Patent Publication Number: US-2013235206-A1

Title: System and Method of On-Shelf Inventory Management

Description:
CROSS REFERENCE TO RELATED INFORMATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/609,725, filed Mar. 12, 2012, the contents of which are hereby incorporated herein in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure is directed to on-shelf inventory management systems, and more particularly to an on-shelf inventory management system that incorporates sensors, such as cameras and IR sensors into the shelf to track inventory. 
     BACKGROUND OF THE INVENTION 
     Shelf space on which products are being displayed is one of the most important resources in retail environment. Retailers cannot only increase their profit but also decrease cost by proper management of shelf space allocation and products display. Retailers who sell various brands of items through displaying on multi-level shelves face a problem of how to most effectively allocate that shelf space. It is assumed that the level of shelf on which the product is displayed has a significant effect on sales. 
     Inventory management is a constant problem for retail outlets. With the advent of bar code labels, UPCs, stores have been using the scanning of merchandise at check out to capture the movement of inventory and to initiate actions to replenish shelf stock. However, using sales information at check out can fail to capture the actual status of stock on the shelves. Cash register inventory tracking cannot capture missing shelf stock that results from theft, breakage, misplaced items, or the like. Also, many stores give the responsibility of shelf management to the product distributors or manufacturers and the store inventory system may not be equipped to timely notify the distributors or manufacturers of low, or no stock conditions. 
     One system, as described in U.S. Pat. No. 6,601,764 to Goodwin describes using RFID to track inventory. Goodwin describes an inventory management system which determines item location and time spent on a shelf The system includes an electronic shelf label (ESL) system including an ESL, a radio frequency identification (RFID) label interrogator associated with the ESL, RFID labels attached to items associated with the ESL, and a computer. The computer uses the ESL system to activate RFID labels on the items, obtains RFID label information from the RFID labels through the ESL system, and stores the RFID label information in a record. The computer completes the process and compares the latest RFID label information with previous RFID label information to determine which items have been added or removed from the shelf. 
     The problem with RFID systems is that each product placed on the shelf needs to have an RFID tag. This requires either the manufacturer or the store to add those tags to their product and meaningful cost in time and expense. 
     What is needed is a monitoring system to monitor the status of stock on a shelf or palette and to communicate that information to parties responsible for maintaining shelf inventory. Also, it would be advantageous for the system to learn patterns in inventory conditions to allow the distributor or manufacturer to optimize delivery and stocking schedules. 
     BRIEF SUMMARY OF THE INVENTION 
     In a preferred embodiment of the present invention, an inventory management system is described that includes two or more cameras mounted on a retail display space and positioned to capture images showing the presence of items of interest in the retail display space. A hub is in communication with each of the cameras mounted on the retail display space and is operable to aggregate information from the cameras related to the items of interest in the retail display space, and to communicate data regarding the status of the item of interest. An inventory management system is operable to receive the data from the hub. 
     In another preferred embodiment of the present invention, a process for managing on-shelf inventory is described that includes capturing an image of a retail display space using a camera mounted in the retail display space. The captured image is processed to determine the nature and quantity of items of interest in the retail display space. Data related to the nature and quantity of items of interest in the retail display space is then sent to an inventory management system using a hub in communication with the camera mounted in the retail display space. 
     In yet another embodiment, a shelving unit for displaying products for sale is described. The shelving unit includes one or more shelves holding the products for sale and a plurality of cameras mounted in the shelving unit such that the plurality of cameras are operable to capture images of the shelves holding the products for sale. A hub is associated with the shelving unit and is in communication with the plurality of cameras, the hub aggregating data from the plurality of cameras related to the nature and quantity of the products on the one or more shelves. 
     The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is perspective view of a retail shelf incorporating various embodiments of the present invention; 
         FIG. 2  is a block diagram of an embodiment of a camera module according to the concepts described herein; 
         FIG. 3  is a block diagram of an embodiment of a hub module according to the concepts described herein; 
         FIG. 4  is a system diagram of an embodiment of a shelf inventory management system according to the concepts described herein; and 
         FIG. 5  is a flow chart showing an embodiment of a process for managing inventory on a retail store shelf according to the concepts described herein. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Many industry experts agree that overstocks and stock-outs are the most significant contributors to retailers profit erosion. The impact of out-of-stocks extends well beyond the lost sales of the out-of-stock item alone. Out-of-stocks carry with them a variety of costs for both retailers and suppliers, including diminishing brand equity and decreasing effectiveness of trade promotions. Out-of-stocks create a ripple effect by distorting demand and leading to inaccurate forecasts. Retailer costs also include the time employees spend trying to satisfy shoppers who ask about a specific out-of-stock item. For a typical U.S. grocery store, the cost can amount to $800 per week. The corollary for shoppers is the amount of time spent waiting for resolution that could be spent more productively for the retailer in shopping—an estimated 20 percent of the average time for a shopping trip. Successfully managing inventory begins and ends with accurate tracking of the product on the shelf. 
     To aid in accurately tracking on-shelf inventory, an inventory management system is described for use in tracking and managing on-shelf inventory, particularly in the retail environment. Existing on-shelf management systems use a variety of techniques to try to manage the status of on-shelf inventory. Some systems use cameras mounted above or in front of the shelves, while others use on the shelf sensors such as pressure or capacitive sensors to try to detect the presence of items on the shelf. Still others use RFID (radio frequency ID) tags and sensors. These technologies have their particular strengths and weaknesses, but none have yet proved to be a comprehensive solution. 
     Referring now to  FIG. 1 , embodiments of an on-shelf inventory management system  100 , according to the concepts described herein, uses camera modules and/or infrared (IR) sensors mounted in the shelving itself to detect the presence of product on the shelf. The camera modules  103 , shown as rectangles, and/or IR sensors  104 , shown as circles, are mounted on the back wall  105 ,  106 ,  107  of the shelving module  100  for each shelf  108 ,  109 ,  110 ,  111 . While the cameras  103  and IR sensors  104  are shown mounted on the back of the shelving facing forward, they could also be mounted on the top, sides or bottom of the shelving without departing from the scope of the concepts described herein. 
     The camera modules  103 , which can use a camera chip such as the ones found in modern smart phones take images in their field of view and perform image processing looking for familiar shapes, patterns, items or even words and logos. The camera module  103  can even be programmed to compare new images with historical images to look for changes in its field of view. The camera modules  103  can be spaced apart along the length of shelving to provide a complete view of the shelving and images of adjoining camera modules can be stitched together to form a larger image. In addition to linear rows of camera modules  103 , as shown on the bottom shelf  111 , arrays of camera modules  103  can be used to get greater field of vision and/or image fidelity. An example of an array of camera modules  103  is shown on the second shelf  110 , though any pattern of camera sensors can be used and chosen to maximize the characteristics required by the particular application and the type of product being monitored. 
     In addition to, or instead of, camera modules  103 , IR sensors  104  can be used in a similar fashion. IR sensors, such as those used to activate paper towel dispensers, can detect the presence, or absence, of materials in their field of view. The use of IR sensors  104  would result in less data for processing and less nuanced determinations, but can be useful in particular applications. In addition to only camera modules  103 , or only IR sensors  104 , arrays of combinations of camera sensors and IR sensors can be used to further increase the amount and accuracy of data available. An example of such an array is shown on the third shelf  109  in shelving module  101 . As with the camera arrays, the ratio of cameras to IR sensors and the number and placement of each type of sensor can be varied according to application requirements without departing from the scope of the concepts described herein. 
     In addition to the camera modules  103  and IR sensors  104 , a hub  102  can be employed to manage the sensor array and provide a communications link to the system operators. The hub can be associated with a particular set of cameras and sensors, such as those arranged on a typical shelving segment, and multiple hub/sensor arrays can be used in a typical retail store environment. The hub can be used to do data processing on the data from the camera modules  103  and IR sensors  104  and to manage a communication link to an inventory management system. In preferred embodiments, the hub can use cellular communication technology to report data and status to the management system. Since cellular communications are used, it is preferable that the data transmitted by the hub be kept to a minimum to reduce the cost of transmissions. In such an embodiment, the images and sensor data processing would be done at the camera module  103 , IR sensor  104  and/or hub  102 . The distribution of the data processing can be determined to minimize the costs of the various parts and to maximize the system capabilities. 
     Referring now to  FIG. 2 , a preferred embodiment of a camera module  200  for use in an on-shelf inventory management system according to the concepts described herein is shown. The camera module  200  includes a camera sensor  201  that captures the images from the ambient light around the device. The camera sensor can by any type of appropriate sensor in any appropriate resolution. The sensor may be of the type or lensed to capture wide angle photographs if required to maximize the field of view. Other configurations of camera are also usable in the system. A microprocessor  202  takes the image data from the camera sensor  201  and can perform some, all or none of the desired image processing. The image processing can include looking for predefined elements, such as shapes, logos, words, etc. within the image and/or comparing the image to historical images to look for changes and patterns. A memory  204  stores historical data, images, configuration information and other programming for the module  200 . A wireless or wired interface  203  controls the external communications of the module  200 . The module  200  can be linked to the hub  102  shown in  FIG. 1  and can also be linked to other modules or sensors to allow the sharing of image data. A power supply  206  provides power to the module  200 . 
     Referring now to  FIG. 3 , an embodiment of a hub module  300  for use in an on-shelf inventory management system according to the concepts described herein is shown. In preferred embodiments, the hub module  300  aggregates the data from the cameras and sensors and communicates with a back end inventory management system. The connections to the sensors and cameras can be wired or wireless depending on the application and environment. Similarly, the communications with the back end management system can be over any type of wired or wireless network, though in preferred embodiments it is anticipated that the use of cellular networks will be preferred. In using data networks that charge for use, it is preferable that the communications from the hub to the back end management system be kept to a minimum. As such, image processing and other data analysis may be done locally at some combination of the hub, camera module and IR sensor. 
     In preferred embodiments the hub itself includes a wired or wireless interface  305  with the cameras and sensors using sensor interface module  304 . A microprocessor  301  and memory  303  perform the data processing and run the programming for the hub  300 , while a communications interface  302 , such as a cellular communications interface, controls the sending and receiving of data  306  from the hub to a back end inventory management system. 
     Referring now to  FIG. 4 , an embodiment of an end-to-end, on-shelf inventory management system  400  is shown. The management system  400  uses the on-shelf cameras and IR sensors, as shown in  FIG. 1 , to gather and process data about the status of product inventory on monitored shelves, such as shelves  108   a - n ,  109   a - n  and  110   a - n . That data is passed to an associated hub module  104   a  through  104   n  and further processed. The hub  104   a  through  104   n  reports the data using, for example, a cellular network  402  to a back end network  401 . Back end network  401  stores and processes the data from the hubs and communicates status with interested parties. 
     Back end network  401  includes data analytics  403  and a data warehouse  404 . The data analytics engine  403  can process the data from the hubs to determine outages, low inventory conditions, overstocks and other inventory conditions of interest related to patterns in the inventory status. Such patterns can be used to optimize delivery and stocking times, routes and quantities to maximize efficiency and availability. Data warehouse  404  can store both the raw data from the hubs and can store processed data derived by the data analytics engine  403 . Back end network  401  can also be used to notify interested parties using a communications module  405 . Interested parties, such as the distributor  407 , store  408 , and/or product manufacturer  409  can receive reports on the inventory status for the monitored shelf space of interest to that party. 
     Referring now to  FIG. 5 , a flow chart of an embodiment of an on-shelf inventory management process is described. Process  500  begins in block  501  where images of shelf space in the field of view of a camera module are taken. The process then passes to block  502  where some, all or none of the captured image is processed at the camera module. The data from the camera module is then sent to a hub associated with multiple camera modules, as shown in block  503 . Additional data processing of some, all or none of the images occurs at the hub, as shown in block  504 . Relevant data from the hub is then transmitted to a back-end inventory management system, as shown in block  505 . The inventory management system is then operable to report the inventory status to interested parties as shown in block  506 . 
     While the use of the inventory management system has been discussed in detail as used on retail shelving space, the system can be used in other contexts and applications while remaining well within the scope of the concepts described herein. In addition to shelf space, the system can be employed for use in gravity feed dispensers, such as those that are used to distribute drinks in convenience stores, end aisle or other palettes where the system could detect the presence and amount of available merchandise. It can also be used with hanging displays in addition to shelves, or in paper or recycling bins. As described, the system can use cameras and IR sensors in any combination and pattern as determined by the requirements of the application. The cameras and IR sensors could also be combined with other types of sensor elements to increase the system capabilities or decrease the costs associated with the system. Other types of sensors could include pressure sensors, capacitive sensors, RFID tags and similar sensors. Other applications could also include monitoring of parking spaces and lots using similar sensors, hubs and methodologies. 
     Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.