AUTOMATIC RACKING MACHINE

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1 e-issn Volume 3 Issue 5, May 2017 pp Scientific Journal Impact Factor : AUTOMATIC RACKING MACHINE Pawan Chaudhary 1, Shivansh Prashar 2 1,2 EEE, GLBITM Abstract This paper is based upon use of PLC (Programmable Logic Controller) and DC motors for the purpose of conveying, store up and retrieves an object. A PLC system has many benefits for control solutions from reliability and repeatability to programmability. In this research, we proposed a prototype of an automatic warehouse which is easy to implement and cost effective. It improves the efficiency of labor and the quality of manufactured product and to create conditions for the optimum utilization of all production resources. Keywords PLC, DC motor, Warehouse, Sensors, Ladder logic I. INTRODUCTION The scope of industrialization, automation is a step beyond mechanization. Automation greatly reduces the need for human sensory and mental requirements as well. Processes and Systems can also be automated. Specialized industrial computers, referred to as programmable logic controllers (PLCs), are frequently used to synchronize the flow of inputs from (physical) sensors and events with the flow of outputs to actuators and events [1]. This leads to precisely controlled actions that permit a tight control of almost any industrial process. Our primary objective of this paper is to design a prototype for Automatic Racking Machine. Our aim is to fabricate it in a way that it can automatically store and retrieve goods. Initially, an understanding is developed about PLC and its software which are required for our system. PLC gives commands to DC motors which lead to motion in three dimensions. An efficient system for resolving material handling issues is to be developed [2]. Finally designed prototype is to be assembled and fabricated keeping in view all the constraints. II. DESIGN OF ARM The design of Automatic Racking Machine (ARM) is based on the structure and its controlling scheme i.e. explained in this paper. Layout for programming is also designed to accomplish successful implementation. Success and failure of any system depend upon its design. The design consists of structure, controlling scheme and programming layout. A. Structure This prototype consists of three moving axes which drive using DC motor and are mounted over teethed gears which are connected through timing a belt. Horizontal DC motor drives the horizontal platform on which vertical axis is mounted. [1] Vertical axis carries the storage trolleys which picks and place the object. Two inductive proximity NO type sensors are connected in which one on the horizontal platform and another on the vertical platform. The horizontal sensor counts the columns and the vertical sensor counts the number of Rows with the help of which ARM locates the particular Rack. Vertical axis moves along the storage racks and stops in front of the particular column according to the ladder logic. Vertical column lifts the storage trolley to the storage rack. As soon as it stops, the storage trolley moves forward and drops the object into the rack. For storage and retrieval, racks are used having racks of same dimensions. A number of racks depend upon a number of rows and columns, which are equal in both All rights Reserved 65

2 A pick and drop point is set which is basically the home position of the trolley. The trolley will start its motion from this point and after storing/retrieving, it will come back to its home position. Model of structure for ARM is shown in figure 1. (a) Prototype (b) 2D Model Drawn on solid works B. Controlling Scheme Figure 1 Automatic Racking Machine (ARM) Basic controller behind DC motors is PLC. PLC consists of Ladder logic and which controls every movement of the ARM by continuously monitoring the input values from the sensors and produces the outputs as desired for operation. Figure 2 Block Diagram of Controlling Scheme (drawn on Power Point) The PLC requires 24V DC Supply which is provided with Switch-Mode Power Supply (SMPS) as shown in figure 2. The address of the desired rack is entered through a computer the computer and PLC are interfaced with each other through RS232 Cable. Now pick up of the object from the All rights Reserved 66

3 position, placing the object and bringing ARM back to the home position is feed manually through the control panel. C. Programming Layout Ladder logic is prepared on PLC Software (WPLSoft All rights Reserved 67

4 III. METHODOLOGY ARM is proposed to solve issues in material handling process [3]. Goods can be stored and retrieved in a specified location in a Block of a particular rack as defined by the user. ARM is designed that performs storage and retrieval of items. The whole system relies on PLC and DC motor s correct functioning. PLC is selected on the basis of sufficient input-output ports for this system. After selection, it is programmed using WPLSoft 2.42 software and ladder logic is burned into PLC memory. Once it is programmed, it works according to the code feed in it. DC motor is selected based on weight and torque requirements. DC motor driving circuitry is used to drive motor in three dimensions (x, y, and z). The motor works followed by commands of PLC which fulfills motions of the column (x-axis horizontal), row (y-axis vertical) and rack selectors (z-axis inward/outward). A. Storage and Retrieval An address (entered by the user) of the particular rack of the specified rack is provided in order to store or retrieve an item [3]. The address corresponds to the particular column, row number, and rack. PLC gives the command to DC motor and it drives trolley by following the address. Storage and retrieval operation has basically three steps. 1. First of all column selector will move in the x-direction and stops in front of the particular column of the rack as addressed by the user, with the help of a sensor it counts the metal strips placed in front of the column. 2. Secondly, in order to reach that address specified by the user, row selector moves in the vertical y-direction and stops in front of entered row similarly with the help of sensor it will detect its position. Now the trolley will be in front of that particular rack. 3. Thirdly, rack selector will move in forward/backward direction for that specified rack as defined by the user and it has limit switches installed on its front and at the back which gives the signal to the PLC that object has been stored. 4. Finally, after storing/ retrieving items in or out of the rack, trolley reverses all of its steps and moves back to its home position near the user. Hence in this way storage/retrieval is done automatically. IV. APPLICATIONS The precise application of ARM affords a wide list of user benefits. It can be seen that automated storage and retrieval systems are capable of effective material handling. 1. ARM can be used in any manufacturing industry for material handling and storage. 2. The concept of ARM can be used for multilevel parking with some modifications in design. 3. ARM can be used for warehouse and inventory management. 4. It can be used in library management and allows a single person to handle the complete library. V. FUTURE WORK So far we have designed a prototype for storage or retrieval for the automatic warehouse. Later we will develop it for storage of books in libraries [1]. It will be served with a scanner which will scan for particular barcode of that particular book and will retrieve it back to pick up and placing position. Similarly, books belonging to the specific category of racks will be stored automatically in defined locations. For this purpose, data has to be updated every time about the current location of that item so that its retrieval can be made possible. VI. CONCLUSION In this paper, all the details of proposed system have been discussed. The problem of material handling can be solved by using Automatic Racking Machine (ARM). As a result of All rights Reserved 68

5 this system storage and retrieval of goods can be made possible, which yields better space utilization and saves time without any damage to the products. This system replaces manual work and can easily be controlled by any man with sufficient knowledge [4]. It is certainly a good and quick way to make storage and retrieval more secure and reliable. REFERENCES [1] Asaad Musaab Ali Yousif, Jiang Dening, Automatic Control for Storage and Retrieval System Based On PLC, IJAREEIE, Vol. 3, Issue 9, September [2] Tayyaba Mudasser, Qurat-Ul-Ain, Design and Development of Prototype for Automated Storage and Retrieval System, Student Research Paper Conference, Vol-1, No-8, Aug [3] P. R. Witt, Automatic storage and retrieval system control, IBM Corporation, Endicott, New York. [4] Abdul Halim Bin Hadzir, development of automated storage and retrieval system (as/rs) prototype, university malaysia pahang, December All rights Reserved 69