See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/281777229

Design of an Automated Storage and Retrieval Machine

Conference Paper · February 2013

CITATIONS READS

0 4,553

1 author:

Ajay Patel
G H Patel College of Engineering and Technology (GCET)
36 PUBLICATIONS   137 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Computational Investigation of Dynamic characteristics of Carbon Nanotubes for atomic scale sensing of objects View project

Experimental investigation to studythe effect of micro coated tool on the surface topology of hard to machine materials View project

All content following this page was uploaded by Ajay Patel on 15 September 2015.

The user has requested enhancement of the downloaded file.

 Proceedings of International Conference on Innovations in Automation and Mechatronics Engineering 2013 (ICIAME-2013)
21-23 February 2013, G H Patel College of Engineering & Technology, Vallabh Vidyanagar, State: Gujarat, INDIA

Design of an Automated Storage and Retrieval

Machine
Pancholi Urva1, Challa Mohit2 and Patel Ajay3
G.H.Patel College of Engineering & Technology
1,2,3

Vallabh Vidyanagar – Anand, Gujarat, India

1
urva222@gmail.com, 2 challamj@gmail.com, 3 ajaympatel2003@yahoo.com

ABSTRACT

This work is about designing an Automated Storage and Retrieval Machine. Our objective was to
come up with an efficient and cost effective solution that would cater an industry’s requirement to
automate their material handling processes, to make a base level transition from manual material
handling and storage to automated one. The idea is a design of scale model using the concepts of
ASRS (Automatic Storage and
Retrieval System), using methodologically selected materials. The machine designed can store or
retrieve materials from rack inventory, and take commands programmed through a Programmable
Logic Controller (PLC). The base design is for handling 4 boxes, in a 2x2 rack, which can be further
implemented on a macro scale for larger storage capacities. The machine can be used in combina-
tion with conveyor belts, altogether forming an Automated Material Handling System (AMHS).
Keywords: Rack Storage & Retrieval, Automated Material Handling, Design, PLC Implementation

1. Introduction belt is also controlled by PLC, which allows the item

to be stored at a remote location, or be fetched from
A majority of small and medium scale industries
a remote location [1].
use manual material handling and rack storage for
tools and inventories. The process involves a lot of
manual labour and inefficient handling. A simple 2.  Main Components and their
way to eliminate that partially or full, in a cost Designs
effective manner, is transition to automation. Major Components of System
The model is a 3 Axis machine, with (1) Position • Rack Storage
control for horizontal movement (X-axis). (2) • Unit Load Container
Position control for vertical movement (Y-axis) • Assembly with X-Axis and Y-Axis Tables for
(3) Position control for Z-axis. The combination corresponding movements
of these 3 movements results in a 3-Dimentional • Fork Lift for Z-Axis movement,
control volume for storage/retrieval process [5]. • Conveyor
To ensure robust control of the machine, with • Control System
good industrial standards, PLC system is interfaced A simple Rack storage with 2 × 2 spaces is used.
with the machine, which controls various positions Let nx = number of load compartments along the
of the end-effector and the processes that take place, length of the aisle = 2 and ny = number of load
like storage or retrieval. The supporting conveyor compartments along the height of the aisle = 2.

191 
 Fig. 1 Design of Storage Rack
Therefore, capacity = nx × ny = 2 × 2 = 4 storage
compartments.
Width = z = 15 cm
Length = nx (x + b) = 2 (15 + 4) = 38 cm
Height = ny (y + c) = 2 (15 + 4) = 38 cm
Thus, the Storage Volume available = 4 (15 ×
15 × 15) = 13500 cm3. Appropriate clearances and
stops are provided in the rack spaces. Material Used:
Mild Steel (Sheet Metal).
The basic storage unit, the unit load container, of
15 cm × 15 cm × 15 cm is used for test purpose. The
material used is mild steel sheet. A slot is provided
in the design, to load/unload using a forklift.
Fig. 2 Design of Unit Load Container
192 
Fig. 3 Axis Designation for S/R Machine [4]
The material and dimension selection had been
done by putting in all calculated maximum loading
conditions into the Autodesk Inventor Stress Analysis
Module, and stresses were calculated according to
von Mises criterion. The deformation for several
feasible materials was checked, in combination
with different thicknesses and accordingly the final
material was selected [3]. The concept of Finite
Element Analysis has been utilized.
The axes designation of Storage/Retrieval (S/R)
Machine has been done as follows:
The machine is housed on the Base Plate. 4
Linear Bush Bearings are housed in the base plate,
which support the four Y Axis Bush Rods, on which
the Y Table moves vertically. Base plate also serves
as a support to the entire fork lift assembly structure.
It also houses the Locking Nuts and Ball Bearings
(6204 Series, 20 mm Diameter) to support Y Axis
Lead Screw [4].
The bush rods used for supporting the movements
of X and Y-Tables are made of stainless steel. The
length for X bush rods is 800 mm while that of Y
bush rods is 600 mm. For horizontal movement of
X-Table, a mild steel lead screw of 800 mm length,
and a calculated pitch of 4 mm and diameter of 25
mm is used. Needle bearings of the type 20-32-20 are
used to support the X-Axis lead screw. The X-Table
moves horizontally by means of X-Axis Lead Screw The Z-Axis mechanism consists of a pneumatic
driven by a 12 V DC, 100 RPM DC Wiper Motor and forklift to lift the unit load container from the storage
supported on the bush rod. The Pneumatic cylinder rack or to store it back in the rack. A pneumatic
and forklift are mounted on the X-Table. Material
Used: Cotton Fibre/ Paper Fibre. The Y-Table
moves by a Y-Axis lead screw, 600 mm in length,
25 mm pitch, driven by a 12 V DC, 90 RPM Truck
Wiper Motor. The selected material for Y-Table
is also cotton/paper fibre, which is light weight in
comparison to iron and steel, thus reducing the load
on vertical movement motor. Actual manufactured
as per this design gives us a further understanding
as follows:

Fig. 7 Y-Axis Mechanism

Fig. 4 Base Plate, with 4 Bush Rods and 1 Y-axis Lead

Screw

Fig. 5 X-Axis Mechanism

Fig. 8 S/R Machine, with Horizontal and Vertical

Fig. 6 X-Axis Motor Mounting Movement Mechanisms

193
cylinder, actuated by a 5/2 way solenoid valve is used
for the forward and reverse strokes of the double
acting cylinder. Such a mechanism ensures smooth
and speedy handling of boxes in a storage and retrieval
system. The major components selected are: A 25
bar capacity Air Tank as a source to our pneumatic
circuit and actuator, A portable car air compressor
compatible with 12 V DC supply used to pump air
into the air tank and A 5/2 Way Solenoid Valve to
control the forward and reverse stroke operation of
the pneumatic cylinder. It is operated at 12 V DC
Supply. (An AIRTAC 4V210-08) valve is used, with Fig. 10 Pneumatic Cylinder and Forklift
¼” thread size and 1.5 to 8 bar pressure rating). An 8
bar pressure rated double acting pneumatic actuator is Table 2 Material Selection Table [10]
used, having 32 mm bore and 200 mm stroke length. Part Proposed Maximum Basic Dimen-
The length of the cylinder is 300 mm. Standard ¼” Material Deforma- sions (mm)**
threaded connectors with quick release system as tion (mm)
well as polyurethane tubing of 8 mm diameter is used X-Axis Mild Steel 0.004522 pitch = 4, length
Lead = 800, diameter
throughout the entire pneumatic circuit. Screw = 25
The forklift, used to lift the unit load container, Y-Axis Mild Steel 0.0003332 pitch = 4, length
is fixed with the pneumatic cylinder. The proposed Lead = 600, diameter
Screw = 25
materials and major dimensions of main components
Pallet Mild Steel 0.0001369 height = 700,
are calculated by trial and error, against deformation Rack length = 400,
under load, using Finite Element Analysis (FEA) width = 300, with
using Autodesk Inventor 2012 software, for various four 170x180
materials and by changing dimensions [9]. Here in storage spaces
this example, Aluminum or Steel can be selected. Unit Mild Steel 0.0053 150 x 150 x 150
For all other parts of the machine, similar procedure Con- Sheets
was carried out. tainer
Y Cotton 0.009395 -
Table 1 Material Selection Table for Forklift Table Fibre/
Part Materials Maximum Defor- Proposed Paper
Considered mation (mm) Material(s) Fibre
Fork Lift Wood 0.113 Steel, X Cotton 0.006325 -
Aluminium 0.01783 Aluminium Table Fibre/
Steel 0.00592 Paper
Fibre

4.  Final Design and Control

Fig. 9 FEA Example: Forklift Design (Deformation:
Wood = 0.113 mm, Aluminium = 0.01783 mm,
Steel = 0.005922 mm) (F = 3 N) [9]
System
The final design drafting of the machine and Actual
model:
The control system comprises of a basic PLC,
preferably SIEMENS S7-200 Series Micro PLC
for basic automation tasks. PLC Trainer kit which
is shown below contains a SIEMENS SIMATIC
S7-200 PLC. It is compatible with 8 inputs and 6
outputs [1].

194 
 Fig. 11 Final Drafting of S/R Machine Fig. 13 PLC Simulation

Fig. 12 Manufactured Model as per the Design

The control can be achieved after interfacing the

motors and solenoid valve with the PLC through
driver circuits. The input and output connections can
be seen in the following diagrams. Limit switches
and proximity sensors are placed at appropriate
places in the S/R machine for feedback. Fig. 14 PLC Inputs and Outputs

195
 4. Conclusion
This research summarizes our attempt at designing
an Automated Storage and Retrieval System. The
most optimum design and methodologies have
been presented here. Results were also compared
with material selection table and software analysis.
This can be further used to make working models
of what is now on paper. Variations in the design
as per requirement can be done, with proper
implementation of mechanical and electronic
components, variety of automation can be achieved,
which can be as complex, versatile and flexible as
required. This model can serve as a reference for
various applications, some of which are automatic
car parking system, automatic baggage handling for
loading/unloading at airports, inventory and raw
material management in large industries, automated
parcel sorting in postal services, books management
in huge libraries, etc.
[10] U.S. Army Institute for Professional Development,
References
[1] Bolton W., “Programmable Logic Controllers”,
5th Edition, (2009).
196 
View publication stats
[2] Elsayed E.A. and Unal O.I., Order Processing
in Automated Storage/Retrieval system with due
dates, IIE Transitions, v28, p567-577, (1996).
[3] Frazelle E.H., “World-class Warehousing and
Material Handling”, 1st Edition, (2001).
[4] Gadhia H., Shah N. and Pathak T., ‘Automated
Storage & Retrieval System”, (2011).
[5] Groover M.P., “Automation, Production Systems
and Computer Integrated Manufacturing”, 3rd
Edition, (2007).
[6] Rashid M.M., New Automated Storage and Retrieval
System (ASRS) using wireless communications,
Mechatronics (ICOM) 4th International Conference
IEEE Xplore, (2011).
[7] Rupapara J. and Prajapati T., “Design And
Manufacturing of Automatic Indexing Fixture”,
(2011).
[8] Shea L., “Development of an Automated Storage
and Retrieval System in a Dynamic Knowledge
Environment”, (2007).
[9] Tickoo S., “Autodesk Inventor 2012 for Designers”,
(2011).
“Metal Properties, Characteristics, Uses and
Codes”, (2005).