Warehouse Inventory Sensing Modules for Real-Time Location Auditing
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Solution Overview
Problem
Conventional warehouse management systems face challenges in accurately tracking the type, quantity, and location of stored items, leading to inefficiencies and stock loss due to improper cataloging and location issues.
Innovation Solution
Deploying a plurality of automation modules around the inventory facility equipped with sensors for continuous data gathering, coupled with an auditing server to aggregate and coalesce inventory signals, creating a digital twin for augmented reality rendering and maintaining a real-time inventory database.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional warehouse management systems are used to track inventory, then basic storage and cataloging can be maintained, but accuracy in tracking type, quantity, and location deteriorates leading to stock loss and inefficiencies
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the physical warehouse inventory system. Sensors throughout the warehouse continuously capture inventory data (type, quantity, location) and transmit it to servers that maintain an accurate digital replica. This digital copy enables precise tracking without physical intervention, eliminating errors from manual counting and providing real-time visibility into inventory status, thereby preventing stock loss.
Solution Approach 2:
The patent replaces manual mechanical inventory tracking methods with automated sensor-based systems. Instead of workers physically counting and recording inventory, the system uses cameras, LIDAR, weight sensors, and RFID readers to automatically detect and track items. This substitution of mechanical human labor with automated sensing and processing systems dramatically improves tracking accuracy and eliminates the errors that lead to stock loss.
2Measurement precision
If multiple sensors and automation modules are deployed for continuous inventory monitoring, then tracking accuracy improves, but system complexity increases
Solution Approach 1:
The patent divides the warehouse into multiple zones with distributed automation modules and sensors in each zone. Each module independently monitors its local area and transmits data to central servers. This segmentation allows the system to achieve high overall tracking accuracy through coordinated local measurements while keeping individual module complexity manageable. The modular architecture makes the system scalable and easier to maintain.
Solution Approach 2:
The patent employs multi-functional automation modules that perform multiple sensing tasks simultaneously. For example, a single module may use cameras for visual identification, LIDAR for spatial mapping, and weight sensors for quantity verification all at once. This multi-functionality reduces the total number of separate devices needed, thereby lowering overall system complexity while maintaining high tracking accuracy through redundant verification methods.
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
Ensures accurate and continuous tracking of inventory, reducing errors and discrepancies by providing a photorealistic representation of the warehouse for virtual and augmented reality applications, enhancing inventory management efficiency.
Implementation Method 1
LIDAR (Light Detection and Ranging)
Data Source
AI summary
An automation module deployed in static or mobile form around an inventory facility such as a warehouse employs multiple modes of sensors for continuously gathering inventory signals indicative of a location, type and quantity of each of the types of items stored in the inventory facility. An auditing server receives the inventory signals from each of the automation modules around the inventory facility for aggregating and coalescing the inventory signals to eliminate duplicate references and compute a discrete quantity and location of each type of item in the inventory facility. The automation modules may be adhered to a vehicle such as a forklift, installed on the weight-bearing prongs of the forklift, and/or affixed to walls or exit doorways, and each automation module may gather sensor data through video, weight, Lidar, inertial/gyroscopic, GPS (Global Positioning System) and other mediums that may aid in accurate cataloging and auditing of warehouse contents.