Tool Storage Inventory Control Using Image-Based Presence Detection
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Solution Overview
Problem
Existing inventory control systems for tools in manufacturing environments, particularly in aerospace, face challenges such as inaccurate tracking of tool types, inefficiencies in identifying incorrect tool returns, and the need for integration with network systems, while also being prone to sensor malfunctions and high costs.
Innovation Solution
An inventory control system utilizing image sensing devices to capture and process images of storage locations, apply visual contrast elements, and integrate with network systems through web services for efficient tool tracking, authorization levels, and multi-factor authentication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact sensors, magnetic sensors or infrared sensors are disposed in or next to each tool storage location to detect tool presence, then the toolbox can determine whether tools are missing, but the system becomes costly, tedious to implement, and prone to sensor malfunctions producing false alarms
Solution Approach 1:
The patent uses image capture devices to create visual copies (images) of tools in storage locations, replacing the need for physical sensors at each location. The image processing system analyzes these visual copies to detect tool presence, absence, and identity, achieving reliable tracking without deploying numerous physical sensors.
Solution Approach 2:
The patent replaces mechanical and electromagnetic sensor systems with an optical imaging system. Instead of using contact sensors, magnetic sensors, or infrared sensors that require physical placement at each storage location, the system uses image capture devices to optically detect tool presence and identity, eliminating the mechanical sensor deployment complexity.
2Ease of operation
If sensors detect that something is occupying a storage location, then the toolbox determines no tool is missing, but the system cannot distinguish between the correct tool and incorrect objects placed to cheat the system
Solution Approach 1:
The system captures images of tools and creates visual copies for analysis. By processing these image copies, the system can identify specific tool characteristics, patterns, and features to distinguish the correct tool from incorrect objects, maintaining operational simplicity while improving identification precision.
Solution Approach 2:
The image processing system provides feedback by analyzing visual characteristics of objects in storage locations. The system compares detected features against expected tool characteristics, enabling it to distinguish correct tools from incorrect objects and provide accurate identification feedback to the inventory management system.
3Measurement precision
If automated tool control systems capture and process images of storage locations to determine inventory conditions, then tool tracking accuracy improves, but the system requires integration with network systems and additional processing capabilities
Solution Approach 1:
The image capture and processing system serves multiple functions: detecting tool presence, identifying tool types, monitoring storage location status, and providing inventory data. This multi-functional approach achieves precise inventory condition detection while reducing the need for separate specialized systems, thereby managing complexity through consolidation.
Data Source
AI summary
An inventory control system is described that includes a tool storage device including a drawer or a tray providing a pallet, wherein the pallet includes storage locations for objects; a sensing device configured to form an image of the storage locations; and a data processor configured to determine presence or absence of the pallet and presence or absence of objects within the storage locations of the pallet using the information from the image.