Patent Description:
Knowing the number of articles stored, in particular in the case of warehouses, is essential for operating a business. Articles present in a stock or in a warehouse could in principle be derived from inflows and outflows. However, in practice, deviations are routine due to human errors such as articles placed in the wrong place, picking errors, WMS (Warehouse Management System) recording errors or lost articles, or due to other factors such as theft. Therefore, an inventory, which is a process of identifying, counting and valuing articles present in a site or in a company, is typically regularly required. Additionally, companies, which have stocks, generally have legal obligations in terms of inventory. For example, in France, the commercial code requires that at least one inventory be performed every year.

For a logistics service provider, an inventory is a physical operation, which can be an extremely tedious operation requiring significant resources and time. In order to optimize space, usually goods are placed in boxes, which are placed onto pallets, and are stored in large pallet racks. Pallet racks may have several rack levels and may culminate at more than <NUM> meters in height. Accessing all levels of the racks and precisely identifying all pallets and/or articles, requires the usage of an elevator such as a scissor lift <NUM> or a vertical mast <NUM> as represented on <FIG>. Such elevators include an elevator platform <NUM> or <NUM> on which an operator can stand for performing inventory activities. A location in a pallets rack in a warehouse can be identified with a codification based on area, aisle, column and level. <FIG> illustrates a storage organization of a warehouse and an associated localization codification. The warehouse is divided in areas <NUM> such as area <NUM> on <FIG>. Pallet racks <NUM> are aligned forming aisles in front of which a pallet truck <NUM> or an elevator <NUM> or <NUM> can drive along. For each pathway between two racks, there are two aisles <NUM> and <NUM> named aisle A and aisle B on <FIG>, each corresponding to one of the two racks bordering the pathway. Each rack is organized in columns <NUM> and rack levels <NUM>. For example, on <FIG>, a palette can be stored in column <NUM> at rack level D. A standard codification for a palette localization is 01A004D, where <NUM> indicates the area <NUM> within the warehouse, A indicates the aisle A of area <NUM>, <NUM> indicates the column <NUM> of the aisle A and D indicates the rack level D of column <NUM>.

Generally, an inventory procedure includes the following steps: moving the elevator in a first area and aisle of the warehouse, positioning the elevator in front of a first column, and, once the operator is positioned onto the elevator platform, elevating the elevator platform to a first level of the palette rack. Then, the operator can scan the pallet or the article present on the pallet depending on the inventory level required. For an exhaustive physical inventory corresponding to a scanning of all the palettes stored in the warehouse, the elevator must be moved in front of each column of each palette rack, and the elevator platform must be elevated up to each rack level, which is a tedious resources and time consuming operation. So, there is a need for a solution improving the productivity and increasing the reliability of a warehouse inventory. With a faster and more reliable inventory operation, a logistics provider may be able to perform inventories more often. In addition to be more easily compliant with any local legislation, a faster inventory operation also provides an opportunity for a logistics provider to know almost in real time the actual status of its stock and benefit from this knowledge for optimizing his overall operation.

Technological background for the disclosed solution can also be found in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

It is an object of the present invention to at least substantially overcome or ameliorate at least one or more of the disadvantages described above. This object is achieved by providing a system for inventorying items by reading attached identifying RFID tags stored on palette racks comprising at least one vertical reference post equipped with at least one post marker, the system comprising an apparatus configured for reading said identifying tags, characterized in that the apparatus comprises: at least one telescopic mast, which can be vertically deployed and folded, at least one RFID antenna mounted onto said telescopic mast for emitting RFID signals towards said identifying RFID tags and for receiving response messages from the identifying RFID tags, a RFID reader for energizing said at least one RFID antenna and for reading said identifying RFID tags, a computer unit for controlling the RFID reader and storing data, and at least one height sensor for detecting said at least one post marker.

In a preferred embodiment, the telescopic mast is constituted of a set of at least two cylinders, wherein the at least two cylinders of the set can slide into each other.

According to a feature of the invention, the at least one height sensor and the at least one RFID antenna are attached on each of said at least two cylinders.

According to another feature of the invention, the at least one height sensor is positioned at a fixed vertical distance from the center of the at least one RFID antenna.

The system according claim <NUM>, characterized in that a value of the fixed vertical distance is stored in the computer unit.

In a particular embodiment, the apparatus further comprises a supporting pedestal and the supporting pedestal is shaped with two parallel longitudinal cavities for being easily handled by a forklift.

Advantageously, the at least one RFID antenna is oriented and is emitting in a direction perpendicular to a longitudinal axis of the two parallel longitudinal cavities.

In another embodiment, the palette racks comprise several rack levels and, for each rack level of the palette racks, a height marker is attached on the at least one vertical reference post at a same distance above a shelf corresponding to the rack level. Advantageously, the height marker is an optical reflector.

In a particular embodiment, the height marker is a RFID tag. And, preferably, the at least one height sensor is the at least one RFID antenna.

In a particular embodiment, the height values are stored in the height marker.

According to a feature of the invention, the computer unit is configured for calculating a travel adjustment Ta for the at least two cylinders based on the height values.

According to another feature of the invention, the at least one post marker is attached at the same height as the height marker.

In a preferred embodiment, the at least one post marker is a RFID tag.

In another embodiment, the computer unit is configured for calculating a travel adjustment Ta for the at least two cylinders based on height information stored in the post marker. Advantageously, the height information comprising a height indicator indicating a change in shelf height and whether the shelf height is taller or lower, is stored in the post marker.

In a particular embodiment, the apparatus is constituted of two telescopic masts, each comprising the at least one RFID antenna.

According to a feature of the invention, the apparatus comprises two sets of the at least one RFID antenna, each set emitting in an opposite direction of the other one.

Advantageously, the apparatus is attached to and conveyed by an automatic guided vehicle.

The invention also concerns an apparatus for inventorying items by reading attached identifying RFID tags stored on palette racks comprising at least one vertical reference post equipped with at least one post marker, characterized in that it comprises: at least one telescopic mast, which can be vertically deployed and folded, at least one RFID antenna mounted onto said telescopic mast for emitting RFID signals towards the identifying RFID tags and for receiving response messages from the identifying RFID tags, a RFID reader for energizing said at least one RFID antenna and for reading said identifying RFID tags, a computer unit for controlling the RFID reader and storing data, and at least one height sensor detecting said at least one post marker.

Preferably, the telescopic mast is constituted of a set of at least two cylinders, wherein the at least two cylinders of the set can slide into each other.

Advantageously, the at least one height sensor is positioned at a fixed vertical distance from the center of the at least one RFID antenna.

In a preferred embodiment, a value of the fixed vertical distance is stored in the computer unit.

In a particular embodiment, a supporting pedestal of the apparatus is shaped with two parallel longitudinal cavities for being easily handled by a forklift.

Preferably, the at least one RFID antenna is oriented and is emitting in a direction perpendicular to a longitudinal axis of the two parallel longitudinal cavities.

According to another feature of the invention, the at least one presence sensor is attached onto the at least two cylinders for detecting a presence of a palette wherein the computer unit is configured for displaying empty palettes locations or for providing a warning explaining that identifying RFID tags may be missing when a palette is detected by a presence sensor and no RFID signal is received by the corresponding RFID antenna.

In another embodiment, the apparatus comprises two telescopic masts, each comprising said at least one RFID antenna.

According to a feature of the invention, the apparatus comprises one telescopic mast comprising two sets of said at least one RFID antenna, each set emitting in an opposite direction of the other one.

The invention also concerns a method for inventorying items with an apparatus by reading attached identifying RFID tags stored on palette racks comprising at least one vertical reference post equipped with at least one post marker within a warehouse comprising the following steps: deploying vertically the telescopic mast of said apparatus, reading said identifying tags by said apparatus with RFID antennas mounted onto the telescopic mast, wherein the RFID antennas are energized by a RFID reader, when said at least one post marker attached onto said at least one vertical reference post is detected by height sensors of said apparatus, identifying said at least one vertical reference post based on the reading of said at least one post marker, and adjusting the vertical deployment of said telescopic mast before continuing reading said identifying RFID tags, and folding vertically the telescopic mast when all items are inventoried.

In a preferred embodiment, the telescopic mast is constituted of a set of at least two cylinders, wherein the at least two cylinders of the set can slide into each other and wherein the telescopic mast is deployed starting with the lowest cylinder up to the highest cylinder. Therefore, the deployment of the lowest RFID antenna does not impact the position of the above RFID antennas.

In another embodiment, one height sensor amongst the height sensors and one RFID antenna amongst the RFID antennas are attached onto each of said at least two cylinders.

Preferably, the palette racks comprise several rack levels and for each rack level of the palette racks, a height marker is attached on the at least one vertical reference post at a same distance above a shelf corresponding to the rack level.

According to another feature of the invention, the method further comprises: orienting the height sensors in the direction of the height markers, activating the one height sensor, raising the at least two cylinders, capturing a signal returned from a height marker detected by the height sensor, determining a position of the at least two cylinders based on the returned signal and based on a fixed distance Hms between height markers and corresponding shelves of the palette racks and based on a stored value of a fixed vertical distance Hsa between the one height sensor and the one RFID antenna, and stopping the raising of the at least two cylinders according to the determined position. Thus, the vertical positioning of the RFID antennas is automated by using height markers and height sensors, and the operator only has to initiate the deployment of the telescopic mast for the RFID antennas to be automatically positioned at their correct height.

In a preferred embodiment, the at least one post marker is a RFID tag and the height sensors are the RFID antennas and the method further comprises: orienting the height sensors in the direction of the height markers, activating the one height sensor, raising the at least two cylinders, capturing a signal returned from a height marker detected by the one height sensor, calculating a travel adjustment Ta based on a distance H between a targeted height for the one RFID antenna and a corresponding shelf position and based on a fixed distance Hms between the height markers and corresponding shelves of the palette racks, continuing raising the at least two cylinders according to the travel adjustment, and stopping the raising of the at least two cylinders.

In a particular embodiment, the travel adjustment is calculated according to the formula: Ta = H - Hms.

Advantageously, the high values corresponding to the distance H and to the fixed distance Hms are stored in the at least one post marker.

In a preferred embodiment, the method further comprises: initiating inventory capture, automatically energizing the RFID antennas, transporting the apparatus along an aisle of the warehouse, while reading the attached identifying tags with the RFID reader, processing into data totally or partly information read from the attached identifying tags or from the at least one post marker or the height markers affixed onto the palette racks, and wirelessly transferring the data to a remote data processing system.

In a particular embodiment, the method further comprises: reading the at least one post marker while transporting the apparatus along an aisle of the warehouse, stopping in front of at least one post marker for adjusting the telescopic mast deployment, if the post marker is detected by the lowest height sensor, interpreting shelf height as lower and lowering the at least two cylinders starting with the lowest cylinder up to the highest cylinder and stopping lowering the at least two cylinders based on a signal returned from a height marker, and, if the post marker is detected by a height sensor other than the lowest height sensor, interpreting shelf height as taller and raising the at least two cylinders starting with the lowest cylinder up to the highest cylinder and stopping raising the at least two cylinders based on a signal returned from a height marker. Thus, the telescopic mast is automatically adjusted for the RFID antennas to be positioned at their correct height.

Other aspects, features and advantages of the teachings of the invention will become clearer to those ordinary skilled in the art upon review of the following description in conjunction with the accompanying drawings where:.

<FIG> represents an apparatus <NUM> constituted of several RFID antennas <NUM> mounted on a telescopic mast <NUM> in a folded configuration according to an embodiment of the invention. Each RFID antenna can be used for reading identifying RFID tags attached onto palettes or articles stored on a palette rack. These RFID antennas can be with circular or linear polarization. The telescopic mast <NUM> can be positioned in front of a column of a palette rack and can be vertically deployed so that each RFID antenna may be positioned in front of a different level of the palette rack. The number of RFID antennas needs to be equal or larger than the number of levels of the palette rack. The deployment of the telescopic mast <NUM> is illustrated on <FIG>, which represents the apparatus <NUM> with the telescopic mast in a deployed configuration according to an embodiment of the invention. The folded configuration of the telescopic mast is applied for example when the apparatus <NUM> is stored between inventories as it is not in use, or when the apparatus <NUM> must be displaced at a high speed. The deployed configuration of the telescopic mast <NUM> is applied when the apparatus <NUM> is used for reading identifying RFID tags once positioned in front of a column of a palette rack, or when the apparatus <NUM> is displaced at low speed. Once the telescopic mast is deployed in front of a rack within an aisle, the apparatus <NUM> may be displaced along the aisle and the inventory may be performed continuously.

The telescopic mast is constituted of cylinders <NUM>, which can slide into each other. The cylinders represented on <FIG> have a circular section, but other sections may be used such as square or almost square sections. The telescopic mast is maintained vertically by a base <NUM>. The sliding of the mast cylinders and the vertical positioning of the RFID antennas is controlled by a mast controller <NUM> included in the apparatus <NUM>. An RFID reader <NUM> can energize the RFID antennas for emitting RFID signals towards identifying RFID tags attached to pallets or articles and for receiving response messages from the identifying RFID tags. This RFID reader, which is embarked onto the apparatus <NUM>, can be attached to the base <NUM> of the telescopic mast <NUM>. The RFID reader is controlled by a computer unit <NUM>, which also manages the flow of data captured by the RFID antennas and performs the storing information exchanged between the reader and the RFID tags. The computer unit attached to the apparatus <NUM> may integrate the mast controller <NUM> as illustrated on <FIG> or may be separate and working in cooperation with the mast controller <NUM> as illustrated on <FIG>. The apparatus <NUM> is powered by an autonomous power supply block <NUM>, which provides energy to all electrical components comprised in the apparatus <NUM>. In a preferred embodiment, a height sensor <NUM> may be attached to each mast cylinder <NUM> for automating the deployment of the telescopic mast as it will be described in more details below in the section corresponding to <FIG>. For each mast cylinder, the height sensor is positioned at a fixed vertical distance Hsa <NUM> from the center of the corresponding RFID antenna. A value <NUM> of the fixed vertical distance Hsa is stored in a memory of the computer unit <NUM>.

According to <FIG>, the apparatus <NUM> can include a communication module <NUM> for transferring data collected by the apparatus <NUM> to a remote data processing system, which manages the warehouse inventory. Preferably, this transfer is performed wirelessly for example using Bluetooth or WiFi communication. In such a configuration, depending on the available memory capacity and processing capabilities of the computer unit of the apparatus <NUM>, the information captured regarding the warehoused objects may be processed totally or partly, in real time or latter, by the computer unit or may be remotely processed by the remote data processing system.

In a particular embodiment of the invention, the different components of the apparatus <NUM> are attached to a supporting pedestal <NUM>, which in particular securely holds the base of the telescopic mast. The supporting pedestal, preferably in metal, is shaped for being easily handled by a forklift, which is the most commonly used transporting vehicle in warehouses. The mast <NUM> is solidly attached to such a supporting pedestal, preferably in a central position of the supporting pedestal. All control and electrical equipment, including the mast controller <NUM>, the autonomous power supply block <NUM>, possibly the RFID reader <NUM> or the communication module <NUM>, and eventually the computer unit <NUM> can be attached onto the supporting pedestal. Two parallel and longitudinal cavities <NUM> provided in the lower part of the supporting pedestal would be used for sliding in the forks of a forklift, so that the apparatus <NUM> can be held and transported by the forklift. The apparatus <NUM> could be controlled by the operator of the forklift with a user interface installed onto the forklift and communicating via wireless short distance communication with the controller of the apparatus <NUM> via the communication module <NUM>. This user interface can provide to the operator some information and feedback regarding the inventory and the operation of the apparatus <NUM>. It may in particular display, preferably graphically, the status of the different components of apparatus <NUM> and the positions of the RFID antennas, as well as inventory data and statistics regarding for example inventoried items and their locations, palettes and their locations, and missing items or palettes. The user interface may be common for WMS reporting and for the control and monitoring of the apparatus <NUM>. According to this embodiment, the apparatus <NUM> can be transported along the aisles of the warehouse for performing a continuously inventory, using a forklift commonly used by warehouse personnel and therefore optimizing the handling of this new equipment. All the RFID antennas <NUM> of the apparatus <NUM> are oriented in the same direction and the emitting direction of the RFID antennas is perpendicular to the longitudinal axis of the cavities <NUM>. Thus, the RFID antenna emitting surface is parallel to the movement direction of the apparatus <NUM> along the aisle and is parallel to the front plane of the palette rack to be inventoried, therefore the RFID antenna emitting direction is oriented towards the palettes and/or articles to be inventoried.

The low level RFID antenna <NUM> is positioned for scanning ground level palettes and/or articles. It may not need to be attached to a mobile mast cylinder, but could be attached at a fixed vertical position onto the base <NUM> of the telescopic mast. In some warehouses, the ground level is used for picking articles eventually stored into palettes. When the need is only to inventory palettes or complete palettes, no scanning is required at the ground level and a low level RFID antenna <NUM> would not be used or may not have to be installed. In such a case, the lowest inventoried rack level is the first rack level or level B on <FIG>.

<FIG> represents the apparatus <NUM> with a deployed telescopic mast and with a configuration with an integrating computer unit <NUM>. Advantageously, a presence sensor <NUM> is attached onto each mast cylinder as represented on <FIG> for detecting the presence of a palette. This presence sensor can be for example an ultrasound sensor, and is preferably attached below a corresponding RFID antenna <NUM> and attached onto the same mast cylinder. There is no particular constraint on the position of the ultrasound sensor, except that it should not be too far below the corresponding RFID antenna so that it can be positioned in front of the lower part of palettes to be detected, and can easily detect the palettes whatever the height of these palettes. The ultrasound sensor can for example be attached just below the height sensor <NUM>. RFID antennas are energized by a RFID reader <NUM>. The integrating computer unit <NUM> controls the RFID reader, manages the flow of data captured by the RFID antennas, controls the mast deployment or folding and includes a communication module. All electrical components comprised in the apparatus <NUM> are powered by an autonomous power supply block <NUM>. Data captured by a presence sensor and the corresponding RFID antenna can be compared by the computer unit <NUM>. When a palette is detected by a presence sensor, but no RFID signal is received by the corresponding RFID antenna, a warning explaining that identifying RFID tags may be missing can be provided to the remote data processing system and/or to the operator via the user interface installed onto the forklift. Another benefit of the presence sensor is that empty palettes locations may be detected and mapped by the remote data processing system and/or displayed to the operator via the user interface installed onto the forklift.

For a correct operation of apparatus <NUM>, the RFID antennas need to be correctly positioned compared to the location of the items to be scanned and identified, i.e. each RFID antenna must be positioned in front of each level of a palette rack of a particular aisle. Then, the apparatus <NUM> can be moved along the aisle without changing the height position of the RFID antennas for to scanning all items located in the aisle. An RFID antenna should be positioned at a height corresponding preferably, to one third of the height of the rack level assigned to the RFID antenna. The operator may deploy the telescopic mast and visually adjust the height position of each RFID antenna. However, in a preferred embodiment of the invention, the vertical positioning of the RFID antenna may be automatized in order to ease the personnel operation and secure the height positions of the RFID antennas. <FIG> illustrates an example of rack for automating the deployment of a telescopic mast of an apparatus <NUM>. The palette rack is constituted of vertical posts <NUM> held together by horizontal shelves <NUM> on which palettes <NUM> are stored. An identifying RFID tag <NUM> is attached onto each palette. For each level of the palette rack, a height marker <NUM> is attached on a reference post <NUM> at a fixed distance Hms <NUM> above a shelf corresponding to that rack level, i.e. each height marker are attached at the same fixed distance Hms from the corresponding shelf. Each height markers is designed for interacting with a height sensor <NUM> attached onto each cylinder <NUM> of the telescopic mast <NUM>. For each mast cylinder, the height sensor is positioned at a fixed vertical distance Hsa <NUM> from the corresponding RFID antenna. The detection of a height marker by the corresponding height sensor provides the information for the mast controller <NUM> to vertically deploy the corresponding mast cylinder and position the corresponding RFID antenna at the correct height, i.e. deployment position. Preferably, the height markers can be optical reflectors with corresponding optical sensors used as height sensors, which emit an optical signal and sense a reflected signal from the optical reflectors. When optical reflector and optical sensors are used, the fixed distance Hms is defined so that during the deployment of a mast cylinder, when the optical sensor of that particular mast cylinder detects a reflected signal from an optical reflector, the deployment of the mast cylinder is stopped and the RFID antenna of that particular mast cylinder is positioned at the correct height for reading identifying RFID tags of pallets and/or articles stored on the corresponding rack level. Optical reflectors are attached at a fixed distance Hms, which depends on the targeted height for the RFID antenna and on the position of the height sensor relatively to the RFID antenna (i.e. Hsa) according to the relation: <MAT> where H is the distance between the targeted height for the RFID antenna and the shelf position, and Hsa is the distance between the height sensor and the RFID antenna.

The height markers could also be RFID location tags with corresponding specific RFID antennas used as height sensors, which emit a RFID signal and sense a response signal from the RFID location tags used as height markers. In the case of RFID tags used as height markers, a more economical solution is to use each RFID antenna <NUM> as a height sensor and define its deployment position based on the vertical position where the RFID antenna detects a signal peak received from the corresponding RFID location tag. Preferably, signal peak detection shall be based on RSSI (Received Signal Strength Indication) value calculation. In this particular case where each RFID antenna is used as a height sensor, the fixed distance Hsa <NUM> is nul. When the fixed distance Hsa is nul, a value <NUM> of the fixed distance Hsa is not required to be stored in the computer unit <NUM>. The RFID height markers are attached on reference posts at a fixed distance Hms from a shelf. The deployment of a RFID antenna depends on the position of the RFID height markers and on the targeted height for the RFID antenna, and, once the RFID height marker has been detected, a travel adjustment Ta for the corresponding mast cylinder can calculated by the mast controller according to the relation: <MAT> where H is the distance between the targeted height for the RFID antenna and the shelf position, and Hms is the fixed distance between the height marker and the shelf.

Each height marker referencing a particular rack level must be attached on a reference post at the same fixed distance Hms from a shelf corresponding to that rack level. A controller attached to the apparatus <NUM>, either the mast controller or the computer unit controller, can perform the calculation of Ta based on Height values (<NUM>) of the height parameters H and of Hms. These Height values can be stored in the remote data processing system and transferred to the controller attached to the apparatus <NUM> via the communication module <NUM>. Preferably, these Height values can be stored in the RFID height markers. In the simplest implementation, all the stored Height values are identical and all the height markers referencing a particular rack level are attached on a reference post at exactly the same fixed distance Hms from a shelf corresponding to that rack level. However, storing Height values in the RFID height markers allows for using different values and adjusting the deployment of the mast at different rack levels depending on the shelf heights. In a simplified embodiment of the invention, the height markers are attached at the targeted height for the corresponding RFID antenna. In such a case: H = Hms, and no Height values need to be stored either in the remote data processing system or the RFID height markers.

For an aisle with homogeneous shelf heights, a reference post hosting the height markers should be positioned at the entry of the aisle. If the shelf heights changes within an aisle or within a palette rack, an intermediate reference post <NUM> needs to be installed at the location where the shelf height changes so that the telescopic mast may be automatically adjusted. Conveniently, this intermediate reference post should be identified by a post marker <NUM> and preferably automatically detected so that the RFID antennas could be redeployed according to the height markers of this intermediate reference post. If the shelf heights are homogeneous within an area of the warehouse, only one reference post would be required at the entry of the area. If the shelf heights are homogeneous within the whole warehouse, only one reference post would be required for the entire warehouse. In such a case, a non-telescopic mast with predefined RFID antenna positions could be used, but would not be convenient for storage between inventories or for transportation especially at high speed. A reference post may be installed at the entry of each area or of each aisle so that an inventory may be started or continued after an interruption from any area or any aisle of the inventory and the telescopic mast may be deployed in front of that entry reference post. In the case of non-homogeneous shelf heights, there should be as many intermediate reference posts with a post marker <NUM> as there are changes of shelf heights.

In a preferred embodiment, the post marker of each intermediate reference post is attached at the same height as one of the height markers of the preceding reference post (either an entry reference post or an intermediate reference post). Therefore, the height sensor <NUM> corresponding to this particular one of the height markers can easily detect the post marker. Conveniently, the apparatus <NUM> should be able to capture an information indicating whether the shelf heights are taller or lower so that the telescopic mast may be automatically adjusted. The vertical position of the post marker can provide such an information. For example, when the post marker is detected by the lowest height sensor, the computer unit interprets the shelf height is lower and that the mast cylinders need to be lowered. When the post marker in detected by a height sensor other than the lowest height sensor, the computer unit interprets the shelf height is taller and that the mast cylinders need to be raised. Preferably, the post marker can be an optical reflector cooperating with a corresponding optical sensor, which emits an optical signal and senses a reflected signal from the optical reflector. The post marker could also be a RFID location tag cooperating with a corresponding specific RFID antenna, which emits an RFID signal and senses a response signal from the post marker. In the case of RFID tags used as height markers, as discussed above, the height sensors can simply be the RFID antennas <NUM>. The signal returned by the post marker to the height sensor is specific so as to indicate that there is a change in the shelf heights and that the telescopic mast requires a deployment adjustment. If the post marker is a RFID tag, a specific information indicating a shelf heights change is pre-stored in the RFID tag and returned within the response message when interrogated by the apparatus <NUM>. If the post marker is an optical reflector, its detection by a height sensor indicates the presence of an intermediate reference post and of a change in shelf heights. Therefore, a post marker can be an optical reflector identical or similar to a height marker. If the post marker is a RFID tag, height information (<NUM>) including a height indicator indicating a change in the shelf heights and whether the shelf heights are taller or lower, can be stored digitally in the post marker. A controller attached to the apparatus <NUM>, either the mast controller or the computer unit controller, can process the height indicator stored in the RFID post marker and read by the RFID antenna and RFID reader system. Based on the height indicator value, the telescopic mast deployment is automatically adjusted and the mast cylinders are either lowered or raised.

In another embodiment of the invention, in order to improve inventory efficiency, both aisles A and B on <FIG> may be scanned at the same time by the apparatus of the invention being driven between two parallel pallets racks. The apparatus is constituted of two telescopic masts, each having a set of RFID antennas. A first telescopic mast has its RFID antennas directed towards the left, i.e. towards the pallet rack of aisle A and a second telescopic mast has its RFID antennas directed towards the right, i.e. towards the pallet rack of aisle B. Each telescopic mast can be deployed independently according to reference posts positioned at the entry of the aisles. If the shelf heights are the same for the two aisles, only one reference post is required at the entry of the aisle and the deployment of the two telescopic masts can be synchronized. In the particular embodiment of an apparatus <NUM> comprising a supporting pedestal <NUM>, all the RFID antennas <NUM> are oriented so that the emitting direction of the RFID antennas is perpendicular to the longitudinal axis of the cavities <NUM> with the RFID antennas of the first telescopic mast being directed towards the pallet rack of aisle A on the left and the RFID antennas of the second telescopic mast being directed towards the pallet rack of aisle B on the right.

In a particular embodiment, if both aisles A and B on <FIG> are symmetric or if the shelf heights are homogeneous, a set of RFID antennas directed towards the left, i.e. towards the pallet rack of aisle A and a set of RFID antennas directed towards the right, i.e. towards the pallet rack of aisle B, can be deployed at the same heights. The apparatus can be constituted of only one telescopic mast as described in <FIG>, but with two sets of RFID antennas. The RFID antennas of each set would be respectively attached at the same height position on the telescopic mast and would be positioned symmetrically relatively to the vertical axis of symmetry of the telescopic mast and directed either towards the pallet rack of aisle A or towards the pallet rack of aisle B.

It is easily devised by those ordinary skilled in the art that vehicles other than forklifts could be used for moving the apparatus <NUM> of the invention within the aisles of a warehouse. The apparatus <NUM> may in particular be attached to and conveyed by an Automatic Guided Vehicle (AVG). Such AVG can follow marked lines or wires on or within the floor, or may use radio waves, vision cameras, magnets, or lasers for navigation. This way, a route is defined for controlling a passage of the apparatus <NUM> of the invention through all areas to be inventoried. The AGV can be equipped with additional sensors to adapt its displacement in function of a modification of its environment or a presence of an immediate danger. The AGV can be continuously monitored and controlled via the communication module <NUM> by the remote data processing system managing the inventory. A hand-checking between the AGV and the inventory system can be performed for controlling the position and for confirming the progress of the inventory.

A method using the apparatus <NUM> for inventorying a warehouse is now described in reference with <FIG>. In a preliminary step <NUM>, an identifying RFID tag must have been attached on each of the pallets and/or articles which has to be inventoried. These identifying RFID tags can be read by the apparatus <NUM>, which can then transfer collected information to a remote data processing system managing the warehouse inventory. Each identifying RFID tags includes a unique identification, which is known by the inventory system, and which can be stored in the remote data processing system or in the memory of the apparatus <NUM>. In step <NUM>, an operator prepares the apparatus <NUM> for transport and for performing the inventory. This preparation includes folding the telescopic mast <NUM> for transporting the apparatus <NUM> at high speed to the starting location for the inventory for example from the location where the apparatus <NUM> is stored. In the case of an apparatus <NUM> comprising a supporting pedestal <NUM>, the operator operates a forklift so as to slide the forks of the forklift into the two longitudinal cavities <NUM> provided in the lower part of the supporting pedestal. Then, in step <NUM>, the operator transports the apparatus <NUM> to the first aisle to be inventoried in the warehouse and stops at the entry of the first aisle so that the RFID antennas <NUM> are oriented with their emitting direction pointing towards the palettes and/or articles to be inventoried, i.e. the RFID antenna emitting surface is parallel to the front plane of the palette rack to be inventoried. In step <NUM>, the operator deploys the telescopic mast. Firstly, the lowest mast cylinder <NUM> is deployed so that the associated RFID antenna is positioned at the targeted height for the lowest inventoried rack level, preferably corresponding to one third of the height of the rack level. Secondly, the second lowest mast cylinder is deployed so that the associated RFID antenna is positioned at the targeted height for the second lowest inventoried rack level. Thus, the telescopic mast deployment is performed starting with the lowest mast cylinder up to the highest mast cylinder. This method is preferred as the deployment of the lowest RFID antennas does not impact the position of the above RFID antennas. If the number of rack levels to be inventoried is lower than the number of mast cylinders, the remaining highest mast cylinders are not deployed.

In a preferred embodiment of the invention, the vertical positioning of the RFID antennas is automated by using height markers <NUM> and height sensors <NUM>. The apparatus <NUM> is stopped near a reference post <NUM> located at the entry of the first aisle so that the RFID antennas <NUM> and the height sensors <NUM> are oriented in the direction of the height markers attached to the reference post. When a mast cylinder is deployed, the corresponding height sensor is activated and emits in the direction of the reference post. Based on the signal returned from a first height marker, which the height sensor detects, and eventually based on the fixed distance Hms <NUM> between the height marker and the corresponding shelf and based on the stored Hsa value <NUM> of the fixed distance Hsa between the height sensor and the corresponding RFID antenna and based on the distance between the targeted height for the RFID antenna and the corresponding shelf position, the mast controller <NUM> can determine the position where the mast cylinder deployment must be stopped, therefore positioning the corresponding RFID antenna at the correct height. Thus, the operator only has to initiate the deployment of the telescopic mast for the RFID antennas to be automatically positioned at their correct height.

Once the mast deployment is finalized, in step <NUM>, the operator initiates the inventory capture and begins transporting the apparatus <NUM> along the first aisle of the warehouse. Preferably, the RFID antennas are automatically energized once the deployment of the telescopic mast is completed. In the particular case where each RFID antenna is used as a height sensor, the RFID antennas are energized one after the other during the mast deployment and are therefore all energized when the deployment of the telescopic mast is completed. As the apparatus <NUM> is transported along the first aisle of the warehouse, the identifying RFID tags of the pallets and/or the articles stored on the rack are read. In a preferred embodiment, information collected by the apparatus <NUM> is wirelessly transferred to a remote data processing system, which manages the warehouse inventory. Depending on the available memory capacity and processing capabilities of the computer unit of the apparatus <NUM>, the information captured regarding the warehoused objects may be processed totally or partly, in real time or latter, by the computer unit or may be remotely processed by the remote data processing system.

If the shelf heights are homogeneous within the whole warehouse or within the area to be inventoried, no adjustment regarding the mast deployment is required. Otherwise, a post marker attached to an intermediate reference post is used for indicating that there is a change of shelf heights. When the post marker is detected by a height sensor (step <NUM>), the conveyance of the apparatus <NUM> is stopped in front of the intermediate reference post for adjusting the telescopic mast deployment in step <NUM>. The height sensors <NUM> are oriented in the direction of the height markers attached to this intermediate reference post. If the post marker is a RFID tag, because of the angular spread of the emission cone of the RFID height sensor, the post marker can be detected before the apparatus <NUM> arrives in front of the reference post. The computer unit can therefore operate a smooth automated stop exactly in front of the reference post.

In step <NUM>, based on the information returned by the post marker to the height sensor, the computer unit interprets whether the shelf heights are taller or lower so that the telescopic mast may be automatically adjusted accordingly. For example, when the post marker is detected by the lowest height sensor, the computer unit interprets the shelf height is lower. When the post marker is detected by a height sensor other than the lowest height sensor, the computer unit interprets the shelf height is taller. If the shelf heights are interpreted as taller, in step <NUM> the mast cylinders are raised and adjusted in a similar manner as described above for the mast deployment. The mast adjustment is performed starting with the lowest mast cylinder up to the highest mast cylinder. When a mast cylinder is raised, the corresponding height sensor continues emitting in the direction of the reference post. Based on the signal returned from a first height marker, which the height sensor detects, and based on the fixed distance Hms <NUM> between the height marker and the corresponding shelf and based on the stored value <NUM> of the fixed distance Hsa between the height sensor and the corresponding RFID antenna, the mast controller <NUM> can determine the position where the raising of the mast cylinder must be stopped, therefore positioning the corresponding RFID antenna at the correct height. Thus, the telescopic mast is automatically adjusted for the RFID antennas to be positioned at their correct height.

If the shelf heights are interpreted as lower, in step <NUM> the mast cylinders are lowered and adjusted according to the following procedure. The mast adjustment is performed starting with the lowest mast cylinder up to the highest mast cylinder. When a mast cylinder is lowered, the corresponding height sensor continues emitting in the direction of the reference post. Based on the signal returned from a first height marker, which the height sensor detects, and based on the fixed distance Hms <NUM> between the height marker and the corresponding shelf and based on the stored value <NUM> of the fixed distance Hsa between the height sensor and the corresponding RFID antenna, the mast controller <NUM> can determine the position where the raising of the mast cylinder must be stopped, therefore positioning the corresponding RFID antenna at the correct height. Thus, the telescopic mast is automatically adjusted for the RFID antennas to be positioned at their correct height.

Once the mast deployment is finalized, in step <NUM>, the operator resumes transporting the apparatus <NUM> along the aisle of the warehouse. As the apparatus <NUM> is transported along the first aisle of the warehouse, the identifying RFID tags of the pallets and/or the articles stored on the rack are read and the collected information is processed, thus is the inventory performed. As part of this inventory data capture, palette detection can be performed by presence sensors <NUM>. If a palette is detected by a presence sensor, but no RFID signal is received by the corresponding RFID antenna, a warning explaining that identifying RFID tags may be missing is provided to the remote data processing system and/or to the operator via a user interface. If a presence sensor does not detect any presence, and no RFID signal is received by the corresponding RFID antenna, the system records an empty palette location and a mapping of empty palettes locations can be performed and can be displayed to the operator via the user interface.

If another intermediate post marker is detected by a height sensor (step <NUM>), the conveyance of the apparatus <NUM> is stopped in front of this intermediate reference post for adjusting the mast deployment (return to step <NUM>). Each aisle can be scanned with the apparatus <NUM>, and once the scanning is completed, the telescopic mast can be folded in step <NUM> in preparation for transport. Each mast cylinder is lowered. The apparatus <NUM> is returned to storage in step <NUM>. Inventory information collected by the apparatus <NUM> is transferred to the remote data processing system. When the apparatus <NUM> is equipped with wireless communication, inventory information may be transferred partly or totally while the apparatus is being transported.

The method can also be applied to a dual apparatus constituted of two telescopic masts. Such a dual apparatus can scan two face to face aisles of two parallel racks - each having an entry reference post. When the dual apparatus is stopped at the entry of an aisle with each of the two telescopic masts facing one of the entry reference posts, each of the two telescopic masts is deployed independently, eventually in parallel, based on the position of height markers of the entry reference posts. Then, the two face to face aisles are scanned in parallel while the dual apparatus is transported along the aisles. As soon as a post marker is detected in either of the two aisles, the dual apparatus is stopped in front of an intermediate reference post hosting the post marker, and the deployment of the telescopic mast facing the intermediate reference post is adjusted based on the positions of the height markers of the intermediate reference post. Then, the parallel scanning of the aisles can resume.

In a preferred embodiment of the invention, a dedicated height sensor is affixed onto the apparatus <NUM> at a fixed distance from the ground. Preferably, the dedicated height sensor is affixed onto the base <NUM>, and may be, in the case of RFID, a low level RFID antenna <NUM>. A post marker is attached onto each reference post at a fixed distance from the ground, which is essentially equal to the fixed distance between the dedicated height sensor and the ground. According to the invention, post markers are easily and systematically detected by the dedicated height sensor whatever the deployment conditions of the telescopic mast and whatever the positions of the RFID antennas. In particular, a post marker is detected whether the apparatus <NUM> passes by the post marker in a direction or in the reverse direction. Without the use of a dedicated height sensor, when a post marker is attached at the same height as one of the height markers of the preceding reference post for convenient detection, an aisle must be scanned in a particular direction from the entry to its end. The use of the dedicated height sensor allowing the detection of a post marker whether the apparatus <NUM> passes by the post marker in a direction or in the reverse direction, provides a warehouse compatible with a combined use of both single mast and dual masts apparatus, which may pass by a post marker in different directions.

When a RFID tag is used as a post marker and the dedicated height sensor is a RFID antenna, height data regarding the height positions for all the RFID antenna can be stored in the height information (<NUM>) the RFID post marker. Based on the height data read by the apparatus <NUM>, the mast controller <NUM> can deploy the telescopic mast or adjust the telescopic mast deployment and position each RFID antenna at the targeted height. Then, height markers are not required anymore. However, the correct positioning of an antenna may be checked and ensured by a rangefinder attached to the apparatus <NUM>.

In the particular embodiment of the invention where the apparatus <NUM> is attached to and conveyed by an Automatic Guided Vehicle (AVG), the method using the apparatus <NUM> for inventorying a warehouse can be applied particularly efficiently. The only humane action for performing a warehouse inventory may be limited to providing an order initiating the inventory, eventually sent wirelessly to the apparatus <NUM>. Thereafter, the overall warehouse inventory can be carried out automatically by the apparatus <NUM> conveyed by the AVG. The AVG can transport the apparatus <NUM> to a pre-defined starting point or a starting point defined as part of the order for initiating the inventory - starting point which is typically an entry point of an aisle, in front of a reference post or a couple of reference posts for a dual apparatus. The telescopic mast or masts are automatically deployed based on the height markers attached on the reference posts, and eventually based on the height parameters stored in the height markers. The use of a dedicated height sensor affixed onto the apparatus <NUM> at a fixed distance from the ground, in this particular embodiment of the invention where the apparatus <NUM> is attached to and conveyed by an AVG, is particularly convenient for allowing the detection of a post marker whether the apparatus <NUM> passes by the post marker in a direction or in the reverse direction.

The different embodiments of the invention described above allow for easier and more reliable warehouse inventories, which can therefore be performed more regularly. By carrying out inventories regularly, a logistic provider has a better vision of his actual stock and can better manage supply and improve picking, therefore optimizing his stock.

Claim 1:
A system for inventorying items by reading attached identifying RFID tags (<NUM>) stored on palette racks (<NUM>) comprising at least one vertical reference post (<NUM>, <NUM>) equipped with at least one post marker (<NUM>), said system comprising an apparatus (<NUM>) configured for reading said identifying RFID tags, said apparatus comprises:
- At least one telescopic mast (<NUM>) constituted of a set of at least two cylinders (<NUM>), which can be vertically deployed and folded, wherein said at least two cylinders of said set can slide into each other,
- at least one RFID antenna (<NUM>) mounted onto said telescopic mast for emitting RFID signals towards said identifying RFID tags and for receiving response messages from said identifying RFID tags,
- a RFID reader (<NUM>) for energizing said at least one RFID antenna and for reading said identifying RFID tags,
- a computer unit (<NUM>; <NUM>) for controlling said RFID reader and storing data, being characterised by
- at least one height sensor (<NUM>; <NUM>; <NUM>) for detecting said at least one post marker (<NUM>), wherein said at least one height sensor and said at least one RFID antenna are attached on each of said at least two cylinders.