Patent Description:
Radio frequency systems, such Radio Frequency Identification ("RFID") systems and Near Field Communication ("NFC") systems, allow suitable transceivers to query and receive messages from nearby radio frequency tags. Such tags can allow users to perform inventory management functions without having to manually count individual articles.

Radio frequency tags can operate in various ranged such as, but not limited to, the High Frequency ("HF") range and Ultra High Frequency ("UHF") range. RFID tags often include a chip that is coupled to at least one suitable antenna, such as an antenna for RFID systems that operate in a desired range. The RFID tag receives power when excited by a nearby electromagnetic field emitted the resonant frequency of the RFID tag. Once the chip has received sufficient power, (e.g., 10µW), the chip turns on and transmits a coded return signal or message via the coil antenna.

<CIT> discloses a computer-implemented method for product management. The method can include obtaining user identification information from a user, wherein the identification code is associated with a financial account, of the user; validating, by a processor, that the identification information is authentic based on registration information that was previously received; providing first access signal to a locking mechanism of a locking enclosure to unlock the locking mechanism based on the validating, wherein the locking enclosure securely stores a purchasable product; obtaining product identification information from a scan of a bar code associated with the product providing the product information that was obtained to be rendered on a display; receiving an indication from the user that the product information is correct; and providing a second access signal to the locking mechanism to lock the locking mechanism based on the indication that was received. <CIT> discloses a system and method for monitoring retail shelf inventory that combines bar code and RFID technologies to permit electronic data entry of retail item shelf assignments and real time reporting of item removal from display/dispensing shelves. <CIT> discloses a computer-assisted method of tracking and handling inventory that includes obtaining identification information of inventory components of a group of inventory units and comparing the identification information obtained to inventory unit composition data to determine which inventory units include the identified inventory components. Location information is obtained for at least one of the inventory units that include the identified inventory components. The location information is compared to a reference location for determining a location of the at least one inventory unit. <CIT> discloses a system and method for interrogating RFID tags. In some implementations, a method includes transmitting an RF command signal to RFID tags in an inhibited zone during a first time period. The RF command signal substantially prevents the RFID tags in the inhibited zone from responding to RF interrogation. RFID tags in a target zone are interrogated during a second time period different from the first time period. The target zone located differently from the inhibited zone. <CIT> discloses an order-picking system which includes a picking cart having a radio frequency (RF) antenna arranged above an object-stacking surface of the picking cart. The order-picking system further includes a radio frequency identification (RFID) tag reader coupled to the RF antenna. The RFID tag reader is configured to identify a first RFID tag attached to a first tagged object placed on the picking cart and further configured to eliminate identification of a second RFID tag attached to a second tagged object located outside a perimeter of the object-stacking surface of the picking cart.

According to certain embodiments, a radio frequency identification ("RFID") based inventory system includes an RFID reader for interrogating RFID tags on inventory, and an RFID barrier that is configured to substantially inhibit interrogation of RFID tags associated with active inventory until a picked item from the active inventory is moved away from the RFID barrier. The RFID based inventory system determines that an item is picked when there is an increase in the number of responses to the RFID interrogation.

In certain other embodiments, a method includes interrogating RFID tags associated with inventory by an RFID reader that is in proximity to inventory, and inhibiting the interrogation of an active inventory item until an item in picked and removed from proximity of the RFID barrier.

According to yet other embodiments, a method of hands-free item picking from active inventory includes transmitting a first interrogation signal, inhibiting transmission of the first interrogation signal to active inventory by an RFID barrier, receiving a plurality of first responses from substantially only the replenishment inventory, transmitting a second interrogation signal, receiving a second plurality of responses, and determining that an item was picked from active inventory using one or more of when the second plurality of response is greater in number than the first plurality of responses; an RSSI of one of the first responses is not substantially below the RSSI of other responses; and responses are received from both a picked item and a non-inventory asset such as a forklift.

Various embodiments will become better understood with regard to the following description, appended claims, and accompanying drawings.

Accurate inventory management and tracking is essential to the successful operation of a modern warehouse. For example, accurate inventory management and tracking ensures adequate goods or supplies are purchased and then used or dispatched appropriately. As can be appreciated however, traditional inventory management and tracking in a warehouse is inherently prone to error, inefficiencies, and even fraud.

For example, it is difficult to accurately count and track the movement of individual items, or cases of items, to ensure that the desired product is picked from a shelf and then shipped to the proper location. The individual operator who performs the picking is required to accurately execute the picking operations to not only locate the correct items in a warehouse full of potentially vast numbers of items, but to also accurately count the proper number of items to be pulled from the shelves for the particular customer order to be filled. Errors can occur with paper forms, pick lists, hand counts, and even barcode scanning as each can involve some degree of human judgment.

Further, if hand held devices are used, such as bar code scanners, then the operator's efficiency can be impaired if the operator would otherwise need to use both hands to handle a carton or manipulate individual items. Also, if a hand held RFID scanning device is used then the operator can be required to expend time to scan particular cartons, items, or pallets of cartons decreasing worker efficiency. Additionally, many hand held RFID scanning devices have limitations in how they project RF energy which can require the operator to have to manipulate the RFID scanning device over the items in order to obtain an accurate read from the identifying RFID devices in the items, cartons, and pallets.

Although RFID devices allow for some degree of inventory management in warehouses, even the best systems can provide incomplete coverage in very large warehouse environments due to the sheer number of RFID tagged items. Further, the sheer number of individually tagged items can lead to an inability to accurately account for the location of individual items within a large warehouse.

The systems and methods provided herein resolve the challenges described above by allowing for an accurate hands-free picking process. Such a system can allow the individual worker, or picker, to focus on their primary function of physically picking items from shelves and then moving those items into a suitable area in the warehouse for shipment to customers while also providing accurate accounting and quality control processes. Generally, the present disclosure details the use of an RFID reader infrastructure which can track active goods by distinguishing between inventory, such as, but not limited to active inventory and replenishment inventory.

The systems and methods disclosed herein are described in detail by way of examples and with reference to <FIG>. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatuses, devices methods, systems, etc. can suitably be made and may be desired for a specific application. In this disclosure, any identification of specific techniques, arrangements, etc. are either related to a specific example presented or are merely a general description of such a technique, arrangement, etc. Identifications of specific details or examples are not intended to be, and should not be, construed as mandatory or limiting unless specifically designated as such.

The systems and methods disclosed herein describe new modalities for using Radio Frequency Identification ("RFID") tags to perform inventory functions. Although the systems and methods described herein are particularly applicable to tags that include RFID communication capabilities, the disclosed structures and methodologies can be adapted for use with other types of wireless tags. For example, the systems and methods described herein can be adapted for use in Electronic Article Surveillance ("EAS") systems that use High Frequency ("HF") radio waves, nominally at <NUM>, or the systems and methods can be suitably adapted for use with wireless protocols such as Bluetooth, NFC, and WiFi or IEEE <NUM> wireless transmission protocols.

Referring to <FIG>, an embodiment of a simplified RFID system <NUM> is presented for background understanding. The RFID system <NUM> includes an RFID reader <NUM>, for example a radio frequency transceiver, that is configured to interrogate one or more RFID tags <NUM>, <NUM>. The RFID reader <NUM> can transmit a radio signal and can receive information back from nearby RFID tags (e.g., <NUM>, <NUM>) that receive the transmitted radio signal. Each RFID tag <NUM>, <NUM> that receives the radio signal can respond by sending back an encoded signal to the RFID reader <NUM>. The encoded signal can individually identify the particular box <NUM> or item <NUM>, <NUM>, <NUM> to which the RFID tag <NUM>, <NUM> is attached or the encoded signal can generically identify a box <NUM> or item <NUM>, <NUM>, <NUM> depending on how the particular RFID tag <NUM>, <NUM> is encoded. For example, an RFID tag <NUM> can be attached to a box <NUM> that contains multiple individual items <NUM>, <NUM>, <NUM>. Each of the individual items <NUM>, <NUM>, <NUM> in that box <NUM> can optionally include an individual RFID tag <NUM> as well if, for example, the individual items will be separated before distribution. As can be appreciated, boxes can generically contain any number of items, each with an optional RFID tag.

Placement of an RFID tag <NUM> on a box <NUM> of individual items <NUM>, <NUM>, <NUM> can facilitate inventory management operations in several ways. For example, the placement of the RFID tag <NUM> on the box <NUM> can help to ensure that the RFID reader <NUM> is able to interrogate the RFID tag <NUM>. Individual items <NUM>, <NUM>, <NUM> in the box <NUM> may not be able to receive sufficient signal from the RFID reader <NUM> to transmit back a response to a query due to proximity or blocking of the signal by the box <NUM> itself. Also, the response from the RFID tag <NUM> on the box can be correlated with responses from individual items <NUM>, <NUM>, <NUM> to verify inventory counts.

Referring now to <FIG>, an embodiment of an RFID based hands-free stock picking system <NUM> is disclosed. In the RFID based hands-free stock picking system <NUM>, an RFID reader <NUM> is disposed over an aisle between shelving <NUM> and an RFID barrier <NUM> is disposed on the shelving <NUM>. Replenishment inventory <NUM> is disposed on one portion of the shelving <NUM>. RFID signals from the RFID reader <NUM> are able to interrogate the replenishment inventory <NUM>. Pick inventory or active inventory <NUM> is disposed on the shelving <NUM> such that RFID signals from the RFID reader <NUM> are blocked by the RFID barrier <NUM>.

Example RFID readers <NUM> can include readers known in the art understood in the art. As can be appreciated, the RFID readers <NUM> can be fixed reader systems, temporarily installed reader systems, or moving reader systems. Examples of suitable RFID barriers <NUM> can include deck covering such as an RF reflective material such as solid metal sheets or foil, or RF absorptive materials as would be understood in the art. Additionally, or alternatively, suitable RFID barriers <NUM> can actively block RF signals either at the barrier or in the active inventory <NUM>.

The RFID barrier <NUM> can block the RFID signals from the RFID reader <NUM>. As a result, the fixed overhead RFID reader <NUM> is able to interrogate the replenishment inventory <NUM> but unable to interrogate the active inventory <NUM>. In certain embodiments, the RFID reader <NUM> can discriminate between the replenishment inventory <NUM> and the active inventory <NUM> using software methods described later herein. Such embodiments are useful to facilitate use of the system where the RFID reader <NUM> can inadvertently read certain tags in the active inventory <NUM>.

In one embodiment presently contemplated, in order to enhance an operator's or end user's productivity, efficiency and accuracy it can be understood that a visual reference, may be included with the hands-free stock picking system <NUM> such as a touchscreen display or other such display device. This would be advantageous to both direct and inform the operator of completeness of ongoing work task. A display may be a small wireless device attached to a user's forearm/wrist or may simply reside as a fixed unit on an asset to provide visual reference to pick order, pick location, and pick accumulation. This visual reference provides feedback to the operator as to completeness to order requirements and would be tied into the warehouse management system to handle ongoing tabulation and direction of picking task. This linkage also can act as an alarm to alert both the operator and supervisor as to incorrect or incomplete work if the asset with the pallet of goods is attempted to be moved through doorway choke points as described herein. It is also contemplated that a type of visual reference could be incorporated within the RFID reader <NUM> in another embodiment.

In operation, the fixed overhead RFID reader <NUM> can operate in a substantially or semi-continuous operation. As a result, the fixed overhead RFID reader <NUM> can continuously interrogate the replenishment inventory <NUM>. The RFID based hands-free stock picking system <NUM> can tabulate the responses from the replenishment inventory <NUM>.

When an item is picked from the active inventory <NUM> and moved into the aisle and placed on a pallet <NUM> (as illustrated), cart, or other movable platform, etc., the RFID signal from the fixed overhead RFID reader <NUM> can interrogate the picked item <NUM> which was previously blocked from being interrogated by the RFID barrier <NUM>. The RFID based hands-free stock picking system <NUM> can determine that a picked item <NUM> has been removed from the active inventory <NUM> by comparing the tabulated responses from the replenishment inventory <NUM> and the additional received response from the picked item <NUM>.

For example, when a worker, or picker, moves stock from the replenishment inventory <NUM> into the active inventory <NUM>, the RFID based hands-free stock picking system <NUM> can detect the reduction in the number of responses from the replenishment inventory <NUM> compared with the previously tabulated responses. The RFID based hands-free stock picking system <NUM> can tabulate the number of items in the active inventory <NUM> by adding the reduction in responses from the replenishment inventory <NUM> to the tabulated active inventory <NUM>. As picked items <NUM> are detected, the RFID based hands-free stock picking system <NUM> can subtract those items from the tabulated number of items in active inventory <NUM>.

The RFID based hands-free stock picking system <NUM> can also determine when active inventory <NUM> needs to be replenished from replenishment inventory <NUM> and appropriate staff can be dispatched in advance of the active inventory <NUM> being depleted. Due to the high degree of worker activity, replenishment of active inventory <NUM> from replenishment inventory <NUM> is usually performed by forklift crews at specified intervals to maximize workflow and to ensure worker safety from objects that could fall from high rack or shelving locations. By tracking inventories closely, the RFID based hands-free stock picking system <NUM> can determine optimal times to perform such replenishment.

The RFID based hands-free stock picking system <NUM> can advantageously improve the picking experience by the worker. For example, the worker is not burdened with a barcode scanner for individual barcode scanning of items using, for example, a handheld scanning device. As used herein, this is a "hands-free" operation. Instead, the power and flexibility of a fixed overhead RFID reader <NUM> is leveraged during the pick process to monitor and tabulate the picked items <NUM> as they are pulled from active inventory <NUM> and placed onto a cart, tote, box, or pallet <NUM>.

Referring now to <FIG>, another embodiment of an RFID based stock picking and asset tracking system <NUM> is presented. As depicted in <FIG>, a fixed overhead RFID reader <NUM> is disposed over an aisle between shelving <NUM>, and an RFID barrier <NUM> is disposed on the shelving <NUM>. With replenishment inventory <NUM> disposed on one portion of the shelving <NUM>, RFID signals from the RFID reader <NUM> are able to interrogate the replenishment inventory <NUM> but the RFID barrier <NUM> blocks RF signals from active inventory <NUM>.

In the RFID based stock picking and asset tracking system <NUM>, each asset <NUM> is configured with an RFID asset tag <NUM>. The RFID asset tag <NUM> can be encapsulated within a plastic housing to provide a degree of durability and longevity required in a warehouse environment so as to remain functional during the useful life of the asset <NUM>. Example assets <NUM> can include a forklift as illustrated or any other material handling equipment such as the pallet <NUM>, a pallet jack, a cart, or other movable devices as would be understood in the art.

As described above for <FIG>, the fixed overhead RFID reader <NUM> continuously or semi-continuously interrogates the replenishment inventory <NUM>. The RFID based stock picking and asset tracking system <NUM> can place these reads into a suitable table or database so as to be able to determine when there is an increased number of reads during a stock picking event. When the asset <NUM> moves into the proximity of the fixed overhead RFID reader <NUM>, the RFID based stock picking and asset tracking system <NUM> can detect the RFID asset tag <NUM> of the asset <NUM> as a trigger event. Once a trigger event has occurred, the RFID based stock picking and asset tracking system <NUM> can detect additional RFID responses as picked items <NUM>. For example, as picked items <NUM> are removed from active inventory <NUM> and placed onto pallets <NUM>, the fixed overhead RFID reader <NUM> can detect the elevated number of responses from the picked items <NUM> by comparing the number of previous responses from the replenishment inventory <NUM> that are stored on the table. The RFID based stock picking and asset tracking system <NUM> can record these new reads as picks from active inventory <NUM> and can associate these new responses from the picked items <NUM> with the asset <NUM>.

As can be appreciated, although the RFID barrier <NUM> can substantially or completely block all RFID energy from reaching the active inventory <NUM>, some RFID energy from the fixed overhead RFID reader <NUM> or another RFID reader may reach portions of the active inventory <NUM> leading to unintended reads. Advantageously, by waiting for a trigger event, such as when an asset <NUM> moves into range of the fixed overhead RFID reader <NUM>, the RFID based stock picking and asset tracking system <NUM> can suppress spurious inadvertent reads from active inventory <NUM>.

Additionally, the RFID based stock picking and asset tracking system <NUM> can suppress inadvertent reads from active inventory <NUM> through software and other techniques. For example, when the fixed overhead RFID reader <NUM> receives a response from an RFID tag, the fixed overhead RFID reader <NUM> can determine an RSSI or received signal strength indicator value of the response. RFID based stock picking and asset tracking system <NUM> can suppress those reads that have substantially lower RSSI values, indicating active inventory <NUM>, than reads from the replenishment inventory <NUM>. Additionally, the RFID based stock picking and asset tracking system <NUM> can detect and track those reads that have both lower RSSI values and are spurious in nature, which combined suggest that those reads are from active inventory <NUM>.

Referring now to <FIG>, an embodiment of an RFID based stock tracking system <NUM> is presented. The RFID based stock tracking system <NUM> includes a plurality of RFID readers disposed in and around a warehouse or other environment. In certain embodiments, the RFID readers can be deployed to cover an entire facility. For example, the RFID readers can be distributed so as to cover choke points such as doorways between adjoining sections of a building. In particular embodiments, RFID readers <NUM> can be disposed proximate to an entrance leading to a shipping area, while other RFID readers 404a, 404b, 404c, 404d, 404e, 404f (collectively RFID readers <NUM>) can be disposed along aisles between shelving <NUM>. The RFID readers <NUM> disposed along aisles between shelving <NUM> can track item picking from inventory <NUM> as described above with regard to <FIG> and <FIG>. RFID readers <NUM> can also be used to further improve the accuracy of the RFID based stock tracking system <NUM> to determine if items have been moved from replenishment inventory <NUM> to active inventory <NUM>.

In certain embodiments, the RFID readers <NUM>, <NUM> can be configured to monitor the movement of RFID tagged items throughout a facility, for example, the movement of picked items and associated assets as described above. The RFID based stock tracking system <NUM> can monitor picked items and associated assets as then travel in the facility and pass within proximity of the RFID readers <NUM>, <NUM>. The RFID based stock tracking system <NUM> can determine if the operator picked the proper items and ensure that the picked items are being transferred to the correct location for distribution to individual retail stores or other regional distribution centers. The RFID based stock tracking system <NUM> can determine if a particular pallet has been loaded with all of the items necessary to fulfil a customer's order. The RFID based stock tracking system <NUM> can track the progress of customer orders so as to provide real time tracking updates or projected delivery times of picked items to customers and also to other departments associated with the facility. For example, delivery personnel can be updated with the status of an order as items for a particular customer's order are picked by an operator and placed onto a pallet for future delivery. This advantageously can allow various departments to work together to manage work flow.

By tracking assets and associated pick items as they move about a facility, the RFID based stock tracking system <NUM> can also analyze work flow patterns. For example, the RFID based stock tracking system <NUM> can monitor which worker picked which items and combine that information with the particular asset that was used in the picking process to accomplish the task. This allows the RFID based stock tracking system <NUM> to compile valuable data around utilization rates and route management efficiency within a facility. In certain embodiments, the RFID based stock tracking system <NUM> can provide graphical representations to assist in developing better route management and increasing efficiency. For example, the RFID based stock tracking system <NUM> can determine if operators are consistently being delayed at choke points and reroute operators or change the order in which picks from inventory are made. The RFID based stock tracking system <NUM> can also determine optimal placement for inventory <NUM> on the shelving <NUM> to maximize worker efficiency.

As describe above with regard to <FIG>, active inventory may need to be replenished from replenishment inventory. This may require forklift crews to cordon off portions of aisles at specified intervals to ensure worker safety from objects that could fall from high rack or shelving locations. The RFID based stock tracking system <NUM> can evaluate traffic flows and monitor active picking to determine optimal times to perform replenishment. The RFID based stock tracking system <NUM> can reroute pick staff to ensure optimal workflow during stock replenishment operations.

As can be appreciated, the systems and methods described herein can provide numerous advantages to both warehouse owners and the pickers. Pickers benefit by being able to focus on movement of assets or inventory without the need to handle paper forms, pick lists, hand counts, or scanning of barcodes or RFID tags. Warehouse owners benefit from accurate inventory counts, improved efficiencies in the movement of their goods, and a better understanding of how to distribute items to end customers.

The values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited.

The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests, or discloses any such invention.

The foregoing description of embodiments and examples has been presented for purposes of description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed and others will be understood by those skilled in the art. The embodiments were chosen and described for illustration of various embodiments. The scope is, of course, not limited to the examples or embodiments set forth herein.

Claim 1:
A radio frequency identification, RFID, based inventory system (<NUM>, <NUM>, <NUM>), comprising:
an RFID reader (<NUM>; <NUM>, <NUM>) configured to interrogate RFID tags associated with inventory, wherein the inventory comprises active inventory (<NUM>) and replenishment inventory (<NUM>);
shelving (<NUM>) configured to hold the active inventory and the replenishment inventory; and
an RFID barrier (<NUM>) configured to inhibit interrogation of RFID tags associated with items of the active inventory until an item of the active inventory is picked and removed from proximity of the RFID barrier, thereby allowing for an RFID tag of the item picked from the active inventory to be interrogated,
wherein the RFID based inventory system is configured to determine:
a number of items in the replenishment inventory based on a number of responses indicative of a number of responding tags in the replenishment inventory;
that an item has been picked from the active inventory based at least in part on the number of responses plus one response from a tag on the picked item; and
that an item has been moved from the replenishment inventory to the active inventory based on the number of responses minus one response from a tag of the moved item.