Shelving structure and validation apparatus for improved image processing of codes on storage bins

Inventors: Nicholas J. Poker (Knoxville, TN); Dhanvin S. Desai (Knoxville, TN); Sallie P. Patrick (Maryville, GB); Joe L. Smith (Powell, TN)

Assignee: DeRoyal Industries, Inc.

G06Q10/087 A47F5/0043 G06K7/10722 G06K7/1417 G06K19/06037

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Quick Facts

Patent No.: US 12688485
App. No.: 18/609,394
Granted: Jul 21, 2026
Kind: B2

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Abstract

In an optical imaging based Kanban inventory replenishment system, a top shelf structure is configured to enhance the visibility of optical codes on empty bins that are placed on the top shelf of a shelving unit, and a validation apparatus placed on top of the top shelf structure is configured for use in validation procedure that confirms a proper installation and alignment of cameras used in capturing images of the optical codes on the empty bins.

Claims (39)

1 . An apparatus for use in a process of monitoring and replenishing an inventory of goods stored in bins disposed on a multi-shelf shelving unit having a top shelf, wherein the process involves placing empty bins on or above the top shelf to signal that replenishment of the inventory is needed, the apparatus comprising:

a front panel configured to attach to a front surface of the top shelf of the multi-shelf shelving unit, the front panel having a top edge disposed above the upper surface of the top shelf, and having a forward surface disposed below the top edge;

one or more optical codes disposed on the forward surface of the front panel;

a middle panel having a front edge attached to the top edge of the front panel, a rear edge configured to rest upon the upper surface of the top shelf, and a planar surface that slopes downward from the front edge to the rear edge, wherein the planar surface is configured to receive the empty bins; and

a rear panel extending upward from the rear edge of the middle panel, wherein the rear panel prevents the empty bins from sliding beyond the rear edge of the middle panel; and

a plurality of slots distributed across the planar surface of the middle panel.

2 . The apparatus of claim 1 wherein the planar surface is disposed at a non-zero angle with respect to the upper surface of the top shelf.

3 . The apparatus of claim 2 wherein the non-zero angle is between 3 degrees and 15 degrees.

4 . The apparatus of claim 3 wherein the non-zero angle is 5 degrees.

5 . The apparatus of claim 1 wherein the one or more optical codes comprise a first optical code disposed adjacent to a first end of the front panel, and a second optical code disposed adjacent to a second end of the front panel opposing the first end.

6 . The apparatus of claim 1 wherein the one or more optical codes comprise QR codes or barcodes.

7 . The apparatus of claim 1 wherein a distance from the front edge to the rear edge of the middle panel is substantially equivalent to a length dimension of one of the empty bins.

8 . The apparatus of claim 1 further comprising a channel structure disposed between the front panel and the front surface of the top shelf that provides for attachment of the front panel to the top shelf.

9 . The apparatus of claim 1 further comprising a code holder having a pair of tabs configured to be removably received in a pair of the plurality of slots distributed across the planar surface of the middle panel, the code holder including one or more attachment mechanisms for removably attaching one or more moveable structures on which one or more optical codes are disposed.

10 . The apparatus of claim 9 wherein the one or more attachment mechanisms comprise one or more of a hook-and-loop mechanism, a magnetic mechanism, and a snap mechanism.

11 . The apparatus of claim 1 further comprising at least one first aperture disposed adjacent to a first end of the front panel and at least one second aperture disposed adjacent to a second end of the front panel, the first and second apertures configured to receive fasteners for attaching the front panel to the top shelf.

12 . The apparatus of claim 1 further comprising a challenge board disposed on the middle panel, the challenge board comprising:

a bottom panel disposed on the planar surface of the middle panel, the bottom panel having a rear edge that abuts the rear panel and a front edge spaced apart from the rear edge;

a top panel extending upward from the front edge of the bottom panel;

a plurality of optical perimeter codes attached to a forward surface of the top panel; and

a plurality of protrusions extending outward from the top panel, each protrusion configured to simulate a portion of a first bin stacked above a forward surface of a second bin, wherein each protrusion includes an optical bin simulation code disposed on the forward surface.

13 . The apparatus of claim 12 wherein each of the plurality of protrusions includes:

a rear support structure attached to and extending outward from the forward surface of the top panel;

a front portion supported by the rear support structure; and

a stacked bin simulation structure disposed above the front portion.

14 . An apparatus for use in a process of monitoring and replenishing an inventory of goods stored in bins disposed on a multi-shelf shelving unit having a top shelf, wherein the process involves placing empty bins on or above the top shelf to signal that replenishment of the inventory is needed, the apparatus comprising: