Inventory management system using image processing of codes on shelving and storage bins
An apparatus for monitoring and replenishing an inventory of goods includes a first inventory area and a first movable structure having a first optical code associated with the first distinct inventory area. The first movable structure is placed in a replenishment signaling area after a supply of goods in the inventory area is depleted. Boundary optical codes are disposed near a boundary of the replenishment signaling area. A camera generates periodic images of the replenishment signaling area and the boundary optical codes. A computer processor detects the boundary optical codes in the images and determines a boundary line of the replenishment signaling area based thereon. The processor determines a spatial relationship between the first optical code and the boundary line in the images and generates a replenishment notification based on the spatial relationship. The replenishment notification indicates that the supply of the first type of goods needs to be replenished.
1 . An apparatus for monitoring and replenishing an inventory of goods disposed within an inventory storage space that includes a multi-shelf shelving unit having a top shelf and one or more lower shelves below the top shelf, the apparatus comprising:
a first inventory area on one of the one or more lower shelves of the multi-shelf shelving unit within the inventory storage space, the first inventory area configured to store a first supply of goods;
a second inventory area on one of the one or more lower shelves of the multi-shelf shelving unit within the inventory storage space, the second inventory area configured to store a second supply of the goods;
a slider panel disposed within the inventory storage space and adjacent to the first and second inventory areas, the slider panel configured to be moveable between at least:
a first position in which the slider panel allows access to the first inventory area and blocks access to the second inventory area; and
a second position in which the slider panel allows access to the second inventory area and blocks access to the first inventory area;
a first movable structure removably attached to the slider panel;
a first optical code disposed on the first movable structure, the first optical code encoding a unique identification number that identifies the goods in the first supply of goods;
a second movable structure removably attached to the slider panel;
a second optical code disposed on the second movable structure, the second optical code encoding the unique identification number that identifies the goods in the second supply of goods;
a replenishment signaling area on the top shelf of the multi-shelf shelving unit within the inventory storage space, the replenishment signaling area configured to receive the first movable structure that is placed therein after the first supply of the goods stored in the first inventory area has been depleted, and configured to receive the second movable structure that is placed therein after the second supply of the goods stored in the second inventory area has been depleted;
one or more boundary optical codes disposed adjacent to a boundary of the replenishment signaling area, the one or more boundary optical codes comprising:
a first boundary optical code attached to the shelving unit adjacent a first end of the top shelf; and
a second boundary optical code attached to the shelving unit adjacent a second end of the top shelf opposing the first end;
one or more cameras that each have a field of view at least partially encompassing the replenishment signaling area and the first and second boundary optical codes, the one or more cameras for generating images of the replenishment signaling area and the first and second boundary optical codes; and
one or more processors in electrical communication with the one or more cameras, the one or more processors operable to execute programmed instructions to:
detect the first and second boundary optical codes present within the images generated by the one or more cameras;
assign location coordinates to the first and second boundary optical codes detected within the images generated by the one or more cameras;
based on the location coordinates of the first and second boundary optical codes, determine an equation of a boundary line that defines the boundary of the replenishment signaling area, wherein the boundary line coincides with the location coordinates assigned to the first and second boundary optical codes;
detect the first optical code present within the images generated by the one or more cameras;
assign location coordinates to the first optical code detected within the images generated by the one or more cameras;
based on the location coordinates of the first optical code, determine a spatial relationship between a location of the first optical code and the boundary line; and
generate a first replenishment notification based at least in part on the location coordinates of the first optical code indicating that the first optical code is above the boundary line, wherein the first replenishment notification indicates that the first supply of the goods in the first inventory area needs to be replenished.
2 . The apparatus of claim 1 wherein the one or more processors are further operable to execute programmed instructions to:
detect the second optical code present within the images generated by the one or more cameras;
assign location coordinates to the second optical code detected within the images generated by the one or more cameras;
based on the location coordinates of the second optical code, determine a spatial relationship between a location of the second optical code and the boundary line; and
generate a second replenishment notification based at least in part on the location coordinates of the second optical code indicating that the second optical code is above the boundary line, wherein the second replenishment notification indicates that the second supply of the goods in the second inventory area needs to be replenished.
3 . The apparatus of claim 1 further comprising a substantially vertical structure disposed above the boundary line and within the field of view of the one or more cameras, and wherein:
the first movable structure comprises a first label on which the first optical code is disposed, wherein the first label is removably attachable to the slider panel and removably attachable to the vertical structure; and
the second movable structure comprises a second label on which the second optical code is disposed, wherein the second label is removably attachable to the slider panel and removably attachable to the vertical structure.
4 . The apparatus of claim 3 wherein the substantially vertical structure and the slider panel include one or more attachment mechanisms for removably attaching one or both of the first label and the second label to the vertical structure and the slider panel, the one or more attachment mechanisms comprising one or more of a hook-and-loop mechanism, a magnetic mechanism, and a snap mechanism.
5 . The apparatus of claim 1 wherein the one or more processors execute the programmed instructions to determine the equation of the boundary line to comprise one or more of a horizontal line, a vertical line, a diagonal line, a curved line, and a line forming a closed shape.
6 . The apparatus of claim 1 wherein the one or more processors execute the programmed instructions to determine the equation of the boundary line as intersecting the location coordinates of the first and second boundary optical codes.
7 . The apparatus of claim 1 wherein the first and second optical codes comprise QR codes or barcodes.
8 . The apparatus of claim 1 wherein the first and second boundary optical codes comprise QR codes, barcodes, or color codes.
9 . The apparatus of claim 1 wherein the one or more cameras comprise one or more of a camera mounted on a ceiling, a camera mounted on a horizontal or vertical track system, an infrared camera, and a camera having remotely-adjustable zoom, tilt and pan.
10 . The apparatus of claim 1 wherein at least one of the one or more processors is disposed in the inventory storage space.
11 . The apparatus of claim 10 wherein at least one of the one or more processors is a cloud-based server that is in communication with the at least one processor disposed in the inventory storage space via a communication network.
12 . The apparatus of claim 1 wherein the one or more processors execute the programmed instructions to:
decode one or both of the first and second optical codes to determine the unique identification number that identifies the goods, and
generate the replenishment notification to include the unique identification number.
13 . A method for monitoring and replenishing an inventory of goods disposed within an inventory storage space that includes a multi-shelf shelving unit, the method comprising:
(a) providing a first inventory area within the inventory storage space, the first inventory area configured to store a first supply of goods;
(b) providing a second inventory area within the inventory storage space, the second inventory area configured to store a second supply of the goods;
(c) providing a slider panel adjacent the first and second inventory areas within the inventory storage space;
(d) providing a first movable structure associated with the first inventory area, the first movable structure having a first optical code disposed thereon, the first optical code encoding a unique identification number that identifies the goods;
(e) removably attaching the first movable structure to the slider panel;
(f) providing a replenishment signaling area within the inventory storage space, the replenishment signaling area configured to receive the first movable structure;
(g) moving the slider panel to a first position in which the slider panel provides access to the first supply of goods in the first inventory area and blocks access to the second supply of goods in the second inventory area;
(h) upon depletion of the first supply of the goods from in the first inventory area, removing the first movable structure from the slider panel and placing the first movable structure in the replenishment signaling area;
(i) providing first and second boundary optical codes adjacent to a boundary of the replenishment signaling area, wherein the first boundary optical code is attached to the shelving unit adjacent a first end of the top shelf and the second boundary optical code is attached to the shelving unit adjacent a second end of the top shelf opposing the first end;
(j) providing one or more cameras that each have a field of view at least partially encompassing the replenishment signaling area and the first and second boundary optical codes;
(k) using the one or more cameras, periodically generating images that encompass the replenishment signaling area and the first and second boundary optical codes;
(l) executing programmed instructions on one or more processors to detect the first and second boundary optical codes present within the images;
(m) executing programmed instructions on the one or more processors to assign location coordinates to the first and second boundary optical codes detected within the images;
(n) executing programmed instructions on the one or more processors to determine an equation of a boundary line that defines the boundary of the replenishment signaling area based on the location coordinates of the first and second boundary optical codes, wherein the boundary line coincides with the location coordinates of the first and second boundary optical codes;
(o) executing programmed instructions on the one or more processors to detect the first optical code present within the images;
(p) executing programmed instructions on the one or more processors to assign location coordinates to the first optical code detected within the images;
(q) executing programmed instructions on the one or more processors to determine a spatial relationship between a location of the first optical code and the boundary line based on the location coordinates of the first optical code; and
(r) executing programmed instructions on the one or more processors to generate a replenishment notification based at least in part on the location coordinates of the first optical code indicating that the first optical code is above the boundary line, wherein the replenishment notification indicates that the first supply of the goods in the first inventory area needs to be replenished.
14 . The method of claim 13 further comprising:
(s) providing a second movable structure associated with the second inventory area, the second movable structure having a second optical code disposed thereon, the second optical code encoding the unique identification number that identifies the goods;
(t) removably attaching the second movable structure to the slider panel;
(u) moving the slider panel to a second position in which the slider panel provides access to the second supply of goods in the second inventory area and blocks access to the first inventory area;
(v) upon depletion of the second supply of the goods stored in the second inventory area, removing the second movable structure from the slider panel, and placing the second movable structure into the replenishment signaling area;
(w) executing programmed instructions on the one or more processors to detect the second optical code present within the images;
(x) executing programmed instructions on the one or more processors to assign location coordinates to the second optical code detected within the images;
(y) executing programmed instructions on the one or more processors to determine a spatial relationship between a location of the second optical code and the boundary line based on the location coordinates of the second optical code; and
(z) executing programmed instructions on the one or more processors to generate a replenishment notification based at least in part on the location coordinates of the second optical code indicating that the second optical code is above the boundary line, wherein the replenishment notification indicates that the second supply of the goods in the second inventory area needs to be replenished.
15 . The method of claim 14 further comprising providing a substantially vertical structure disposed above the boundary line and within the field of view of the one or more cameras, wherein:
step (d) comprises providing a first label on which the first optical code is disposed, wherein the first label is removably attachable to the slider panel and removably attachable to the vertical structure; and
step(s) comprises providing a second label on which the second optical code is disposed, wherein the second label is removably attachable to the slider panel and removably attachable to the vertical structure.
16 . The method of claim 15 wherein the substantially vertical structure and the slider panel include one or more attachment mechanisms for removably attaching one or both of the first label and the second label to the vertical structure and the slider panel, the one or more attachment mechanisms comprising one or more of a hook-and-loop mechanism, a magnetic mechanism, and a snap mechanism.
17 . The method of claim 13 wherein step (n) comprises executing the programmed instructions on the one or more processors to determine the equation of the boundary line to comprise one or more of a horizontal line, a vertical line, a diagonal line, a curved line, and a line forming a closed shape.
18 . The method of claim 13 wherein step (n) comprises executing the programmed instructions on the one or more processors to determine the equation of the boundary line to intersect the location coordinates of the first and second boundary optical codes.
19 . The method of claim 13 wherein the first and second optical codes comprise QR codes or barcodes.
20 . The method of claim 13 wherein the first and second boundary optical codes comprise QR codes, barcodes, or color codes.
21 . The method of claim 13 further wherein step (n) comprises providing the one or more cameras that include one or more of a camera mounted on a ceiling, a camera mounted on a horizontal or vertical track system, an infrared camera, and a camera having remotely adjustable zoom, tilt and pan.
22 . An apparatus for monitoring and replenishing an inventory of goods disposed within an inventory storage space, the apparatus comprising:
a first distinct inventory area within the inventory storage space, the first distinct inventory area configured to store a supply of a first type of goods;
a first electronically detectable element disposed on a first movable structure associated with the first distinct inventory area, the first electronically detectable element encoding a first unique identification number that identifies the first type of goods;
a replenishment signaling area within the inventory storage space, the replenishment signaling area configured to receive the first movable structure that is placed therein after the supply of the first type of goods stored in the first distinct inventory area has been depleted;
one or more detectors associated with the replenishment signaling area, the one or more detectors configured to detect the first electronically detectable element; and
one or more processors in electrical communication with the one or more detectors, the one or more processors operable to execute programmed instructions to maintain a state machine representing a plurality of states of the first distinct inventory area, wherein the plurality of states include:
a first state in which the first electronically detectable element is not in the replenishment signaling area;
a second state in which the first electronically detectable element is in the replenishment signaling area; and
a third state in which an order has been placed or is to be placed to replenish the supply of the first type of goods in the first distinct inventory area,
wherein execution of the programmed instructions causes:
a transition from the first state to the second state based on the one or more detectors detecting the first electronically detectable element in the replenishment signaling area;
a transition from the second state to the third state and generation of a replenishment notification in association with the transition from the second state to the third state, wherein the replenishment notification indicates that the supply of the first type of goods in the first distinct inventory area needs to be replenished;
a transition from the third state to the first state based on the one or more detectors in the replenishment signaling area not detecting the first electronically detectable element in the replenishment signaling area for at least a predetermined period of time; and
a transition from the third state to the second state based on:
(1) a line item of a reordering requisition associated with the first type of goods being designated as filled;
(2) passage of more than a threshold level of time after the line item of the reordering requisition associated with the first type of goods was designated as filled; and
(3) the first electronically detectable element is still detected in the replenishment signaling area.
23 . An apparatus for monitoring and replenishing an inventory of goods disposed within an inventory storage space that includes a multi-shelf shelving unit, the apparatus comprising:
a first inventory area disposed on at least one of the shelves of the multi-shelf shelving unit within the inventory storage space, the first inventory area configured to store a first supply of goods;
a second inventory area disposed on the at least one of the shelves of the multi-shelf shelving unit on which the first inventory area is disposed or on at least one of the shelves of the multi-shelf shelving unit other than the at least one of the shelves on which the first inventory area is disposed, the second inventory area configured to store a second supply of the goods;
a slider panel disposed within the inventory storage space and adjacent to the first and second inventory areas, the slider panel configured to be moveable between at least:
a first position in which the slider panel allows access to the first inventory area and blocks access to the second inventory area; and
a second position in which the slider panel allows access to the second inventory area and blocks access to the first inventory area;
a first movable structure removably attached to the slider panel;
a first optical code disposed on the first movable structure, the first optical code encoding a unique identification number that identifies the goods in the first supply of goods;
a second movable structure removably attached to the slider panel;
a second optical code disposed on the second movable structure, the second optical code encoding the unique identification number that identifies the goods in the second supply of goods;
a replenishment signaling area disposed on a shelf of the multi-shelf shelving unit other than the at least one of the shelves on which the first inventory area is disposed and other than the at least one of the shelves on which the second inventory area is disposed, the replenishment signaling area configured to receive the first movable structure that is placed therein after the first supply of the goods stored in the first inventory area has been depleted, and configured to receive the second movable structure that is placed therein after the second supply of the goods stored in the second inventory area has been depleted;
one or more boundary optical codes disposed adjacent to a boundary of the replenishment signaling area, the one or more boundary optical codes comprising:
a first boundary optical code attached to the shelving unit adjacent a first end of the shelf on which the replenishment signaling area is disposed; and
a second boundary optical code attached to the shelving unit adjacent a second end of the shelf on which the replenishment signaling area is disposed;
one or more cameras that each have a field of view at least partially encompassing the replenishment signaling area and the first and second boundary optical codes, the one or more cameras for generating images of the replenishment signaling area and the first and second boundary optical codes; and
one or more processors in electrical communication with the one or more cameras, the one or more processors operable to execute programmed instructions to:
detect the first and second boundary optical codes present within the images generated by the one or more cameras;
assign location coordinates to the first and second boundary optical codes detected within the images generated by the one or more cameras;
based on the location coordinates of the first and second boundary optical codes, determine an equation of a boundary line that defines the boundary of the replenishment signaling area, wherein the boundary line coincides with the location coordinates assigned to the first and second boundary optical codes;
detect the first optical code present within the images generated by the one or more cameras;
assign location coordinates to the first optical code detected within the images generated by the one or more cameras;
based on the location coordinates of the first optical code, determine a first spatial relationship between a location of the first optical code and the boundary line; and
generate a first replenishment notification based at least in part on the first spatial relationship indicating that the first optical code is within the replenishment signaling area, wherein the first replenishment notification indicates that the first supply of the goods in the first inventory area needs to be replenished.
24 . The apparatus of claim 23 wherein the one or more processors are further operable to execute programmed instructions to:
detect the second optical code present within the images generated by the one or more cameras;
assign location coordinates to the second optical code detected within the images generated by the one or more cameras;
based on the location coordinates of the second optical code, determine a second spatial relationship between a location of the second optical code and the boundary line; and
generate a second replenishment notification based at least in part on the second spatial relationship indicating that the second optical code is within the replenishment signaling area, wherein the second replenishment notification indicates that the second supply of the goods in the second inventory area needs to be replenished.