The present disclosure is directed to radio-frequency identification (RFID) methods and systems for monitoring a storeroom and inventory management.
FIGS. is a flowchart illustrating a second method according to the present disclosure; and
The systems, methods, and devices of the present disclosure each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this disclosure as expressed by the claims that follow, some features will now be discussed briefly. After considering this discussion, and particularly after reading this section, one will understand how the features of this disclosure provide advantages that include improved monitoring of items in a storeroom.
The items that are stored in a storeroom could include consumable and non-consumable items, collectively referred to as “items” herein. Consumable items can include things such as lubricants, wear plates, gloves, paper, toner cartridges, cleaners, and fuel. Non-consumable items can include tools, diagnostic equipment, rentals and other maintenance items that are returned back to the storeroom.
It may be helpful or necessary to restrict access to a storeroom to ensure items are not improperly removed and to ensure records regarding the items in the storeroom are kept properly updated. For example, many industrial sites, such as refineries, have storerooms that are managed by one or more individuals that examine the storeroom and its contents on a regular basis to inspect non-consumable items, to determine the quantities of consumable items that have been used, to prepare invoices for items removed from the storeroom and to manage replenishment of the items in the storeroom.
Workers may work more efficiently when they have free access to the consumable and non-consumable items in a storeroom. But allowing free access to these items presents a risk that items may be taken for inappropriate purposes. For these reasons, it is desirable to track both the movement of items into and out of the storeroom, and possibly also the identity of the individuals bringing items into the storeroom and removing items from the storeroom.
In addition to monitoring items in a storeroom for purposes of preventing or tracking inappropriate uses of items, it is desirable to track information about the quantities of consumable supplies so that additional consumable supplies may be purchased before the currently available consumable supplies run out.
In the case of non-consumable items, such as maintenance and rental items, it may be helpful to track how often such non-consumable items are removed from the storeroom, used, and then returned to the storeroom. Information about uses of non-consumable items may be useful in determining when to calibrate tools and diagnostic equipment, and when to schedule and perform maintenance actions.
The present disclosure is directed to systems and methods for monitoring and tracking the items in a storeroom while still allowing workers free access to the items in the storeroom. In the disclosed systems and methods, records of items that are carried into and removed from the storeroom are automatically maintained using radio-frequency identification (RFID) tags and associated RFID readers/antennas.
As used herein, an RFID tag generally refers to a device with an antenna or resonator that can produce a wireless signal when activated or powered. The wireless signal produced by the RFID tag is typically low power and intended for transmission over short distances. The RFID tag may be formed of any material and may be flexible or rigid. In some implementations, the RFID tag may include an adhesive on a portion of the exterior of an RFID tag surface to enable attachment of the tag to an item, such as an inventory item.
An RFID tag may be an active RFID tag in which the RFID tag includes an internal power supply (e.g., a battery), a passive RFID tag in which the RFID tag does not include a power supply and is activated by power supplied by an RFID reader/antenna, a battery-assisted RFID tag in which the RFID tag includes a power supply (battery) but is activated by power supplied by an RFID reader/antenna, an active near field communication (“NFC”) tag, a passive NFC tag, a Bluetooth tag, or any other type of tag that can be configured to provide an identifier over a radio frequency. Likewise, an RFID reader/antenna, as used herein, refers to any type of RFID reader/antenna that can communicate with, interrogate and/or receive information from an RFID tag.
When an RFID tag is assigned to or attached to an item, a relationship between the particular RFID tag and the corresponding item is recorded in a database of items. When the RFID tag is detected by an RFID reader/antenna, the signal from the RFID tag may be read to identify the particular RFID tag. The database can then be consulted to identify the corresponding item to which the RFID tag is attached. Similarly, when an RFID tag is assigned to a person, a relationship between the particular RFID tag and the corresponding person is recorded in a database. When the RFID tag is detected by an RFID reader/antenna, the particular RFID tag may be identified. The database can then be consulted to identify the person associated with the identified RFID tag.
A “storeroom,” as used herein, refers to any container with walls and an opening that may be used for storing items. For example, a storeroom may be a room or a space in a warehouse or other building, a trailer, a portable container, or a shed. As used herein, a “doorway” of a storeroom may be any opening, portal, or access point through which items may be removed from the storeroom. Such a doorway may or may not have a door.
As noted above, RFID tags are attached to one or more items that are to be placed in a storeroom. One or more RFID tag readers are located at or adjacent to a doorway of the storeroom. As each item is brought into the storeroom, one or more RFID tag readers detect the RFID tag on the item, and an inventory of the storeroom is updated to reflect the addition of the item to the storeroom. Likewise, when an item is removed from the storeroom, one or more RFID readers/antennas detect the RFID tag attached to the item, and the inventory is updated to reflect the removal of the item from the storeroom.
In some instances, individuals that bring items into the storeroom and that remove items from the storeroom may carry their own RFID tag, such as an RFID tag that is attached to an individual's ID card or apparel. In these circumstances, when an individual brings an item into the storeroom, one or more RFID tag readers/antennas could detect both the RFID tag attached to the item and the RFID tag of the individual bringing the item into the storeroom. As a result, the inventory may be updated to reflect both that the item has been added to the storeroom, and the identity of the individual that brought the item into the storeroom. Likewise, when an individual removes an item from the storeroom, one or more RFID tag readers/antennas may detect both the RFID tag attached to the item and the RFID tag associated with the individual, and the inventory can be updated to reflect both the removal of the item from the storeroom and the identity of the individual that removed the item from the storeroom.
In instances where the RFID tag readers/antennas are configured to read the RFID tags of individuals bringing items into the storeroom and removing items from the storeroom, the control system may be configured to issue an error report if the RFID tag readers/antennas detect a RFID tag of an item entering or leaving the storeroom, but not an RFID tag of an individual that is carrying the item into or out of the storeroom.
In some systems and methods as disclosed in the present application, a storeroom has only a single doorway through which all items and individuals must pass. In alternate embodiments, a storeroom may have multiple doorways. Regardless, RFID readers/antennas are installed at or adjacent to a doorway and are configured to detect any RFID tags that pass through the doorway. In preferred embodiments, two RFID readers/antennas are positioned in or adjacent the doorway such that an RFID tag on an item or individual moving into the storeroom will be detected first by a first RFID reader/antenna, and then subsequently will be detected by the second RFID reader/antenna. In the same fashion, an RFID tag moving out of the storeroom will be detected first by the second RFID reader/antenna, and then subsequently by the first RFID reader/antenna. By noting the timing at which each RFID reader/antenna reports detection of the RFID tag, one can determine whether the RFID tag is passing into or out of the storeroom.
Because the first and second RFID readers/antennas are both positioned in or adjacent to the doorway of the storeroom, it is necessary to position and/or configure the first and second RFID readers/antennas so that they do not simultaneously detect an RFID tag, which would make it impossible to discern whether the RFID tag is passing into or out of the storeroom. This can be accomplished by properly aiming the first and second RFID readers/antennas such that the areas over which they detect RFID tags do not substantially overlap. It can also be helpful to configure the detection sensitivity of the RFID readers/antennas such that the distance over which they detect RFID tags is sufficiently short that substantial overlap of the detection areas does not occur.
A first embodiment of a system for monitoring a storeroom is illustrated in
When an individual 150 carries an item 160 to which an RFID tag 162 is attached into the storeroom 110, the first RFID reader/antenna 120 will detect the RFID tag 162 before the second RFID reader/antenna 124 detects the RFID tag 162. Conversely, if the individual 150 removes the item 160 from the storeroom 110, the second RFID reader/antenna 124 will detect the RFID tag 162 before the first RFID reader/antenna 120 detects the RFID tag 162 attached to the item 160. Thus, the timing of when each of the first and second RFID readers/antennas 120/124 detect the RFID tag 162 can be used to determine if the item 160 is being brought into or removed from the storeroom 110.
As noted above, an RFID tag 152 may be associated with and carried by the individual 150 that is bringing an item 160 into the storeroom 110 or who is removing an item 160 from the storeroom 110. If the first RFID reader/antenna 120 detects both the RFID tag 162 attached to the item 160 and the RFID tag 152 associated with the individual 150 at approximately the same time, and before the second RFID reader/antenna 124 detects the RFID tags 162, 152, the monitoring system is able to determine and record the fact that the item 160 has been brought into the storeroom, and the identity of the individual that brought the item into the storeroom. Likewise, if the second RFID reader/antenna 124 detects both the RFID tag 162 attached to the item 160 and the RFID tag 152 associated with the individual 150 at approximately the same time, and before the first RFID reader/antenna 120 detects the RFID tags 162/152, the monitoring system is able to determine both the fact that the item 160 has been removed from the storeroom, and the identity of the individual that removed the item 160 from the storeroom.
In instances where the exterior of the storeroom 110 is exposed to the elements and weather, the first RFID reader/antenna 120 mounted outside the storeroom 110 may be specifically configured to be weather resistant.
As illustrated in
In some instances, the first and/or second RFID readers/antennas 120/124 could be coupled to a local or public computer network, such as the Internet, via wired or wireless means, and the RFID readers/antennas 120/124 could communicate with one or more processing systems 130 via that local or public computer network. Also, the way in which the first RFID antenna/reader 120 communicates with one or more processing systems can differ from the way in which the second RFID reader/antenna 124 communicates with the one or more processing systems.
As used herein, a “processing system” refers to one or more computers, including both their hardware and software, used to implement and/or perform the various steps and operations described herein. When two or more computers are used as a processing system 130, the networking peripherals the computers use in communicating with each other are included in the processing system 130.
The processing system 130 may be configured to receive signals from the first and second RFID readers/antennas 120/124 each time that one of the RFID readers/antennas 120/124 detects an RFID tag. Alternatively, the processing system may periodically poll the first and second RFID readers/antennas 120/124 to obtain information about any RFID tags that were recently detected by the first and second RFID readers/antennas 120/124. That information could include the identity of the detected RFID tags and the times at which the RFID readers/antennas detected each RFID tag. Likewise, the RFID readers/antennas 120/124 may be configured to periodically send information about detected RFID tags to the processing system 130.
The processing system 130 is coupled to an alarm system 170 that can generate various types of alarms and/or alerts when potentially improper actions are detected by the processing system 130. For example, the alarm system 170 may be configured to generate an audio and/or optical signal when the processing system 130 determines that an improper action may have occurred. The alarm system 170 may also be configured to generate and send one or more alert messages to monitoring personnel when a potentially improper action is detected. Those alert messages could take the form of email messages, text messages, push notifications, audio or video telephone calls, or other forms of alert messages.
The processing system 130 is also coupled to an inventory control system 180 that tracks the items being placed into and removed from the storeroom 110. The inventory control system 180 may be configured to record and track the type, quantity, condition, cost, location, assigned RFID tags 162, or any other suitable parameters of items that are placed in a storeroom. The inventory control system 180 may be configured to report on the current inventory in the storeroom 110 and to provide information about the current inventory in response to inquiries.
The inventory control system 180 may also be designed to automatically order new supplies when the supplies of certain items becomes lower than a threshold value. The inventory control system 180 may also be configured to send work orders for maintenance or calibration of items in a storeroom according to usage records of the items. The inventory control system 180 may further include one or more databases relating to employees and their authorizations to use or remove items stored in the storeroom 110.
The processing system 130 may be connected to the first and second RFID readers/antennas 120/124, the alarm system 170 and the inventory control system 180 via hardwires, optical fibers, a wired or wireless computer network (e.g., Ethernet or an internet protocol (IP) network), or via a wireless communication system such as Bluetooth, Wifi or a cellular telephony system.
The first and second RFID readers/antennas 120/124 may be mounted adjacent to and aimed at the doorway 112 to thereby monitor items moving through the doorway 112. One or both of the first and second RFID readers/antennas 120/124 may also be mounted within the doorway 112 itself, such as in the doorframe. In still other instances, one or both of the first and second RFID readers/antennas 120/124 may be mounted in the floor or ceiling of the storeroom 110.
The first RFID reader/antenna 120 may be configured and/or aimed so as to not monitor the interior of the storeroom and/or be configured to have a detection range that is so short that the first RFID reader/antenna 120 is unable to detect RFID tags that are inside the storeroom. Similarly, the second RFID 124 reader/antenna may be configured and/or aimed so as to not monitor the exterior of the storeroom and/or be configured to have a detection range that is so short that the second RFID reader/antenna 124 is unable to detect RFID tags that are outside the storeroom.
In the embodiment illustrated in
The first RFID reader/antenna 220 is positioned such that its detection field covers items moving through the doorway 212. The second RFID reader/antenna 224 is positioned such that its detection field is aimed 180 degrees away from the detection field of the first RFID reader/antenna 220, and thereby detects RFID tags that are located inside the storeroom, but adjacent the doorway 212. As a result, the detection fields of the first and second RFID readers/antennas 220/224 do not overlap. However, the operations of the first and second RFID readers/antennas 220/224 are otherwise quite similar to those of the first and second RFID readers/antennas 120/124 described above in connection with
In the embodiments depicted in
Similarly, the first and second RFID readers could be positioned on the ceiling or in the floor, either inside or outside the doorway of the storeroom. For example, the first RFID reader could be positioned in the ceiling adjacent the doorway, with the detection field of the first RFID reader being aimed downward at an angle out of the storeroom. The second RFID reader could be positioned adjacent the first RFID reader in the ceiling with its detection field aimed downward at an angle into the storeroom. For example, there could be a 90 degree angle formed between the detection fields of the first and second RFID readers, similar to what is shown in
The storeroom monitoring system may also include a third RFID reader (not shown in
In alternate embodiments, the second RFID reader/antenna 124/224/324 located inside the storeroom could monitor for and detect RFID tags 162 of multiple items 160 within the storeroom or within a zone of the storeroom. Likewise, multiple additional RFID readers/antennas could be mounted at different locations inside the storeroom, with each respective RFID reader/antenna being responsible for detecting the RFID tags of items in different zone of the interior of the storeroom. The processing system 130 could be configured to cause the one or more RFID readers/antennas to periodically detect the RFID tags 162 of items 160 in their respective zones as a way of taking an inventory of items located within the storeroom.
This type of an inventory can be useful in determining when to order new supplies of consumable items. This type of inventory could also be used to periodically conduct audits of the inventory of the storeroom as a way of determining whether there have been errors in detecting movement of items into and out of the storeroom or of identifying theft.
A monitoring system as described may allow entities (e.g., businesses and government agencies) to eliminate significant manual work in monitoring a storeroom, as embodiments of the monitoring system can automatically perform actions such as preparing invoices and managing replenishment of items in the storeroom. The reduction in manual work can reduce traffic, reduce personnel needs, and eliminate human error in inventory management. Such an automatic monitoring system can provide a real-time analysis of item usage and inventory, and also detect usage patterns and replenishment needs. In addition, embodiments of the monitoring system permit tracking of how individual employees use certain items. Further, embodiments of monitoring system may also enable more accurate calculation of desirable minimum or maximum amounts of specific items.
In step 406, the processing system 130 determines whether T1 is before T2. If so, indicating that the first item is being brought into the storeroom, then the method proceeds to step 408, and the processing system 130 instructs the inventory control system 180 to update the storeroom inventory to reflect the fact that the first item 160 is now located inside the storeroom. If the check perform in step 406 indicates that T1 is not before T2, indicating that the first item was removed from the storeroom, then the method proceeds to step 410 and the processing system 130 instructs the inventory control system 180 to update the storeroom inventory to indicate that the first item has been removed from the storeroom. The method then ends.
The method 500 begins and proceeds to step 502 where a second RFID reader/antenna 124 detects a first RFID tag 162 attached to a first item 160 at time T1. Next, in step 504, a first RFID reader/antenna 120 detects the first RFID tag 162 at time T2, where T2 is later than T1. Because T2 is later than T1, the first item 160 is being removed from the storeroom. In step 506, the first RFID reader/antenna 120 detects a second RFID tag 152 that is associated with an individual 150 at approximately time T2. Because the first RFID reader/antenna 120 detected the second RFID tag 152 at approximately the same time (T2) that the first RFID reader/antenna 120 detected the first RFID tag 162, we know that the individual 150 associated with the second RFID tag 152 is the individual that removed the first item 160 from the storeroom.
In step 508, the processing system 130 instructs the inventory control system 180 to update the inventory for the storeroom to indicate that the first individual 150 removed the first item 160 from the storeroom. The method then ends.
Step 506 of the method depicted in
In some embodiments, the processing system 130 may be configured to receive signals from the RFID readers indicating detection of both an RFID tag attached to an item and an RFID tag associated with an individual that occur at substantially the same time. If the processing system 130 receives signals from an RFID reader indicating detection of an RFID tag attached to an item, but no associated substantially concurrent detection of an RFID tag associated with an individual, the processing system could signal the alarm system 170 to sound or illuminate an alarm or to issue an electronic alert (such as by an email, a text message, a push notification etc.), as this could indicate that an unauthorized individual is improperly removing the item from the storeroom.
Similarly, the inventory control system 180 and/or the processing system 130 could track which individuals are authorized to remove and return individual items from the storeroom. If the processing system 130 receives signals from an RFID reader indicating that an individual is removing an item from the storeroom or replacing an item in the storeroom, and the individual is not authorized to handle the item, the processing system 130 could instruct the alarm system 170 to issue an alarm or to send an alert message.
The method 600 begins and proceeds to step 602 where a second RFID reader/antenna 124 detects a first RFID tag 162 attached to a first item at T1. Next, in step 604, a first RFID reader/antenna 120 detects the first RFID tag 162 at time T2, which is later than time T1. This means the item 160 is being removed from the storeroom. As a result, in step 606, the processing system 130 instructs the inventory control system 180 to update the inventory for the storeroom to indicate that the first item 160 was removed from the storeroom.
In step 608 the first RFID reader/antenna 120 detects the first RFID tag 162 at time T3, which is later than time T2. Next, in step 610, the second RFID reader/antenna 124 detects the first RFID tag 162 at time T4, which is later than time T3. This indicates the first item 160 is being brought back into the storeroom. As a result, in step 612, the processing system 130 instructs the inventory control system 180 to update the inventory for the storeroom to indicate that the first item 160 has been returned to the storeroom. The method then ends.
In some embodiments, where the identity of each individual that moves an item out of or into the storeroom is tracked in addition to movement of the item itself, the processing system 130 may be configured to cause the alarm system 170 issue an alarm or to send an electronic alert if a first individual removes an item from the storeroom, but a second, different individual thereafter brings the same item back into the storeroom
The systems and methods described above may be implemented in and performed by hardware, software, or a combination thereof. In the context of software, the described operations represent computer-executable instructions stored on one or more computer-readable media that, when executed by one or more processors, perform the recited operations. Generally, computer-executable instructions include routines, programs, objects, components, data structures, and the like that perform particular functions or implement particular abstract data types.
The computer-readable media may include nontransitory computer-readable storage media, which may include hard drives, floppy diskettes, optical disks, CD-ROMs, DVDs, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, flash memory, magnetic or optical cards, solid-state memory devices, or other types of storage media suitable for storing electronic instructions. In addition, in some implementations, the computer-readable media may include a transitory computer-readable signal (in compressed or uncompressed form). Examples of computer-readable signals, whether modulated using a carrier or not, include, but are not limited to, signals that a computer system hosting or running a computer program can be configured to access, including signals downloaded through the Internet or other networks. Finally, the order in which the operations are described is not intended to be construed as a limitation, and any number of the described operations can be combined in any order and/or in parallel to implement the process.
This application claims the benefit of the filing dates of U.S. Provisional Patent Application Nos. 63/192,514, filed May 24, 2021, U.S. Provisional Patent Application No. 63/225,843, filed Jul. 26, 2021, and U.S. Provisional Patent Application No. 63/278,311, filed Nov. 11, 2021, the contents of all of which are incorporated herein by reference.
Number | Date | Country | |
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63192514 | May 2021 | US | |
63225843 | Jul 2021 | US | |
63278311 | Nov 2021 | US |