DEVELOPMENT OF AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS) PROTOTYPE ABDUL HALIM BIN HADZIR BACHELOR OF ENGINEERING UNIVERSITI MALAYSIA PAHANG

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1 DEVELOPMENT OF AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS) PROTOTYPE ABDUL HALIM BIN HADZIR BACHELOR OF ENGINEERING UNIVERSITI MALAYSIA PAHANG 2010

2 UNIVERSITI MALAYSIA PAHANG BORANG PENGESAHAN STATUS TESIS JUDUL: Saya DEVELOPMENT OF AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS) PROTOTYPE SESI PENGAJIAN: 2010/2011 ABDUL HALIM BIN HADZIR ( ) (HURUF BESAR) mengaku membenarkan tesis (Sarjana Muda/Sarjana /Doktor Falsafah)* ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hakmilik Universiti Malaysia Pahang (UMP). 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh: (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: NO. 369 KG. TJG. TEMIANG, MUHAMMAD HATIFI BIN MANSOR BT 3 ½ JLN SALLEH, ( Nama Penyelia ) 84000, MUAR, JOHOR. Tarikh: 6 DISEMBER 2010 Tarikh: : 6 DISEMBER 2010 CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu dikelaskan sebagai atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Ijazah doktor Falsafah dan Sarjana secara Penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).

3 DEVELOPMENT OF AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS) PROTOTYPE ABDUL HALIM BIN HADZIR Report submitted in fulfilment of the requirements for the award of the degree of Bachelor of Mechanical Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG DECEMBER 2010

4 ii UNIVERSITI MALAYSIA PAHANG FACULTY OF MECHANICAL ENGINEERING I certify that the report entitled Development of Automated Storage and Retrieval System (ASRS) Prototype is written by Abdul Halim Bin Hadzir. I have examined the final copy of this report and in my opinion; it is fully adequate in terms of scope and quality for the award of the degree of Bachelor of Engineering. I herewith recommend that it be accepted in partial fulfilment of the requirements for the degree of Bachelor of Mechanical Engineering. DAYANGKU NOORFAZIDAH AWANG SH RI Examiner Signature

5 iii SUPERVISOR S DECLARATION I hereby declare that I have checked this report and in my opinion, this report is adequate in terms of scope and quality for the award of the degree of Bachelor of Mechanical Engineering. Signature : Name of Supervisor : MUHAMMAD HATIFI BIN MANSOR Position : LECTURER Date : 6 th DECEMBER 2010

6 iv STUDENT S DECLARATION I hereby declare that the work in this report is my own except for quotations and summaries which have been duly acknowledged. The report has not been accepted for any degree and is not concurrently submitted for award of other degree. Signature : Name : ABDUL HALIM BIN HADZIR ID Number : MA07013 Date : 6 th DECEMBER 2010

7 ix TABLE OF CONTENTS EXAMINER S DECLARATION SUPERVISOR S DECLARATION STUDENT S DECLARATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS LIST OF ABBREVIATIONS Page ii iii iv vi vii viii ix xiii xiv ixi xx CHAPTER 1 INTRODUCTION 1.1 Project Background Problem Statement Objectives of the Project Project Scope Conclusion 3 3 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction Automated Storage Systems Carousel Storage Systems AS/RS Types Sizing The AS/RS Storage Structure AS/RS Throughput Microcontroller Types of Microcontroller 20

8 x 2.7 Conclusion 22 CHAPTER 3 METHODOLOGY 3.1 Introduction Component and Material Selection Mechanical Structure Design Process Sketching Computer Aided Design Drawing Stepper Motor Finalized Design Material and Equipment Preparation The Fabrication Process of Fabrication Basic Circuit for PIC 18F Stepper Motor Circuit Software Programming Design Stepper Motor Programming Conclusion 44 CHAPTER 4 RESULT AND DISCUSSION 4.1 Introduction Result of Fabrication Properties of Components/Part The Modification The Real Time Testing AS/RS Working Power and Torque Transmitted Analysis The Predicaments Problem of Fabrication Process The Defects of Prototype The Troubleshooting Solution of Fabrication s Problems 61

9 xi 4.9 Conclusion 62 CHAPTER 5 CONCLUSION AND RECOMMENDATION 5.1 Introduction Conclusion Recommendation 64 REFERENCES 65 APPENDICES A1 2D Engineering Drawing 66 A2 2D Engineering Drawing 67 A3 2D Engineering Drawing 68 A4 2D Engineering Drawing 69 A5 2D Engineering Drawing 70 A6 2D Engineering Drawing 71 A7 2D Engineering Drawing 72 A8 2D Engineering Drawing 73 A9 2D Engineering Drawing 74 A10 2D Engineering Drawing 75 A11 2D Engineering Drawing 76 A12 2D Engineering Drawing 77 A13 2D Engineering Drawing 78 A14 2D Engineering Drawing 79 A15 2D Engineering Drawing 80 A16 2D Engineering Drawing 81 A17 2D Engineering Drawing 82 A18 2D Engineering Drawing 83 A19 2D Engineering Drawing 84 A20 2D Engineering Drawing 85 B1 Gantt Chart For Final Year Project 1 86 B2 Gantt Chart For Final Year Project 2 87 C1 Finished Prototype 88

10 xii C2 Finished Prototype 89 D1 Programming for Drawer Coordinate X=1 and Y=1 (Drawer 1) 90 D2 Programming for Drawer Coordinate X=2 and Y=1 (Drawer 2) 91 D3 Programming for Drawer Coordinate X=3 and Y=1 (Drawer 3) 92 D4 Programming for Drawer Coordinate X=4 and Y=1 (Drawer 4) 93 D5 Programming for Drawer Coordinate X=5 and Y=1 (Drawer 5) 94 D6 Programming for Drawer Coordinate X=1 and Y=2 (Drawer 6) 95 D7 Programming for Drawer Coordinate X=2 and Y=2 (Drawer 7) 97 D8 Programming for Drawer Coordinate X=3 and Y=2 (Drawer 8) 98 D9 Programming for Drawer Coordinate X=4 and Y=2 (Drawer 9) 101 D10 Programming for Drawer Coordinate X=5 and Y=2 (Drawer 10) 103

11 xiii LIST OF TABLES Table No. Title Page 2.1 The differences between AS/RS and Carousel storage system Types of materials generally stored in a factory Properties of components Velocity and acceleration of S/R machine for drawer coordinate x=1 and y=2 4.3 Velocity and acceleration of S/R machine for drawer coordinate x=5 and y=2 4.4 Velocity and acceleration of lifter for drawer coordinate x=1 and y=2 4.5 Velocity and acceleration of lifter for drawer coordinate x=5 and y=2 4.6 Velocity and acceleration of drawer picker for drawer coordinate x=1 and y=2 4.7 Velocity and acceleration of drawer picker for drawer coordinate x=5 and y= Transaction time Torque and power transmitted Problems encountered during the progress of fabrication Defects of the fabricated AS/RS Solution for problems faced during fabrication Future prospects for defection of fabricated AS/RS 64

12 xiv LIST OF FIGURES Figure No. Title Page 2.1 Unit load AS/RS Mini load AS/RS Man-on-board AS/RS Deep-lane AS/RS Horizontal carousels Vertical carousels Classification of various AS/RS options Top and side views of a unit load AS/RS, with nine storage compartments horizontally (ny = 9) and six compartments vertically (nz = 6) Microcontroller feature PIC 18F452 microcontroller Flow Chart for Project Methodology Single mast of S/R machine Double mast of S/R machine Front view of AS/RS Left side view of AS/RS Right side view of AS/RS Top view of AS/RS Isometric view of AS/RS S unipolar stepper motor PM42S-048 unipolar stepper motor Hydraulic shear machine 35

13 xv LIST OF FIGURES Figure No. Title Page 3.12 Truma bend V series machine Drilling machine Rivet pop gun Schematic circuit diagram for PIC 18F Schematic diagram for stepper motor circuit Process flow chart for PIC programming MikroC compiler WinPIC800 interface Control system circuit Isometric view of AS/RS prototype Modification of AS/RS prototype The complete prototype a S/R machine move to right b Drawer picker move forward c Drawer picker move reversely with the drawer d S/R machine move to left until initial position e Drawer picker move forward until arrive P/D station Transaction involves retrieving the drawer from cabinet Technical drawing for S/R machine Technical drawing for lifter Technical drawing for drawer picker 68

14 xvi LIST OF FIGURES Figure No. Title Page 6.4 Technical drawing for drawer (unit load) Technical drawing for cabinet (storage structure) Technical drawing for spur gear holder Technical drawing for spur gear shaft Technical drawing for pinion 38 teeth s Technical drawing for gear 73 teeth s Technical drawing for pinion D40 mm Technical drawing for rack gear 388 mm Technical drawing for pinion D24 mm Technical drawing for rack gear 109 mm Technical drawing for pulley D20 mm Technical drawing for pulley D20 mm track Technical drawing for pulley D30 mm Technical drawing for pulley D30 mm middle Technical drawing for pulley D40 mm Technical drawing for pulley D40 mm track Technical drawing for AS/RS assembly Project planning for FYP Project planning for FYP Front view of AS/RS prototype Right side view of AS/RS prototype 88

15 xvii LIST OF FIGURES Figure No. Title Page 6.25 Left side view of AS/RS prototype Top view of AS/RS prototype 89

16 xviii LIST OF SYMBOLS ny nz W L H x y z Number of load compartments along the length of the aisle Number of load compartments that make up the height of the aisle Width of the one aisle of the AS/RS rack structure Length of the one aisle of the AS/RS rack structure Height of the one aisle of the AS/RS rack structure Depth of dimensions of a unit load Width of dimensions of a unit load Height of dimensions of a unit load a, b, and c Allowances designed into each storage compartment to provide clearance for the unit load and to account for the size of the supporting beams in the rack structure. The cycle time of a single command cycle The velocity of the S/R machine along the length of the AS/RS The velocity of the S/R machine in the vertical direction of the AS/RS Tpd Pickup and deposit time The cycle time for dual command cycle Number of single command cycles performed per hour Number of dual command cycles per hour U Rc Rt T F System utilization during the hour Total S/R cycle rate Total number of transaction performed per hour Torque Weight

17 xix LIST OF SYMBOLS r P Radius of gear Power Angular velocity N Number of gear s teeth

18 xx LIST OF ABBREVIATIONS AS/RS AGV S/R I/O P/D FCFS NN 3D RAM ROM PROM EPROM ICs PIC PSP A/D C 3D Automated Storage And Retrieval System Automated Guided Vehicle Storage/Retrieval Input/output Pick/Deposit First Come First Serve Nearest Neighbour Three dimensional Random access memory Read only memory Programmable read-only memory Erasable programmable read-only memory Integrated circuits Programmable interface controller Parallel slave port Analog-to-digital Computer Three dimension