RFID based Robot Automation System for
Transport of Rafter like Materials
P.A.S.H. Perera
Sri Lanka Institute of Information Technology
Malabe, Sri Lanka
it19950464@my.sliit.lk
W.P.V.T. Wickramarathna
Sri Lanka Institute of Information Technology
Malabe, Sri Lanka
it19970264@my.sliit.lk
Dr. Pradeep Abheyagunawardhena
Senior Lecturer (Higher Grade)
Sri Lanka Institute of Information Technology
pradeep.a@sliit.lk
Abstract—A warehouse is a workplace where everyone is al-
ways busy and pressed for time. A rafter-like material storehouse
is unique among these since it requires a lot of effort to manage.
Hand over these jobs to automotive robots, especially as a
solution to these issues. Two robots are expected to be used to
transport a bar, depending on the length of the bar to maintain
a certain distance between the two robots during transport.
The two robots follow each other in the same way, moving
in the same direction in parallel with holding the rafters. A
PID(Proportional–Integral–Derivative) control system is used to
keep a certain distance between the two robots. Also, for the two
robots to move together, they must be moving the same distance
at the same time. But in practical, it does not. There are errors
in the speeds at which the two travel. Therefore, these errors
should be corrected every short period. Therefore, it explores
how a PID control system with an Ultrasonic Distance Measuring
System can be effectively applied for PWM Motor Controlling
for a self-driving mechanism of two robots together.
Index Terms—A rafter-like material storehouse, PID Control
System, Ultrasonic Distance Measuring System, PWM Motor
Controlling, Self-driving
I. I NTRODUCTION
If a robotic automation system is used to perform a task,
the system must be able to perform the task more efficiently
than manually. The overall purpose of this study is to provide
a detailed explanation of the requirements for an RFID - based
robotic automation system for the transportation of materials
such as rafters. The main challenge here is the size and weight
of the rafters. If the average person is moving these rafters
from one place to another, two or more people are needed. It is
also designed to use two robots when using a robot automation
system for this purpose.
L.R.W.D.E.Rajasekara
Sri Lanka Institute of Information Technology
Malabe, Sri Lanka
it19965482@my.sliit.lk
G.A.C.Hirushan
Sri Lanka Institute of Information Technology
Malabe, Sri Lanka
it19091594@my.sliit.lk
A rafter is something like a long rod with a large weight.
There are a few things to keep in mind if two robots are
holding this and moving from one place to another. [12]
They must have an arm so that the robots can hold them,
the robots must maintain a certain distance between them
along the length of the rafter and when carrying the rafter,
the two robots must move in the same direction at the same
speed, not overtaking each other. This study provides an proper
explanation to these difficulties. [11]
The robot arm used can move up and down and is designed
to hold more weight and more rafters. In order to maintain
a certain distance between the two robots, there must be
a methodology to measure this distance. To do that it use
ultrasonic sensor. The problem we found when trying to
maintain a certain distance without a controlling mechanism
is that it goes back to the wrong value beyond the specified
distance required to correct the relevant distance. Therefore
it is prone to error again. As a solution for this use a PID
(Proportional–Integral–Derivative) controller mechanism. [1]
[2] The PID controller continuously calculates the error value
as the difference between the expected fixed point (SP) and
the measured process variable (PV) and corrects based on the
proportional, integral, and derivative terms. it automatically ap-
plies to the problem as an accurate and responsive correction to
a control function. To prevent the two robots from overtaking
each other, one acts as the main robot and the other as the robot
he follows. Here, too, a mechanism is introduced to correct
the error if the follower makes a error. [4] Also, if the main
robot stops, the follower must stop. Use the ultrasonic distance
measuring system and PWM (Pulse-width modulation) motor
controlling for this process. [5]
 II. PID C ONTROL M ECHANISM TO MOVE THE the P component. It amplifies the error proportionally. This
MAINTAINING A CERTAIN DISTANCE also helps to improve the reaction time to errors and it does
A. Problem Identification that something that calls it gain. So, the proportional gain is
typically denoted as KP. If increase KP that would increase the
When carrying something like a rafter from one place to
speed of the response. The integral component is looking at
another, even a human being cannot carry it alone. Similarly,
the relative history of the error even a small error over a long
two robots are used in this system. But the problem with using
time will have an impact. D component stands for derivative.
two robots is that both robots must move at the same speed, in
The derivative is looking at the future of the error as well
a linear parallel, while carrying the rafter. There should also
as the rate of the change of the error. This can improve the
be a certain distance between the two.Here one robot is always
stability of reducing oscillation. [2]
named main and the other robot follower.This allows the main
robot to move forward in a uniform path and the follower to
move at a certain distance with main. Although the ultrasonic
sensor is easy to use, the chart below shows a problem with
using it.

Fig. 2. Block diagram of PID closed-loop control system

C. Methodology
Although there is a definite distance between the two robots,
we call it the set point. The set point here is x. This takes the
actual value of the follower robot from y to main robot.
Fig. 1. Distance from follower to main without control mechanism

The set point in the chart above is the exact distance to

be kept between the main robot and the follower. The starting
distance is less than the set point and the follower increases his
distance by varying the PWM signals provided to the L298N
motor driver. Even if it reaches the set point after a certain
period of time, it will pass the relevant set point and go higher
than that due to the delay errors in grasping it and slowing
down the DC motors. That is, the distance between the two at
that moment becomes greater. Attempts were made to reduce
the distance by changing the speed of the motors again, but it
passed the set point and came to a lower value. So again the
distance has to be increased as before. Here too, as before,
the set point is exceeded. This happens again and again in the
same way as above. This is by no means a suitable movement
Fig. 3. The position of the two robots at a reasonable moment
to a rafter
B. Solution
So once the follower comes to the set point, you have to do error = set point − actual value (1)
a complicated process to keep it accurate without criticizing. error = x − y (2)
That is why the PID control system is used. [1]
The PID controller continuously calculates the error value In this way the error can find the pwm value to be given to
as the difference between the expected fixed point (SP) and the motor. This pwm value is proportional to the error. But if
the measured process variable (PV) and corrects based on this error is a small value then you will not have to see a big
the proportional, integral, and derivative terms. PID it’s a difference as the error was given to the pwm value. Therefore
kind of three independent components that are added together. we need to scale this value and multiply the error as KP by a
PID stands for proportional, integral, and derivative. First is constant. [4] [5]
 P = Kp ∗ error (3)

This is a proportional controller that can go approximately

the required distance. One problem with proportional control
is overshoot. Although the PWM value given to the motor
driver at zero is 0, a minus error occurs due to the presence of
DC motors. The motor driver gives power to the other side to
solve it. Therefore this system becomes oscillate. This oscillate
can be identified by differentiating the error. The higher the
oscillation, the higher the difference value. As before, the
differentiated value is multiplied by a constant Kd to a value
that affects to PWM value. [14]
Fig. 5. When all the P, I and D values are given to the motors as PWM
d(error)
I = Kd ∗ (4)
dt
III. U LTRASONIC SENSING MODEL FOR PREVENTING THE
By now our robot has been taken to the required position FOLLOWER FROM PASSING THE MAIN ROBOT
and the robot oscillate has stopped. However, due to the
A. Problem Identification
shortcomings of the system, it may come very close to the
specified value and the distance may remain at another value. After the two robots are set to travel a certain distance,
We call this a steady state error. The best way to catch an error the next problem is that one robot tries to overtake the other.
like this is to integrate the error. As before, this incoming value This is because of the inequality of speed between the two.
is multiplied by the constant Kp value and scaled as required. Such a system is strongly influenced by the fact that the two
Z maintain a certain distance and travel in parallel, but one tries
D = Kd ∗ (error)dt (5) to overtake the other. The reason for this is that the system
needs to carry a long rod with a single line load. So both
Roberts have to move in the same direction as one unit.
After adding the three values obtained in this way, we get
the final PWM pwm value [13].

P W M value to the motor = P + I + D (6)

D. Results
If only the P value is given to the motors as the PWM value,
you can see the following graph. What happens here is that
after being oscillated for a while, the set point returns to a
slightly lower constant.
Fig. 6. Follower passing the main Robot

B. Solution
To remedy this, two ultrasonic sensors are used on the front
and back of the follower. It keeps the two in line by changing
the speed of the motor by varying the distances between the
front and rear. There are two reasonable cases here [6].

C. Methodology

• When the main robot is ahead of the follower

Fig. 4. Only the P value is given to the motors as the PWM value
When all the P, I and D values are given to the motors as
PWM, you can see that the actual value reaches the set point
very quickly and reaches the correct value without any steady
state errors.
At that point, the upper ultrasonic sensor on the Follower
detects a distance (y cm) greater than the distance (x cm)
detected by the bottom ultrasonic sensor. So, we can use
programming code to calculate the distance and time that are
different from each other, and we can give the command that
if the upper Ultrasonic Sensor gives a larger distance than the
bottom Ultrasonic Sensor [7], the Follower must slow down
while both Ultrasonic Sensors give the same distance.
Fig. 7. Follower passing the main Robot
• When the Follower is ahead of the Main Robot
At that point, the bottom ultrasonic sensor on the Follower
detects a distance (y cm) greater than the distance (x cm)
detected by the upper ultrasonic sensor. So, we can use
programming code to calculate the distance and time that
are different from each other, and we can give the command
(PWM Signal) that if the upper Ultrasonic Sensor gives a
larger distance than the bottom Ultrasonic Sensor, the Follower
must slow down while both Ultrasonic Sensors give the same
distance [7] [8].
Fig. 8. Main passing the follower Robot
IV. C ALCULATING THE DISTANCE TRAVELED BY THE
MAIN ROBOT
A. Problem Identification
For our prototype, there are two types of wooden shelves.
These wooden shelves have wood that has been sorted by
length. One is made up of somewhat longer wood, while the
other is made up of short wood. Meanwhile, the robot moves
from the robot’s station to the chosen wooden shelves, which
are located to the right of the wooden shelves. This strategy
is depicted in the diagram below.
Fig. 9. Path of robot
The robot here moves in response to the commands of the
person holding the remote. The robot will only move close that
rack if he tells you to deliver shorter wooden beams. You will
only be able to proceed to the long wooden rack if you select
it. Move it closer to the two racks if the robot controller says
you need both long and short wood. The robot here utilises
RFID technology to verify that it landed on the proper rack.
B. Solution
To figure out where the robot will come to a complete stop,
we employ a strategy. A white ring is connected to one of the
robot’s wheels at the base. A broad line in dark black marks
one location on that white ring. The following is the design
of that wheel.
Fig. 10. Wheel
When the wheel rotates, the white ring that is linked to
it rotates as well. At each specified place, the black border
is then traversed through each round. A Black / White Line
Following Sensor is placed near the white circle to detect this,
as illustrated below. Each time it hits, the sensor identifies
the black boundary in the white circle. Let’s look at how
to bring the robot base to a halt in a certain location. The
base of the robot moves 2πR cm as the wheel spins if the
radius of the wheel at the base is R cm. The white circle
detects the wheel’s rotational circumference in order to detect
the wheel’s rotational circumference. This is because the white
ring’s circumference is the same as the wheel’s circumference.
The two racks, for example, are positioned at appropriate 2πR
multiplication distances from the robot’s station.

Fig. 11. Mechanism to find direction
C. Results
When the operator gives a command to move to the first
rack then the main robot moves to the proper rack while
calculating the distance from the above mechanism. After
reaching the destination robot will stop and back to the start of
the calculations. Rack two also can apply the same procedure.
It can move to the exact location that we want by using this
model.
V. D ISCUSSION
Carrying a rafter from one place to another and handing it
over with a robot automation system is also a huge task. This
system is made up of six components: an IR remote, two robot,
two robot arms, and three smart rack. A rafter is a long and
hefty item that necessitates the use of two robots. In addition,
robots plan to take a large number of rafters at once, rather
than just one. To provide commands through its buttons, an IR
remote is required. The methods listed above are utilized by
self-driving technology to move to the proper location. After
traveling to the appropriate rack at the controller’s order, the
robot utilizes RFID to tell the operator that it has arrived at
its destination. The robot arm is the next component. This is
intended to satisfy any rack height and can support any weight.
The arm is also capable of turning itself around. After then,
the robotic arm activates, indicating that the robot has arrived
at the rack. Our system’s smart rack is the next most essential
element. Make a smart rack that responds automatically when
the robots arrive to collect the rafters. The rollers may be seen
here. A timing belt weaved into these rollers also functions.
As a result, when the rollers are turned on, the rafters on the
timing belts must move. The rollers will then stop functioning.
VI. ACKNOWLEDGMENT
First and foremost, We want to express our gratitude to ev-
eryone who assisted us. This task has been simpler to accom-
plish thanks to Madam Shashika Lokuliyana, Dr. Anuradha
Jayakodi, and our supervisor Prof. Pradeep Abeygunaward-
hanas’ direction and encouragement, and those who spent her
important time answering questionnaires and gathering data
are also respected.
VII. C ONCLUSION
The overall goal of this study is to provide a thorough
explanation of the requirements for an RFID-based Robots
Automation System for Rafter-like Material Transport. The
majority of this project’s components are aimed for wooden
warehouse owners and operators. The main challenge was to
get the two robots to move in the same direction, with same
way. That is, to maintain a certain distance between the two at
all times, and to prevent one from passing the other. Using a
PID control system and an ultrasonic sensor model, we were
able to answer both of these questions. It also designed a robot
arm that could carry heavier and larger rafters, and a smart rack
system for storing rafters and loading them into robots. As a
consequence, the workplace productivity rate will always be
maintained at a reasonable level, providing good opportunities
for future workplaces.
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