item placement into designated containers, using a user interface to output notifications for incorrect placements and prevent errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple bins or totes are used to separate different types of items, then item organization and separation is improved, but the picker has difficulty determining which item goes into which bin and locating items
Solution Approach 1:
The system provides real-time feedback through a user interface that displays the current state of each bin, shows which bin is selected, and confirms item placement. The weight sensor feedback loop continuously monitors bin weight and communicates this information to the user interface, guiding the picker to the correct bin and confirming when items are properly placed.
Solution Approach 2:
The system performs preliminary actions by automatically selecting the target bin based on item identification (scan or manual input) before the picker places the item. The user interface pre-displays which bin should receive the item, and the system pre-positions the container housing to make the target bin easily accessible, reducing the picker's cognitive load and search time.
2Device complexity
If manual processes are used for stocking and replenishing items, then device complexity is reduced, but the process becomes inefficient and time-consuming
Solution Approach 1:
The system performs self-service functions by automatically identifying items through scanning or manual input, determining the correct destination bin, tracking inventory levels, and providing real-time feedback to the picker. The weight sensors automatically detect when items are placed in bins and update the system state without human intervention, allowing the picker to focus solely on the physical movement of items.
Solution Approach 2:
The patent replaces manual mechanical processes with automated electronic systems. Instead of manually tracking which items go into which bins, the system uses weight sensors to detect item placement, processors to determine correct destinations, and user interfaces to guide the picker. This substitution of mechanical tracking with electronic sensing and processing dramatically improves stocking efficiency while adding manageable complexity.
3Manufacturing precision
If weight sensors and automated verification systems are added to the cart, then item placement accuracy is improved, but device complexity increases
Solution Approach 1:
The cart system performs multiple functions using integrated components: weight sensors serve both as verification tools for correct item placement and as inventory tracking devices; the processor determines both destination bin selection and placement verification; the user interface provides both guidance and confirmation. This multi-functionality reduces the need for separate specialized components, managing overall system complexity while achieving high placement accuracy.
4Reliability
If locking mechanisms are used to secure containers in closed configuration, then container security is improved, but ease of access to items worsens
Solution Approach 1:
The locking mechanism is designed to be dynamic rather than static. The housing support member can automatically extend to present the selected bin to the picker, and the locking mechanism can be automatically actuated to release the selected bin while maintaining locked status on other bins. This dynamic behavior allows the system to provide security when needed while enabling easy access when the target bin is identified and selected through the automated system.
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 solution enhances the efficiency of item storage and retrieval by ensuring correct placement of items into the right containers, reducing errors and saving time through automated verification and organization.
Implementation Method 1
A set of one or more weight sensors associated with the set of container housings. The set of weight sensors generates weight data associated with the first storage container and the second storage container.
Data Source
AI summary
Examples provide an item storage cart for verifying correct item placement into containers on the item storage cart. A cart manager component outputs planogram data identifying a location of a selected item. Weight data generated by one or more weight sensors associated with the set of item storage containers is analyzed to verify whether a correct item is placed in a given storage container on the cart and/or verify a selected item is placed into a correct storage container. The cart manager component determines if an unselected item is removed from a storage container and/or if an unselected item is added to a storage container. A notification is output if an incorrect item is added to a cart, an incorrect item is removed from the cart, an item is added to the wrong container or removed from the wrong container.