Abstract:
An apparatus for tracking the movement of a plurality of products. The apparatus includes a shelf with a plurality of products positioned thereon. The shelf has a first end with an optical sensor positioned thereabout. A controller is functionally connected to the optical sensor so as to track the removal of one of the products from the first end of the shelf and to track the insertion of one of the products into the first end of the shelf.

Description:
TECHNICAL FIELD 
     The present invention relates generally to systems and methods for tracking product usage and more specifically relates to systems and methods for tracking product inventory from a shelf within a refrigerated cooler. 
     BACKGROUND OF THE INVENTION 
     Various methods have been employed in the past to track product usage, purchase, or consumption from dispensing apparatus such as vending machines and the like. Various types of sensors or counters may be used to keep track of the number of products dispensed from such a machine. For example, each “drop” of a bottle, a can, or other item from a vending machine may be tracked. These “smart” vending machines can keep an accurate tally of the amount of product dispensed because the machine is a controlled environment, i.e., the product is not dispensed until the selection button is pushed and the sale is completed. 
     This type of “smart” technology, however, has not been applicable to track the sale of products merely placed on a store or a cooler shelf. The existing vending machine technology is not directly applicable because a consumer is free to pick up a product, inspect it, take it, or return it to the shelf and make a different selection, i.e., the shelf is not a controlled environment. For example, a consumer may pick up a bottle or can containing a carbonated soft drink off of a shelf and then return that bottle or can and make a different selection. The return of the bottle or can may inflate the number of items actually removed from the shelf if only the removals are counted or monitored. 
     What is needed therefore is a system and method for tracking the use, purchase, or consumption of items placed on a shelf. The system and method must be able to keep track of removals and additions to the shelf. Further, these systems and methods must be implemented in consumer friendly and/or otherwise non-obtrusive manner. 
     SUMMARY OF THE INVENTION 
     The present invention provides an apparatus for tracking the movement of a plurality of products. The apparatus includes a shelf with a plurality of products positioned thereon. The shelf has a first end with an optical sensor positioned thereabout. A controller is functionally connected to the optical sensor so as to track the removal of one of the products from the first end of the shelf and to track the insertion of one of the products into the first end of the shelf. 
     Specific embodiments of the present invention include the use of a gravity-assisted product slide with a plurality of products positioned therein and the use of optical sensors having one or more emitters and one or more receivers. The emitters are positioned on a first side of the shelf and the receivers are positioned on a second side of the shelf. The emitters may be positioned along a diagonal line with respect to each other. The receivers are positioned on the second side of the shelf in alignment with each of the receivers. 
     A lower one of the emitters and a lower one of the receivers form a lower optical pair while an upper one of the emitters and an upper one of the receivers form an upper optical pair. The upper optical pair and the lower optical pair are blocked when one of the products is adjacent to the first end of the shelf. The upper optical pair is blocked and the lower optical pair is open when one of the products is being removed from the shelf. The upper optical pair is open and the lower optical pair is open after the product has been removed from the shelf. The upper optical pair is open and the lower optical pair is open when one of the products is being inserted into the shelf. The upper optical pair is then blocked and the lower optical pair is open as the product continues to be inserted into the shelf. 
     A further embodiment of the present invention provides for an apparatus for tracking the movement of a plurality of products. The apparatus includes a gravity-assisted product slide with a plurality of products positioned therein. The slide includes a first end, a lower part of the first end, and an upper part of the first end. A lower optical sensor is positioned about the lower part of the first end of the slide while an upper optical sensor is positioned about the upper part of the first end of the slide. A controller is functionally connected to the lower optical sensor and to the upper optical sensor so as to track the removal of one of the products from the first end of the slide and to track the insertion of one of the products to the first end of the slide. 
     The upper optical pair and the lower optical pair are blocked when one of the products is adjacent to the first end of the slide. The upper optical pair is blocked and the lower optical pair is open when one of the products is being removed from the slide. The upper optical pair is open and the lower optical pair is open after the product has been removed from the slide. The upper optical pair is open and the lower optical pair is open when one of the products is being inserted into the slide. The upper optical pair is then blocked and the lower optical pair is open as the product continues to be inserted into the slide. 
     The method of the present invention provides for tracking the number of products on a product slide. The method includes the steps of positioning a first optical sensor along a first part of the product slide, positioning a second optical sensor along a second part of the product slide, and monitoring when the first optical sensor and the second optical sensor change state. The method may further include the steps of determining when the products are removed from the product slide and when the products are inserted into the product slide based upon the change of state. The monitoring step may include determining whether the first optical sensor and the second optical sensor are blocked or open. 
     The determining step includes a removal of one of the products from the product slide when the monitoring step finds that the first optical sensor is blocked and the second optical sensor is open in a first state and that the first optical sensor is open and the second optical sensor is open in a second state. The determining step includes an insertion of one of the products into the product slide when the monitoring step finds that the first optical sensor is open and the second optical sensor is open in a first state and that the first optical sensor is blocked and the second optical sensor is open in a second state. 
     Other objects, features, and advantages of the present invention will become apparent upon review of the following detailed description of the preferred embodiments of the present invention when taken in conjunction with the drawings and the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a diagrammatic representation of a refrigerated cooler. 
     FIG. 2A is a perspective view of a multi-channel dispensing slide for use in the refrigerated cooler. 
     FIG. 2B is a plan view of the emitters. 
     FIG. 2C is a plan view of the receivers. 
     FIG. 3 is a plan view of one channel of the multi-channel dispensing slide. 
     FIG. 4 is a schematic showing the controller and the optical sensors. 
     FIG. 5 is a flow chart of the single tray event recognition logic. 
     FIG. 6 is a flow chart of the signature analysis subroutine. 
     FIG. 7A is a chart showing the various event states of the present invention for a lift event. 
     FIG. 7B is a chart showing the various event states of the present invention for a drop event. 
     FIG. 8 is a flow chart of a single shelf scan diagram with a signature table. 
     FIG. 9 is a sample spreadsheet layout. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now in more detail to the drawings, in which like numerals refer to like parts throughout the several views, FIGS. 1-3 show a refrigerated cooler  100  for use with the present invention. The refrigerated cooler  100  is of conventional design. The cooler  100  may include an insulated shell  110  and an outer door  120 . The outer door  120  preferably is transparent in whole or in part such that the consumer can see within the cooler  100 . The use of the door  120  is not required. The cooler  100  generally has a mechanical refrigeration system (not shown) of conventional design. A preferred cooler  100  is manufactured by the Beverage-Air Company of Spartanburg, S.C. under the mark MT-27 (“Marketeer”). The shell  110  and/or the door  120  also may have a contact switch  125  such that a determination can be made whether the door  120  is open or closed so as to trigger the present invention. 
     Located within the cooler  100  may be a plurality of shelves  130 . Any type of shelf  130  may be used. The shelves  130  are preferably, but not necessarily, gravity feed organizers such as the shelves  130  sold under the mark “Visi-Slide” by Display Technologies of New York, N.Y. Other alternatives would include the use of neck-tracker shelves that hold a bottle by its neck or a horizontal serpentine design. 
     The shelves  130  each preferably have a plurality of channels  140  therein. A plurality of products  150  is placed within each of the channels  140 . Each channel  140  has a first end  160  near the door  120  and a second end  170  near the rear of the cooler  100 . The second end  170  is generally elevated somewhat from the first end  160 . In this fashion, the products  150  will slide under the force of gravity towards the first end  160  of the channel  140  towards the door  120 . The first end  160  of the channel  140  preferably has a barrier  180  such that the products  150  do not fall out of the channel  140 . When a first product  190  is removed from the first end  160  of the channel  140 , a second product  200  then slides into place adjacent to the barrier  180  on the first end  160  of the channel  140 . The channels  140  are preferably made from aluminum, stainless steel, other metals, plastic, vinyl-coated wire, or other types of substantially non-corrosive materials or combinations thereof. 
     The present invention provides for the use of a tracking system  250  within the cooler  100 . The tracking system  250  includes a plurality of optical sensors  260  used in conjunction with a micro-controller  270 . The optical sensor  260  may be a conventional photoelectric sensor using an infrared (IR) emitter  280  and one or more receivers  290 . Specifically, a combination of Light Emitting Diodes (LEDs) and Light Receiving Phototransistors (LRPs) may be used. The optical sensors  260  may be supplied by Touch Controls, Inc. of Fallbrook, Calif. Other types of sensing devices may be used, such as other types of conventional mechanical, electrical, or optical sensors. The micro-controller  270  may be a conventional processing unit. Depending upon the number of optical sensors  260  used, a conventional multiplex card  275  may be used. 
     Each channel  140  may have a first post  300  positioned on a first side  142  of the channel  140  and a second post  310   35  positioned on the opposing side or a second side  144  of the channel  140 . The posts  300 ,  310  are positioned on the first end  160  of the channel  140  near the barrier  180 . Positioned on the first post  300  may be a lower emitter  320  and an upper emitter  330 . The emitters  320 ,  330  are spaced from each other and may be positioned either vertically on top of each other or along a diagonal as is shown in FIG.  2 B. The use of the diagonal alignment is useful when the product  150  is, for example, in the shape of a contoured bottle. If the emitters  320 ,  330  are positioned along a substantially vertical line, the contours of the bottle may cause a false reading. Further, a false reading also may be caused if the emitters  320 ,  330  are positioned along the vertical line and the product  150  is tipping or leaning as it moves. The use of the diagonal alignment therefore is helpful in tracking the movement of the product  150 . This movement may be the up and down motion as the product  150  is being removed from or placed within the channel  140  or the sliding motion as the product  150  slides along the channel  140 . 
     Positioned on the second post  310  may be one or more lower receivers  340  and one or more upper receivers  350 . More than one receiver  290  may be used with each emitter  380 . Preferably, two receivers  340 ,  350  are used with each emitter  320 ,  330 . The receivers  340 ,  350  are positioned on the second post  310  in alignment with the emitters  320 ,  330 . The lower receivers  340  will receive the IR beam from the lower emitter  320  and the upper receivers  350  will receive the IR beam from the upper emitter  330 . 
     The relative position of the emitters  320 ,  330  and the receivers  340 ,  350  described herein are by way of example only. For example, one emitter  320 ,  330  may be on the first post  300  while another emitter  320 ,  330  may be on the second post  310 , or vise versa, with the receivers  340 ,  350  in corresponding locations. The emitters  320 ,  330  and the receivers  340 ,  350  may use a signal filtering method due to the lighting within the cooler  100  or due to ambient lighting. A conventional phase lock loop circuit or similar methods may be used to distinguish the background lighting from the light transmitted by the emitters  320 ,  330 . 
     As is shown in FIG. 4, the emitters  320 ,  330  and the receivers  340 ,  350  create a circuit with the micro-controller  270  and the multiplex card  275 . The emitters  320 ,  330  and the receivers  340 ,  350  are generally positioned near the barrier  180  such that the first product  190  blocks the respective beams when the first product  190  is resting against the barrier  180 . The contact switch  125  of the door  120  also may be connected within the circuit to the micro-controller  270 . A hold switch or a reset switch  127  also may be used. The hold switch  127  may prevent the operation of the tracking system  250  during, for example, restocking of the cooler  100  with the product  150 . 
     FIG. 5 shows a flow chart of the event recognition or the “scan” logic for use in a single channel  140  of a cooler  100 . As is shown therein at step  400 , the micro-controller  270  checks the door switch  125  (only is a door  120  is used), the hold switch  127 , and then scans the next product channel  140 . If the door switch  125  indicates that the door  120  to the cooler  100  is closed, there is no need to go any further because a consumer cannot remove or replace the product  150  if the door  120  is closed. Likewise, if the hold switch  127  is activated, the micro-controller  270  will not proceed. If the door  120  is open and the hold switch  122  is not activated, the micro-controller  270  will select the appropriate channel  140 . 
     At step  410 , the micro-controller  270  reads the present state of the optical sensors  260 . The available states include: 
     (1) the lower emitter  320  and the lower receiver  340  are blocked and the upper emitter  330  and the upper receiver  350  are blocked; 
     (2) the lower emitter  320  and the lower receiver  340  are open and the upper emitter  330  and the upper receiver  350  are open; 
     (3) the lower emitter  320  and the lower receiver  340  are blocked and the upper emitter  330  and the upper receiver  350  are open; and 
     (4) the lower emitter  320  and the lower receiver  340  are open and the upper emitter  330  and the upper receiver  350  are blocked. 
     At step  420 , the micro-controller  270  obtains the previous state of the optical sensors  260 . The possible states of the optical sensors  260  are the same as those as described above. At step  430 , an event signature is created containing the current state and the previous state of the optical sensors  260 . At step  440 , a signature analysis sub-routine is retrieved. The signature analysis sub-routine is described in detail below at FIG.  6 . After the signature analysis sub-routine is completed, a determination of whether a valid event has taken place is made at step  450 . A valid event would be a “lift”, i.e., removing the first product  190  or a “drop”, i.e., replacing the first product  190 . If a valid event has taken place, the micro-controller  270  obtains the cooler identification number and the current time. The combination of the event, the cooler identification, and the time stamp forms an event record. In step  470 , this event record is stored in RAM  277  or other type of memory. 
     FIG. 6 shows the signature analysis sub-routine. At step  500 , the micro-controller  270  determines whether or not a change of state has taken place. If so, at step  510  the micro-controller  270  determines whether or not the lower emitter  320  and the lower receiver  340  are blocked. If so, the signature analysis sub-routine returns to the scan routine of FIG.  5 . If not, the micro-controller  270  next determines whether the upper emitter  330  and the upper receiver  350  are blocked at step  520 . If the upper emitter  330  and the upper receiver  350  are open, the micro-controller  270  determines whether the lower emitter  320  and the lower receiver  340  in the previous state were blocked. If not, the micro-controller  270  returns to the scan routine of FIG.  5 . If so, at step  540  the micro-controller  270  determines whether the lower emitter  320  and the lower receiver  340  were blocked in the previous state. If so, micro-controller  270  returns to the scan routine of FIG.  5 . If not, at step  550 , the micro-controller  270  determines that a valid lift event has occurred and sets the delay timer within the micro-controller  270 . The length of time used by the delay timer is determined such that the lift event can be competed before another scan routine takes place. The micro-controller  270  then returns to the scan routine of FIG.  5 . 
     If at step  520  the micro-controller  270  determines that the upper emitter  330  and the upper receiver  350  are blocked, the micro-controller  270  proceeds to step  560 . At step  560 , the micro-controller  270  determines whether the lower emitter  320  and the lower receiver  340  as well as the upper emitter  330  and the upper receiver  350  were blocked in the previous state. If so, the micro-controller  270  returns to the scan routine of FIG.  5 . If not, at step  570  the micro-controller  270  determines whether the delay timer is on. If so, the micro-controller  270  returns to the scan routine of FIG.  5 . If not, at step  580  the micro-controller  270  determines that a valid drop event has taken place. The micro-controller  270  then returns to the scan routine of FIG.  5 . 
     FIGS. 7A and 7B are diagrammatic representations of the changes of state of the emitters  320 ,  330  and the receivers  340 ,  350 . In FIG. 7A, a valid lift event is shown. The emitters  320 ,  330  and the receivers  340 ,  350  are both open in the present state  590  while the upper emitter  330  and the upper receiver  350  are blocked and the lower emitter  320  and the lower receiver  340  are open in the previous state  600 . In this case, the optical sensors  260  determine that the first product  190  was being lifted out of the channel  140  by the fact that the lower emitter  320  and the lower receiver  340  are open but the upper emitter  330  and the upper receiver  350  were blocked in the previous state  600 . This removal of the first product  190  is then completed in the present state  590  when both pairs of emitters  320 ,  330  and the receivers  340 ,  350  are open. The micro-controller  270  then sets the delay timer so as to permit the first product  190  to be completely removed from the channel  140  and for the second product  200  to slide into place against the barrier  180  by the force of gravity. 
     Likewise, in FIG. 7B a valid drop event is shown. The present state  590  shows that the upper emitter  330  and the upper receiver  350  are blocked while the lower emitter  320  and the lower receiver  340  are opened. In the previous state  600 , both pairs of the emitters  320 ,  330  and the receivers  340 ,  350  are open. This means that the emitters  320 ,  330  and the receivers  340 ,  350  were open in the previous state  600  because either there was no first product  190  within the channel  140  or that the first product  190  was being inserted into the channel  140  and the second product  200  was being pushed back towards the second end  170  of the channel  140 . In either case, the emitters  320 ,  330  and the receivers  340 ,  350  were open. As the first product  190  is being placed within the channel  140  in the present state  590 , the upper emitter  330  and the upper receiver  350  are blocked while the lower emitter  320  and the lower receiver  340  are still open. 
     FIG. 8 shows an alternative scan routine to that found in FIG. 5, but with the use of a lift/drop signature table  650  instead of the signature analysis sub-routine of FIG.  6 . The signature table  650  provides the same analysis as in the signature analysis subroutine but in table form. If the micro-controller  270  determines (1) that the delay timer is not on, (2) that the upper emitter  330  and the upper receiver  350  were open in the previous state, (3) that the lower emitter  320  and the lower receiver  340  were open in the previous state, (4) that the upper emitter  330  and the upper receiver  350  are closed in the present state, and (5) that the lower emitter  320  and the lower receiver  340  are closed in the present state, then a lift event has occurred. Likewise, if the micro-controller  270  determines that (1) the upper emitter  330  and the upper receiver  350  were closed in the previous state, (2) that the lower emitter  320  and the lower receiver  340  were open in the previous state, (3) that the upper emitter  330  and the upper receiver  350  are open in the present state, and (4) that the lower emitter  320  and the lower receiver  340  are open in the present state, then a drop event has occurred. 
     Applying the use of the signature table  650  in FIG. 8, the micro-controller  270  checks the door switch  125  (if a door  120  is used), the hold switch  127 , and selects the next product channel  140  at step  660 . At step  670 , the micro-controller  270  reads the present state of the optical sensors  260 . At step  680 , the micro-controller  270  retrieves the previous state of the optical sensors  260 . At step  690 , an event signature is created with the current state and the previous state of the optical sensors  260 . At step  700 , the signature table  650  is compared with the event signature of step  690 . At step  710 , the micro-controller  270  determines whether a valid event has taken place, i.e., a lift or a drop. If so, at step  720 , the micro-controller  270  obtains the cooler identification number and the time stamp so as to create an event record. At step  730 , the event record is stored in RAM  277  or other type of memory device. 
     The event records may be accessed at any time. The event records may be organized in a conventional spreadsheet format. FIG. 9 shows a sample spreadsheet layout  750 . As is shown, the spreadsheet layout  750  includes the cooler identification number  760 , the channel number  770 , the event  780 , i.e., either a lift or a drop, and the time stamp  790 . A preferred spreadsheet  750  may be the Excel® spreadsheet software sold by the Microsoft Corporation of Redmond, Wash. The data may be downloaded to a standard laptop computer, palmtop, or similar device via a serial port such as a RS232 port. Alternatively, the data may be transmitted via radio frequencies, telephone, or other conventional means. 
     The present invention thus provides an accurate means for monitoring the inventory of a cooler or other type of product shelf. Further, the present invention also may provide consumer purchasing information in that the nature of the products bought, the volume, and even the time the products are bought may be available. This type of data may be used to determine brand and packaging information and optimization. 
     It should be apparent that the foregoing relates only to the preferred embodiments of the present invention and that numerous changes and modifications may be made herein without departing from the spirit and scope of the invention as defined by the following claims.