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Development of a Small Scale Material Handling Machine for Automated Storage and RetrievalSystem (ASRS)Saif Ullah Iqbal, C. B. Yeo and UmarNirmalABSTRACThe current works deals with the design and development of an Automated Storage and Retrieval System (ASRS) machine for Flexible Manufacturing System (FMS). The work involved investigating ASRS machine features and operating procedures, evaluating related hardware, software and communication modules for the machine. The work explored on the different options of hardware and software modules offered in the current market and further selected the suitable one for the ASRS machine development. Several design considerations and the limitations faced during the process of the project development and implementation are given. Arduino was used as the coding system for the Arduino UNO board while stainless steel 305 and aluminium was used as the main frame in fabricating the ASRS machine. Lastly, a final working prototype of a fully-developed ASRS machine with dimensions of: 80cm by 73cm by 94cm (length by width by height) is presented.Keywords: Small scale; material handling; ASRS; FMS; prototype; pick and place machine; Arduino UNO; stainless steel 304; aluminium.INTRODUCTIONAn ASRS involves a selection of computer- controlled structures in order to robotically place and retrieve loads from well-defined stocked places. Their fundamental preferences over usual (pickers to quantities) storeroom systems are vast space practice, decreased work charges, short recovery periods and an improvement in controlling the inventory of stocks. Automated Storage and Retrieval Systems (ASRSs) are generally utilized in stockrooms and primarily in distribution centres in most part of the world. There is a good ground for the idea that this type of automation drive to keep (or even escalate) their wide application in the likely future, along with the discussed model industry trends and certainly all the above benefits. There has been much advancement in Automated Storage and Retrieval technology in the last forty years and the ASRS number is predicted to grow rapidly in the next few decades. The progressing multiplication of item assortment perceptible in numerous businesses expands the assortment of stock-keeping-units (SKUs) to be taken care of in a normal distribution centre. For example, the plant in Dingolfing of German car manufacturer BMW gets material in excess of 13,000 compartments conveyed by around 600 providers on over 400 trucks every day. Taking care of such an enormous measure of parts by solid in-house coordination forms appears to be not really reasonable without mechanized warehousing 1-2. An ASRS stores stock all the supplementary thickly and, in this manner, dispenses with the requirement for such energy to cool, heat, ventilator, and lighting abundance of storing space. One of the Material Handling Industry of America (MIH, 2009), the food business sets aside to 30% cooling cost in chilled distribution centres put on Automated Storage and Retrieval Systems 3-4. With a maturing society in many created nations and an expanding authoritative weight (e.g., EU Machinery Directive, 2006/42/EC, 89/391/EEC, Occupational Safety and Health Act) ergonomic perspectives need extraordinary thought for storing. The above statistics should be a wake-up call for industries to consider ways they can make employee safety significant in the workplace. One of the solutions is to introduce automation. By automating manual repetitive tasks, workers can be reassigned to safer areas where they can exercise imagination, adaptability and decision-making skills. As noted by the World Economic Forum, robots are perfectfor physically demanding or dangerous tasks for humans to carry out and, economically, they can work around the clock at a lower cost than human workers among which, the Automated Storage and Retrieval Systems appears to be favourable 5.Generally, an Automated Storage and Retrieval System is programmed for managing pallets without the interference of a human worker, consequently, the structure is called fully automated. Both in manufacture and supply, locations of Automated Storage and Retrieval Systems are used for putting products (e.g., raw materials or partially finished products) in storage, and for retrieving those products back from storage to complete the task. In designing an Automated Storage and Retrieval System, numerous physical plan and control issues must be tended to in the correct method to completely exploit every one of its professionals. The ASRS will hone the makers opposition as ASRS can diminish the inventories and process duration, and ideally use the capital and work 6. Fundamentally, an ASRS system consists of storage shelves, the control system, storage and retrieval column, human user interface and deposit and withdraw bay. An item would be placed and retrieved from the storage shelves by mean of the storage and retrieval column machine where it is to retrieve or store the objects in the storage system. The automation system generally consists of a conveyor system as automation for storage and retrieval machines and frame structure as automation pathway 7. The automation systems will in charge of vertically, inside/outside and horizontally moving the storage and retrieval mechanism that performs the storage or retrieval course. Therefore, to control the system, The Graphical User Interface is the platform for the user to command a process to either store or retrieve the selected boxes placed on the withdraw and deposit bay or sort the boxes in the shelves of the complete rack itself. The material picking module of ASRS is to meet the targeted user specific operational requirement. After the design phase, the Storage and Retrieval mechanism will be fabricated and used to conduct the storage and retrieve process in an ASRS. The material picking module of ASRS is intended to meet the focused-on consumer- explicit operational necessity. This module consists of a racks structure along with the storage and retrieval column to conduct the storage and retrieval commands by means of ASRS.69Most of the Automated Storage and Retrieval System accessible in the market is normally high-priced or large in size and it is just focusing on the large enterprise 8,9. For the medium and small organizations, the issue of the floor plan and economic report frustrate them to execute the Automated Storage and Retrieval System into the operational organization. Mistakes may occur unintentionally loading and retrieving objects at the exclusive area and notice the things in racking can now and then be difficult. About these issues, an Automated Storage and Retrieval System is planned to suit the operational prerequisite of the little and medium firms, just as to diminish the error rates and expanded reliability quality while saving labor costs and floor space 10,11. Therefore, the current works is aimed to design and develop a state-of-the-art automated storage and retrieval system. The machine will be linked with a developed GUI program to allow users to interact with the machine in a user-friendly manner.1. METHODOLOGY1.1 HardwareIn this section, there are sections in assembly movements, selected components design stability and the design itself and its fabrication process, these subparts with its own specific function for serving its own operational purposes. The general assembly of these subparts will able to achieve the project objectives to perform the storage and retrieval operations precisely.1.1.1 Structure assembly materialsThe structure material for this module is chosen as Stainless Steel 305 and Aluminium 5083, while Aluminium is typically not as strong as Stainless Steel and Stainless Steel has excellent corrosion resistance for two reasons. First, Stainless Steel has chromium added which forms an invisible corrosion resistant film around the Steel. Second, it is non-porous which increases the corrosion resistance. The Stainless Steel are used specifically for load carrying segments, and the Aluminium are used just for coupling or to maintain the overall project weight as compare to Stainless Steel, Aluminium is far way lighter compared to stainless steel. The Stainless Steel 305 rectangular tube (5cm x 2.4cm) and (2.5cm x 1.2cm) are used for Shelve frame base and shelve module structure respectively and aluminium plate 5083 are used for coupling of different assemblies.1.1.2 Information on components usedFollowing are the hardware components are used for the current work and their brief descriptions. Linear screwAccording to Thomson Industries 12-14, the thread of Linear Screw uses a helix angle to make the linear motion. The coefficient of friction between the nut and the screw are aligned with the performance of a lead screw depends heavily on, which relies on the material utilized for the nut and screw. For this project, we used Linear Screw for the three-dimensional shuttle in x, y and z axes so to move the assembly of Storage and Retrieval to left-right, up-down and forward- backward. Hard chrome piston rodThe hard chromium piston rods are produced by Suzhou Weipeng Precision Machinery Co., Ltd. is in Suzhou with JIS S45C material, where the poles initially experience exactness processing and preparing, and are then put through guard surface chromium treatment, permitting a surface accuracy dimension of f7, and a surface hardness coming to HV800 least and up, which help to enhance wear opposition and help to broaden the existence cycle of the bars, hence making a good motion. The module is dual- mounted with the chrome piston rods, for frictionless slider motion of Storage and Retrieval assembly in x, y and z axes. The pair of rods helps the assembly to move precisely in a specific direction using Linear Ball Bearing. Stainless steel support rodThe Stainless Steel rod is installed as a structural support of Z column (Crane) which is fitted vertically, on top with Aluminium plate of Motor base .4 Linear ball bushingsLinear bushing with mechanism utilizes the rolling motion of ball features. As linear motion is achieved with a simple mechanism, the linear bushing can be used in a wide variety of uses, including carriage, food treating, and semiconductor manufacturing tools. Linear slide bushings use a round channel for the guiding axis, causing in space savings, which allows for compacted schemes. The Low Friction, channelsurface is precision ground. Since the contact surface between the ball features and the raceway surface is reduced, linear slide bushing bearings provide low friction related to other linear motion tools. In this module we are using two sizes of Linear Ball Bushings, i.e.,16mm and 20mm for the for the hard chrome plated rods helping the assembly motion .5 Mounting boltsThere are different types and sizes of Allen key and Hex Head bolts used in this project. Further, it is categorized as Button Head Cap, Socket Head Cap, Counter Sunk and Hex Head Cap. In total, the module has 43 Button head cap, 21 Counter Sunk Head, 16 Socket Head Cap and 8 Double Ended bolts of Allen Key plus 4 Hex Head Cap bolts are fitted. So as the net total 92 bolts are fixed in the whole module. Refer Appendix A for more information on the bolds used. Levelling bottom padThe module is fitted with four Levelling Pads while levelling feet are almost always solid metal; levelling pads usually have a rubber or urethane pad at the bottom, which will provide grip to keep the machine from moving and can help stabilize cabinetry, shelving, machinery and more. Levelling pads may be used instead of levelling feet when a floor may be scarred or marred by a steel foot. Electrical / electronic housingAn electrical box is a cabinet for either electrical or electronic kit to mount controls, knobs, and displays and to stop electrical shockwave to kit users and keep the subjects from the surroundings; This housing is made from Acrylic Sheet 25cm by 15cm, Three parallel plates are connected through Long bolt of 12mm leaving a gap inside of 8cm and 12.5cm respectively, creating a design of open shelves The Bottom shelf is assigned for power supply and the top shelf is to mount the control Motor Drivers, Arduino UNO board and Interface Circuit between the limit Switches and Arduino UNO Board. The top shelf sheet is mounted with Safety Switch for any dangerous situation. Drag chainCable carriers, correspondingly well-known as drag chains, drive chains, or cable chainsdepending on the producer, are guides planned to surround and guide bendable electrical cables and hydraulic or pneumatic hoses connected to moving robotic equipment. In this module we are using three sizes of Drag Chains 7 x 7 mm, 10 x15 mm and 15 x 30 mm. For the x-axis, the cables are using 7 x 7 mm size of Drag chain with a length of 450 mm, for z-axis the cable is guided into 10x15 mm Drag Chain with a length of 730 mm whereas for y-axis the cable is hoses into 15x30 mm Drag Chain with a length of 990 mm. The y-axis is carrying all the cables leading from x and z axes where it is acting as a bottleneck to main controller housing. Refer Appendix B for more information on the drag chains used. CouplingIt is a component used for bonding two different rods/shafts composed by their split ends in order to conduct power. Generally, it does not usually let disconnection of shafts through operation, though there are torque controlling couplings in which it slips-up or detaches when some torque perimeter is surpassed. There is only single coupling mounted on z-axis between the motor and lead screw, which was fabricated from Stainless Steel rod of diameter 25mm using a Turning and Milling Machine.0 Wiring spiral ductWire duct application is same as drag chain where it differs only in a way that its flexible and can be shaped in any form; generally, it is a kind of cable management product that permits the users to route bulky packs of cabling in a relaxed & organized style. The project wires are bed in with 700 mm and 400mm long size with a diameter of 15mm and 8mm respectively.1 Frame structureThe Frame is designed with 3 x 3 column and rows. The rows and columns are designed in such a way to achieve the diagonal movement demonstration plus reduction half right angle triangle based to reduce cost and achieve the demonstration objectives. However, the shelf is rack railed with Stainless Steel rail size 10mm wide enough to handle heavy loaded items. The base of the frame is made of Stainless Steel rectangular Tube 503 of size 50 mm x 240 mm, the base dimensions are 600 mm x 600 mm on top of which the shelves are fabricated with Stainless Steel rectangular tube 503 of size 250mm x 120 mm with each shelf internal dimensions of, i.e.,(L x W x H) 200 mm x 180 mm x 150 mm = 5.4 x 106 mm3. Multiplying this with 8 shelves 43.2 106 mm3 of Storage Capacity, whereas the last shelve at column 3 row 2 is Pick and Place shelf and could be connected to a conveyor or human manual loading. Choosing the Stainless Steel as fabrication for the frame was to make it strong enough to handle fairly heavy loads. Due to the storage and retrieval process, this material has a longer life compare to other options. Fig. 1 illustrates the CAD model of the frame structure design.Fig. 1. Frame structure design using CAD1.2 Assembly MotionThe Module assembly is designed in such a way so the motion of the mechanism could be smooth and frictionless. The machine has three assembly motions categorized as coordinated system x, y, and z. The x-axis coordinateassembly is responsible to store and retrieve the packages from the racks by moving back and forth; c.f. Fig. 2. The assembly maximum moving zone is 360mm. The x-axis is mounted through linear ball bushing with z-axis to lift up or down the mechanism of Storage and Retrieval.The z-axis coordinates assembly is responsible to move the Storage and Retrieval mechanism up and down to a specific row by following the specific command from the user input; c.f. Fig. 3. The maximum travel area for this axis is 640 mm. This assembly is mounted to y-axis assembly.The y-axis is the core assembly and it is mounted with frame base to move the other two assemblies in specified directions; the z-axis is mounted with y-axis by linear ball bushings; c.f. Fig. 4. This axis has the maximum allowed movement zone of 650mm either to move the full assemblies together towards left or right to specify the column numbers.1.3 Design and FabricationIn designing such a module the first thing to be taken care of is listing down the material required, cut into the exact size required and then assembling them either by mean of welding or bolt joint. Second and most important, the orientation of the tubes to design the frame in such a way to get a higher moment of inertia, as a higher moment of inertia means higher resistance to bending. Following Fig. 4, the orientation of the fabricated tube suggests the greatest moment of inertia in the Iz-axis compared to the other two axes. The following section will provide brief information on the design and development of the module.Fig. 2. Assemble Fig. 3. Assemble motion at the Z-Axismotion at the X-AxisFig. 4. Assemble motion at the Y-Axis1.3.1 Frame and base designThe frame consists of base and shelves column, i.e., nine racks, the 2D dimensions of the base is shown in Fig. 6 respectively. The rectangular frame comprises a rectangular tube of size 50mm x 240mm, each side the tube was cut at 45-degree angle of length 600mm making four equal length bars and brazing them with tungsten torch wire with a cumulative length of 2400mm providing a great solidity to the whole framework.Remark: All dimensions in mmFig. 6. Base dimensions1.3.2 Rack design and 3D dimensionsOn top of the base frame, the shelves are designed with a rectangular tube of dimensions 250 mm x 120 mm making of three columns, Fig. 7 shows the size of each column tube, i.e., the first column height is 600mm consuming four equal lengths of 600mm rectangular tubes, the second column consists of two rectangular tubes of height of 450mm welded with base and the third column approaches the height of 300mm fitted with two rectangular tubes attached from the base. The racks are made with a gap 150mm in height and 200mm in length. The width of each column is 180mm resulting in eight storage and retrieval for storage and one shelf for deposit and pick up bay. With shelves, the Y-axis assembly holder in welded as the core moment of other assemblies. The end plates are mounted on sides of the base frame to hold the two-piston chrome-plated rods with the linear screw, on the left plate a drive motor is connected to move the assembly towards left or right. Fig. 8 shows the base with shelves and Y-axis assembly holder. They are connected with Y, Z and X axes assembly mechanisms, following the same structure method for x assembly. For z holder,the end supporting plated is connected with Y- axis assembly and the other end in supported by an Aluminium plate with a support of Stainless Steel rod including the linear screw and two piston chrome plated rods.1.3.3 Control system: Electrical works Drive motors: In this module, there are three stepper motors, i.e., NEMA 23, NEMA 23 and NEMA 34, used by X, Y and Z axes respectively. The motors are installed at the end of each assembly to move the assembly in a certain direction with a specified number of steps. The Motors operates with a holding torque (2 Phases) on 1.89 Nm and 8.5 Nm for NEMA 23 and NEMA 34 respectively. Please refer to Appendix C for motor details. Limit switches: The module consists of six limit switches. Each assembly is fitted with two different switches which are Home Position switch. The Home position switch is synchronised is a way that whenever the system is reset it all the respective assembly move to the Home Positions, i.e., X-axis Home, Y axis Home, and Z-axis Home and stop there until the next command is entered by the user to perform the action. In case on any wrong movement, lets assume the assemblies move the opposite directions by not considering its Home Position, and it moves to the assemblies Safety Switch, i.e., X-axis Safety, Y axis Safety, and Z- axis Safety and by hitting it will move back to the opposite direction to reinitialize its home position and protect the assemblies from wear and tear. Power supply: This module is supplied with 12 volt and 25 amperes with the three outputs supplied to the Motor Drivers, where NEMA 23 Motor Driver consumes 3 ampere and NEMA 34 Motor Driver consumes up to 4.5 ampere. Safety switch: For the current work, safety Switches are used for emergency purposes to immediate shutdown of the system for safety purpose. The Safety Switch is connected between the AC input live cable from a power source to Linear Power Supply, connected as Normally Open (NO).Remark: All dimensions in mmFig. 7. Rack with Y-axis assembly dimensionsFig. 8. Main structure of the ASRS machine1.3.4 Control system: Electronic works Arduino UNO: Arduino Uno is a micro controller board dependent on ATmega328P (datasheet). It has fourteen computerized in and out pins (of which six can be utilized as PWM output), six simple bases of info, a 16 MHz quartz speed of the clock, a USB association, a power holder, an ICSP header and a reset control. It contains everything expected to help the micro controller; basically, associate it to a PC with a USB link or power it with an AC to DC connector or battery to launch. You can tinker with your UNO without stressing excessively over accomplishing something incorrectly, most dire outcome imaginable you can swap thechip for a couple of dollars and begin once again. Uno signifies one in Italian and was picked to stamp the launch of Arduino Software (IDE) version 1.0. The version and the board itself of Arduino Software were the reference renditions of Arduino, presently developed to fresher discharges. The Uno board is the first in a progression of USB on the board, and the reference display for the Arduino index stage; for a broad rundown of current, past or obsolete boards see the Arduino list of boards. Fig. 9 demonstrates the Arduino UNO board 17, and the technical data of the board is presented in Table 1. Table 2 illustrates the pin configurations for the Arduino UNO board used.Fig. 9. Arduino UNO board usedTable 1. Technical specifications of the Arduino UNO board-controllerATmega328POperational Voltage5VInput Voltage7-12VLimit of Input Voltage6-20VDigital Input Output Pins14 (of which 6 provide PWM output)PWM Digital Input Output Pins6Analog Input Pins6DC Current per Input Output Pin20 mADC Current for 3.3V Pin50 mAFlash Memory32 Kilo ByteRAM2 Kilo ByteROM1 Kilo ByteCrystal Clock Speed16 MHzBuilt-in LED Pin13Dimension and Weight of BoardL = 68.6 mm, Width = 53.4 mm, Weight = 25gTable 2. Output pins configuration of Arduino UNO board PinDescriptions5VEN +, DIR + and PUL + GNDEN , DIR and PUL 2 Z Step Pin (PUL +)3 Z Direct Pin (DIR +)4 Limit Switch5 Limit Switch6 Limit Switch7 Limit Switch8 Limit Switch9 Limit Switch10 Y Step Pin (PUL +)11 Y Direct Pin (DIR +)12 X Step Pin (PUL +)13 X Direct Pin (DIR +)A0Enable Pin EN+ of X, Y, and Z Motor drivers TB6600: The TB6600 Arduino Stepper Motor Driver is a simple to-utilize proficient stepper motor driver, which could control a double phase stepping motor. It is perfect with Arduino and different microcontrollers that can output a 5 Volts digital pulse signal. The TB6600 driver has a wide range control input, from 9 to 42 Voltage DC power supply. Also, it can supply an output of 4 Ampere peak current, which is sufficient for most of the stepping motors. The driver underpins speed and course control. You can set its small-scale step and an output current with 6 DIP switch. There are 7 small scales steps (1, 2/A, 2/B, 4, 8,16, 32) and 8 sorts of current control (0.5,1, 1.5, 2, 2.5, 2.8, 3, 3.5) Ampere on the whole. Each flag terminal receives fast pick coupler disconnection, upgrading its anti-high-frequency impedance 18,19. More information on the motor driver is provided in Appendix D respectively. Fig.10 presents an example of a connection diagram of Motor Driver with Arduino, Stepper Motor and Power Supply. Interface circuit b/w limit switches and arduino UNO: The Limit switch pins are connected each to ground to Arduino Pin through a resistor of 1 K ohm resistor, the 5 volts is supplied to limit switch through a resistor. The circuit consists of 6 resistors, 2 input pins of GND and 5 volt VCC, 12 terminal blocks from 6 six switches and 6 terminal blocks from Arduino Pins. The schematic diagram of the interface circuit is provided in Fig. 11 while the entire control unit of the module is shown in Fig. 12 respectively.Fig. 10. Connection diagramFig. 11. Schematic diagram of the interface circuitFig. 12. Control circuit of the module1.3.5 SoftwareIn the programming procedure, Arduino is chosen to be utilized for incorporating and leading the logical control activity of the coding. The general software IDE is used to write the coding for controlling the module, the language used is basic C#. A simple method to comprehend the Cartesian facilitate framework in connection to machine is utilizing the Right Hand Rule. Hold your hand out palm up with your thumb and forefinger pointed outwards, and your centre finger pointed upwards. Spot your turn before assembly, lined up with the assemblys segment and youll see the axes line up clearly. The movement of system along the coordinate system is always based on how assembly moves, not the shelves itself. For instance, increasing the Y coordinate value would transport the assembly towards left, but when looked at from the viewpoint of the shelves, its moving right along the assembly. Decreasing the Z-axis coordinate would move the Storage andRetrieval mechanism up, increasing it would move it down reference with the shelves. Every three dimensional system has its own in-house origin place called Assembly Home. When the module initially boots-up, it generally has no clue where it is in physical space and requires calibration to get it to its Home position. When this process happens, all three axes of the machine move toward their extreme mechanical limit. Once a limit is touched, a signal gets directed to a controller which registers the Home position for that specific assembly axis. By completing this for other assemblys axes, the machine is considered as “Homed”. The coordinates system of the module shelves is defined in Fig. 13. Each cell has its coordinate of (z, y) to ease the localization process during storing and retrieving activities. The system structures included are the location of the initial position of the linear motion of assembly, location of stacking and receiving are taken from shelf 8 which in future possibly be linked to a conveyor machinery.Shelf 1 (3, 0)Shelf 2 (2, 0)Shelf 5 (2, 1)Shelf 3 (1, 0)Shelf 6 (1, 1)Shelf 8 (1, 2)Shelf 4 (0, 0)Shelf 7 (0, 1)Shelf 9 (0, 2)Crane AssemblyFig. 13. Coordinates system of shelfs1.3.6 Flow chart and coding descriptionThe program has following functions which interconnect with each other to perform the required tasks. They are:/Assignment of pin numbers to direction and pulse of X-Y-Z axes:const int stepPinX = 12; const int dirPinX = 13; const int stepPinY = 10; const int dirPinY = 11; const int stepPinZ = 2; const int dirPinZ = 3; const int enPin= A0;/Setting up the Global variable to which the pulse pin number is assigned:int stepPin;/Assignment of pin numbers to switches:const int Z_home = 9; const int Y_home = 8; const int X_home = 7; const int X_safety = 6;const int Y_safety = 5; const int Z_safety = 4;/Assignment of fixed number of steps representing:const int dist_col = 15500; /distance between columns const int dist_row = 24000; /distance between rows const int dist_x = 18000; /distance for X-axis to moveconst int offset = 3000; /offset value for retrieve and store operation const int offset_z = 3800; /offset value for Z-axis initial position/Integer values to represent coordinate positions for Z and Y axes:int coordinate_Z; int coordinate_Y;/Integer values to store current coordinate positions:int temp_coordinate_Z; int temp_coordinate_Y;/Integer values representing the difference between coordinates - how far one shelf from another in ZY plane:long int result_Y; long int result_Z;/Integers for calculating the number of steps axes should move from one shelf to another:long int steps_Y; long int steps_Z;/Integers for counting steps of Z and Y axes in while loop:unsigned long int b; unsigned long int c;/Integers that representing shelf to go to and operation (0-retrive;1-store) to perform:int shelfi;int operationi;/Integers for for/while loops & if/else statements:int i=0,y=0,d=1,k=0;Void setup, Void loop, Void move-self, Void retrieve, Void store, Void movement, Void movement_YZ, Void operation_movement_YZ, String getValue and Void initialize.Please refer Appendix E for the functions descriptions of the program.1.3.7 Graphical user interfaceFor this module the Graphical User Interface (GUI) was created using a Microsoft Visual Studio. The application serially communicates with the module through an Arduino Board via 9600 baud rate. Fig. 14 shows the interface of the application. The Application has three mainpanels, i.e., Port Properties, Manual Operation, Reset, Storage and Retrieval. In Port Properties the COM port is designed as drop select function button, where it detects the connected port to the PC, the Baud rate is assigned in the code as 9600 which has to be selected after pressing the Open Port button and thus the module is successfully connected with the PC. The ManualOperation includes shelf selection from 1 to 9, the operation is either retrieval or Storage by entering “0” and “1” and the reset is to initialize the whole system to its “Home Position”. The Move button is to order the machine to perform the given tasks; the Store is the option to save the current data in a text file to keep the machine and app up to date to not perform the operation twice for the same shelf. In the Manual Operation Panel, it has nested panel of Reset, where the two buttons Reset has the value “1” and Dont has the value “0”, by pressing each of the buttons it writes the value in the Reset Box mentioned in the Manual Operations. The Store Panel has all the shelves from 1 to 9 among which one is Pick and Place shelf for the item to be stored. It does the same as Reset Panel by writing the Values in Manual Operation panel under the Operation Box to write “1” and Shelf Box “1” as storage, After the user press the Shelf 1, it will write the value as described “1” and changing its colour to Red from Green, where Red indicates the shelf is stored or full and Green means its vacant, which simultaneously change the colour of Shelf 1 button in Retrieve Panel, to Green. So once the buttons are Red in colour it acts as disabled. The same operation goes to all other shelves, resulting in good communication way between the User and the Machine.1.3.8 Program functionThe GUI constructed by using the Microsoft Visual Studio controls the sorting machine by sending the appropriate commands through serial port communication. It is constructed in a friendly way with buttons and labels to ease the process for the users. On the left side, there is the serial port communication. That opens and closes the serial port connected with the circuit board. If the user wishes to control the machine from the computer, the serial port needs to be open and the baud rate, which represents the speed of transforming information needs to be set as well. The GUI includes two main parts where one for manually inserting the shelf number and operation, and the other one by clicking on the respective buttons, which makes it more convenient for users. The second part of the GUI offers control for both storage and retrieval. The user may easily press a button for a respective shelf under the “store” section to store a container in the shelf or press a button for a respective shelf under the “retrieve” section to retrieve a container from that shelf. Once the store button is pressed, it will turn red to notify the user there is already a container stored in that shelf. Similarly, once the item is retrieved, the button will turn green to notify the user that the shelf is empty and available for storage. All the commands and operations are assembled in the form: shelf number: operation: reset status; where the shelf number represents the respective shelf number to store or retrieve and it is given values from 1 to 8. The operation represents whether to store or retrieve, and is represented by a 1 or 0, for storage and retrieval, respectively. The final subcommand is the reset status, where if set to 0, the machine will reset. So if the user wanted to store on shelf 1, by pressing the “shelf 1” buttonFig. 14. Proposed GUI for the current workin the storage section of the GUI, the command would automatically be constructed as: 8:1:0 Alternatively, the user may manually enter the command under the “manual” section in the respective fields for shelf number, operation and reset. The command is sent using serial WriteLine () which uses the Serial Port Library by C# to send the command to the Arduino board. The button may also be easily switched colour using the button. Color = “red” and button. Color= “green”. The string is also constructed using a string concatenation of the shelf number, operation and reset.2. OUTCOMEOFTHEFABRICATED ASRS MACHINE2.1 ExperimentalOperationResultof Storage and Retrieval MachineThe experimental operation result is tested on the efficiency of the ASRS machine to perform a given task in the aspect of time taken and the maximum handling load. In the Storage and Retrieval process, there are three processes in total which extend platforms, lifting or depositing of platforms and retraction of platforms. The summation of the time taken in these three processes will be the total time taken for Storage and Retrieval machine performs a Storage and Retrieval task. Both the extension and retraction of the platform takes about 25 seconds each with lifting and depositing taking 2 seconds and lifting and depositing taking 2 seconds and retraction of item loads takes same as 25 seconds. Then the all-out time taken is 52 seconds for finishing the Storage and Retrieval undertaking. This speed can be improved by supplying higher voltage so the power in total would be much enough to boost the process in efficiency and time. Overall the movement achieved is smooth just the linear screw which has to be adjusted to eliminate the squeaky noise during machine operation.2.2 ASRS Machine ViewThe different views of the fabricated machine is presented in Fig. 15 respectively. The final dimensions of the machine in terms of its length by width by height is: 80cm by 73cm by 94cm respectively. Fig. 16 depicts the actual image of the developed ASRS machine showing its important segments.2.3 Weight Lifting Calculation Using2.3.1 NEMA 34Maximum weight a 8.5 Nm Stepper Motor torque can lift by the NEMA 34 is computed using Equation 1 where:Torque (T) = 8.5Nm; Radius = 0.007m; Diameter= 0.014mretraction of item loads takes same as 25 seconds. Therefore, the total time taken is 52 seconds for completing the Storage and Retrieval task. This speed can be improved by supplying higher voltage so the power in total would be much enough to boost the process in efficiency and time. Overall the movement achieved is smooth just the linear screw which has to be adjusted to eliminate the squeaky noise during machine operation. The trial activity result is tested on the effectiveness of the Storage and Retrieval machine to carry out the Storage and Retrieval activity in the part of the time taken to carry out the assignment and the most max load of Storage and Retrieval machine ready to deal with. In the Storage and Retrieval process, there are three processes in total which extend item, lifting or depositing of item and retraction of item. The summation of the time taken in these three procedures will be the complete time taken for Storage and Retrieval machine play out a Storage and Retrieval job. Both the expansion and withdrawal of the stage takes 25 seconds each with machine.2.3.2 NEMA 23Maximum weight a 1.89 Nm Stepper Motor torque can lift NEMA 23 is computed using Equation 1 where:Torque = 1.89Nm; Radius = 0.007m; Diameter = 0.014m a) Front viewb) Left viewc) Right Viewd) Back Viewe) Top viewf) Bottom viewFig. 15. Different views of the fabricated ASRS machineFig. 16. Actual image of the fabricated ASRS machine showing its important segments3.4. Proposed Future WorksThe following may be carried out in the future to further enhance the developed ASRS machine. They are but not limited to: Stability of Storage & retrieval assembly can be further improved by adding an additional column. Wifi based Arduino to enhance user- friendliness. Personnel can operate the machine using their cellular devices or tablets. Robotic Arm can be installed based on machine vision to carry out sorting and synchronizing tasks. Power specifications: Currently the module is rated as P = I x E (12 x 4.5 = 54 Watt). To further improve it, we can supply up to 42 Volt to the current system which can derive up to 189 Watt. Speed can further be improved by replacing linear-screw mechanism by gear- chain or linear-gear mechanism. Following the same design, ASRS can be attached to the end of an industrial conveyor. Incoming packages from the conveyor will be placed in the GeneralBay. Later, that package can be moved to its respective bay. Vice versa, outgoing packages can also be placed on the conveyor using the same mechanism.3. CONCLUSIONSThe flat bat of the x assembly permits the Storage and Retrieval machine to manage the load without moving in the whole Storage and Retrieval mechanism assembly underneath the load. This mechanism simplifies the necessities of the storage racks to be altered for having additional room under the loads in which spares the quantity of storage unit in vertical height. Also, the little estimated Storage and Retrieval assembly permits the storage room ready to be considerably smaller which could spare the floor space by trading off the space of the storage unit. In programming, the whole assembly is ready to perceive the present status of the machine and can perform a task intelligently by reinitializing to read the correct amount of movement.ASRS solutions inventory within a fully enclosed system; providing safe, secure and controlled inventory management. For an instance, thesystem can be configured to permit only authorized personnel access to store inventory through a personal login password and the GUI created. This allows missing or misplaced goods to be tracked back to a specific individual. This enhanced level of accountability and security eliminates inventory shrink and its negative impact on the bottom line.ACKNOWLEDGEMENTThe authors would like to thank Mr. Yong Yik Seng and Dr. Lim Wee Kuan for their valuable comments and efforts contributed to the realization of this research.COMPETING INTERESTSAuthors have declared that no competing interests exist.REFERENCES1. Boysen N, Emde S, Hoeck M, Kauderer M. A survey on part logistics in the automotive industry. European Journal of Operational Research. 2015;242:107-120.Bezel YA, White JA. Travel-time models for automated storage/retrieval systems. 11E Transactions. 1984;16:329-338.2. Wauters T, Villa F, Christiaens J, Alvarez- Valdes R, Vanden Berghe G. A decomposition approach to dual shuttle automated storage and retrieval systems. Comput. Ind. Eng. 2016;101:325337.3. Chu WS et al. 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Technol. 2014;12:131143.APPENDIX A: Information on the types of bolds usedAllen keyButton Head CapCounter Suck HeadSocket Head CapDouble EndedDescriptionPcsDescriptionPcsDescriptionPcsDescriptionPcsM4 x 20mm2M4 x 15mm3M4 x 15mm4M2.5 x 5mm8M4 x 30mm32M4 x 20mm16M4 x 20mm12M4 x 35mm4M4 x 25mm2M3 x 10mm5Hex HeadHex Head CapDescriptionPcsM14 x 15mm4APPENDIX B: Information on the types of drag chains usedSizes7 x 7 x 450 mm10 x 15 x 730 mm15 x 30 x 990 mmAPPENDIX C: Information on the Stepper Motor - NEMA 23 on left and NEMA 34 on rightAPPENDIX D: Information on the Features and Specification of Motor Driver TB6600 FeaturesSpecificationSupport eight classes of current controllerInput Current: 0 to 5 Ampere Support seven classes of micro-steps changeableOutput Current: 0.5 to 4.5 Ampere The interface adopts high-speedControl Signal: 3.3 to 48 VoltageAutomatic semi-flow to decrease heatMaximum Power: 160 WattOutsized space heat sinkMicro-Step: 1, 2-A, 2-B, 4, 8, 16, 32 Anti-high-frequency interference abilityTemperature: - 10 to 45 Celsius Input anti-inverse protectionHumidity: No CondensationAPPENDIX E: Functions Descriptions of the program Void setupIn the Setup function, the direct, pulse (step) and enable pins are initializes as High or Low Howeverthe pins are categorized as input and output for their respective operation to perform. Limit Switches are initialized as Input and Motors are initialized as Output. After Initialization the stored coordinated are initialized as coordinates Z=0, Y=0. Lastly, the Serial port is open as 9600 for data transmission.Void loopThe loop function coordinates the movement of assembly as designated positions, by calling the movement function in switch cases. Initially, the initialisation occurs to maintain the Home Position for the assemblies. The Serial String reads the operation by receiving the value from the user as “0” means retrieve, “1” means store and “2” means reset the X, Y and Z axes assemblies. There are nine Switch Cases, Case =1 is assigned for Shelf 1 where the coordinates are z = 3. y = 0. Case 2 is assigned for Shelf 2 and the coordinates are z = 2, y = 0. In Case = 3, coordinates are z = 1, y = 0 and is assigned for Shelf 4. Case = 4, coordinates are z = 0, y = 0 assigning to Shelf 4. The Shelf 5 have coordinates z = 2, y = 1 in Case 5. Case 6, represent Shelf 6 with the coordinates z = 1, y = 1. Case 7 of switch function is assigned to Shelf 7, with the coordinates z = 0, y = 1. Shelf no 8 which is Pick and Place bay, have the coordinates z = 1, y = 2 under Case 8. For Lastly Case 9 is assigned for Shelf no 9 with the coordinates z = 0, y = 2. Else it will print “Wrong entry” if the numbers are other than 0, 1 and 2 for retrieving, storing and resetting the X, Y, and Z assembly. The assembly moves accordingly by specified steps in movement function given the command by the user.Void move-selfThis function performs the movement operation of Z and Y axes. When the Operation reads “0” which means retrieval, the assigned steps are performed with a reference coordinates as when z and y are at (0, 0) respectively. Distance Column and Distance Row are specified initially which are called by dist_col, dist_row and offset. During the movement forward and backward whenever the result_Y or result_Z values are in negative integer, it multiplies them with positive one value to get the right calculated movement. After reading the operation of the Digital Write pin assign the Direct (step) pin as either “High or Low”. In the function, the Z and Y axes are coded as to move simultaneously to directed shelf. Lastly, if operation entered is “0”, means retrieve which will call the retrieve function to perform the task. Else if operation is “1”, means store by calling store function.Void retrieveIn the retrieve function, the responsible assemblies are Z and X axes, as to retrieve the Z-axis have to be 1500 steps lower than the rack levelling position. After which the X-axis direct pin is assigned as “High”, in case if it hit the switch either Safety or Home and the system reads the X_safety or X_Home as “High” it will call the movement function to Stop. However the Z-axis follows the same criteria for the movement where the steps in Z-axis are mentioned by offset which is 3000 Steps, For the retrieval purpose we need to move the Assembly exactly by 3000 steps as it goes below the rack with-1500 and then moving up by 3000 steps lifting the item after which Digital writes the X step pin as “Low” moving the bay backward and the offset is divided by 2 to make the level same as the shelf rail by calling the movement function. The retrieve operations perform successfully.Void storeThe Store function act the same as retrieve function also responsible for Z and X axes assemblies, to store, the Z-axis must be 1500 steps higher than the rack rail position. After which the X-axis direct pin is assigned as “High”, in case if it hit the switch either Safety or Home and the system reads the X_safety or X_Home as “High” it will call the movement function and Stop. However the Z-axis follows the same criteria for the movement where the steps in Z-axis are mentioned by offset which is 3000 Steps, For the storage purpose we must move the Assembly exactly by 3000 steps as it goes above the rack with +1500 and then moving down by 3000 steps putting the item after which Digital writes the X step pin as “Low” moving the bay backward and the offset is divided by 2 to make the level same as the shelf rail by calling the movement function. The storage operations perform successfully.Void movementIn this function, the Digital Write stepPin, “HIGH” with delay in 2 microseconds and for the Digital Write stepPin, “LOW” the delay of microseconds 740. These are the delays that need to be assigned for stepper motors between the steps movement as how precisely it will move.Void movement_YZThis function has the exact same behaviour as the movement function above, adding which just for the simultaneous movement of Z and Y axes assemblies the step pin Z and step Pin Y are instructed together with same microsecond delays for High as 2 and Low as 740. It is called when there is simultaneous movement of Z and Y axes assemblies movement.Void operation_movement_YZFunction operation movement YZ was created for Y and Z axes to move simultaneously. The function is called inside a while loop which condition will be only satisfied when both Y and Z step counters will be equal to the previously calculated number of steps. Inside function, there are few conditions that must be satisfied on order the set the pulse signal high or low for both Y and Z. The first condition is checking whether the Limit Switch is pressed or not, although the number of steps is predefined andthe machine should not exceed its operation limit, this condition is implemented for the safety purposes. Second condition is implemented to verify that either direction pin Y or Z is activated and lastly the third condition is the most important one, as it checks whether the steps counter is equal to the calculated steps for the axis to move to another shelf. Lets say we must move 24 thousand steps, this means that the pulse signal will be sent to the controlling driver 24 thousand times, providing that the previous two conditions are satisfied. At last, how both axes move at the same time, this is by sending pulse high to both Y and Z and only after short delay low. Otherwise, it would be the same as i initialize function where firstly we moved X-axis and only after that Y and Z.Void initializeIn initialization function, we created with a dummy value, i.e., d= 0. It is an infinite loop with no body. The purpose would be to make sure the program doesnt end, yet it does nothing. It is also known as an idle loop. While the System boot up the serial print will print “Doing the Initialization Sequence” Writing the digital stepPin X as Low which will move backward till it hit the switch. By infinite steps where it reads stepPin=stepPin, When d=1, digital read home pin in High, if it is true it will keep moving by calling movement function, if the value is False it reads d=2 which is true value for home position, and the mechanism stops at home position by Printing the “Alignment by x-axis done”. And the While loop for Z-axis and Y-axis follows the same as X-axis by writing the digital stepPin Z and digital stepPin Y as Low. If it reads d=3, it repeats until the assemblies are in Home position when the d=2 after hitting the Limit Switches respectively so the offset is True and it stops if False it repeat.用于自动存储和检索的小型物料堆垛机机的开发系统（ASRS）Saif Ullah Iqbal, C. B. Yeo and UmarNirmal 摘要目前的工作涉及用于柔性制造系统（FMS）的自动存储和检索系统（ASRS）机器的设计和开发。这项工作涉及调查ASRS机器的功能和操作程序，评估该机器的相关硬件，软件和通信模块。这项工作探索了当前市场上提供的硬件和软件模块的不同选项，并进一步选择了适合ASRS机器开发的选项。给出了一些设计考虑因素以及在项目开发和实施过程中面临的局限性。 Arduino被用作Arduino UNO板的编码系统，而不锈钢305和铝被用作制造ASRS机器的主要框架。最后，展示了完全开发的ASRS机器的最终工作原型，该机器的尺寸为：80cm x 73cm x 94cm（长宽高）。关键词：小型；物料搬运； ASRS； FMS；原型;取放机器； Arduino UNO;不锈钢304;铝1. 介绍ASRS涉及一系列计算机控制的结构，以便通过机器人自动放置并从定义明确的存放位置检索负载。他们相对于通常的（按数量选择）储藏室系统的基本偏好是宽敞的空间实践，减少的工作费用，较短的恢复期以及对库存库存控制的改进。自动化存储和检索系统（ASRS）通常在世界大部分地区的储藏室中使用，并且主要在配送中心中使用。这种想法有一个很好的基础，即这种自动化驱动器将在可能的将来保持（甚至升级）其广泛的应用，以及所讨论的模型行业趋势以及上述所有好处。在过去的40年中，自动存储和检索技术取得了很大的进步，并且ASRS的数量在接下来的几十年中预计将迅速增长。在许多企业中可以感觉到的物品分类的不断增加，扩大了库存单位（SKU）的种类，可以在正常的配送中心进行处理。例如，德国汽车制造商宝马公司在丁戈尔芬的工厂每天获得的材料超过13,000个车厢，这些车厢由600多家供应商在400多辆卡车上输送。如果没有机械化的仓储，采用可靠的内部协调形式来对如此大量的零件进行保养似乎是不合理的1-2。 ASRS将所有补充物厚厚地储存起来，从而省去了对这种能量进行冷却，加热，通风和照明的充足储存空间的需求。作为美国物料搬运行业之一（MIH，2009年），食品业务将30的冷却成本留在了自动存储和检索系统上的冷藏配送中心中3-4。随着许多创建国家的社会日趋成熟，权威机构的权重也在不断扩大（例如，欧盟机械指令2006/42 / EC，89/391 / EEC，职业安全与健康法），对人机工程学的观点需要特别的思考来进行存储。上面的统计数据应该引起行业的警觉，请他们考虑如何使工作场所的员工安全变得重要的方法。解决方案之一是引入自动化。通过自动执行手动重复任务，可以将工人重新分配到更安全的区域，在那里他们可以发挥想象力，适应能力和决策能力。正如世界经济论坛所指出的，机器人是完美的对于人类需要执行的体力劳动或危险任务，从经济上讲，它们可以以比人类工人更低的成本进行全天候工作，其中，自动存储和检索系统似乎是有利的5。通常，将自动存储和检索系统编程为在没有人工干预的情况下管理货盘，因此，该结构称为全自动。在制造和供应方面，自动存储和检索系统的位置都用于将产品（例如，原材料或部分成品）存储到存储中，并用于从存储中取回这些产品以完成任务。在设计自动化存储和检索系统时，必须采用正确的方法来解决许多物理计划和控制问题，以充分利用其每一位专业人员。 ASRS可以减少制造商的反对，因为ASRS可以减少库存和流程工期，并且理想情况下可以使用资金和工作6。从根本上说，ASRS系统由存储架，控制系统，存储和取回栏，人机界面以及出入库组成。借助于存储和取回柱机，可以将物品放置在存储架上并从存储架取回，在该机器上取回物品或将对象存储在存储系统中。自动化系统通常由作为存储和取回机器自动化的输送系统和作为自动化路径的框架结构组成7。自动化系统将负责垂直，内部/外部和水平移动执行存储或检索过程的存储和检索机构。因此，为了控制系统，图形用户界面是用户命令处理或存储或取回放置在提取和存放托架上的选定盒子或对整个机架本身的架子中的盒子进行分类的过程的平台。 ASRS的物料拣选模块将满足目标用户特定的操作要求。在设计阶段之后，存储和检索机制将被制造并用于在ASRS中进行存储和检索过程。 ASRS的物料拣选模块旨在满足关注于消费者的明确操作需求。该模块由机架结构以及存储和检索列组成，以通过ASRS进行存储和检索命令。市场上可访问的大多数自动存储和检索系统通常都是高价或大型的，并且只针对大型企业8,9。对于中小型组织，平面图和经济报告的发布使他们无法将自动存储和检索系统执行到运营组织中。错误的情况可能是无意间在专用区域加载和检索对象，并且发现货架上的物品有时会变得很困难。关于这些问题，计划自动存储和检索系统以适应中小型企业的运营先决条件，以减少错误率并扩大可靠性质量，同时节省人工成本和占地面积10,11。因此，当前的工作旨在设计和开发最先进的自动存储和检索系统。机器将与开发的GUI程序链接，以允许用户以“用户友好”的方式与机器进行交互。1. 方法1.1 硬件在此部分中，包括组装运动，所选组件的设计稳定性以及设计本身及其制造过程的各个部分，这些子部分具有自己的特定功能，可满足自己的操作目的。这些子部分的总装将能够实现项目目标，以精确地执行存储和检索操作。1.1.1 结构组装材料该模块的结构材料选择为不锈钢305和铝5083，而铝通常不如不锈钢坚固，并且不锈钢具有出色的耐腐蚀性，原因有两个。首先，不锈钢中添加了铬，从而在钢周围形成了不可见的耐腐蚀膜。其次，它是无孔的，增加了耐腐蚀性。不锈钢专门用于承载部分，与铝相比，铝仅用于联接或保持整体工程重量，与不锈钢相比，铝轻得多。 305不锈钢矩形管（5cm x 2.4cm）和（2.5cm x 1.2cm）分别用于搁板框架底座和搁板模块结构，铝板5083用于耦合不同的组件。1.1.2 有关所用组件的信息以下是用于当前工作的硬件组件及其简要说明。 线性螺丝根据Thomson Industries 12-14，“线性螺杆”的螺纹使用螺旋角进行线性运动。螺母和螺钉之间的摩擦系数与导螺杆的性能密切相关，而导螺杆的性能很大程度上取决于用于螺母和螺钉的材料。对于此项目，我们将线性螺丝钉用于在x，y和z轴上的三维穿梭，以便将“存储和检索”的组件移动到左右，上下和前后。 硬铬活塞杆硬铬活塞杆是由苏州威鹏精密机械有限公司在苏州生产的，采用JIS S45C材料制造，首先对极柱进行精加工和准备，然后对它们进行保护性表面铬处理，以确保表面精度尺寸。 f7，表面硬度至少达到和达到HV800，这有助于增强耐磨性并有助于加宽杆的存在周期，从而产生良好的运动。该模块与铬制活塞杆双重安装，可实现存储和检索组件在x，y和z轴上的无摩擦滑块运动。一对杆通过线性滚珠轴承帮助组件在特定方向上精确移动。 不锈钢支撑杆不锈钢棒安装为Z柱（起重机）的结构支撑，Z柱垂直安装在顶部，顶部为电动机底座15的铝板。 直线球衬套带机构的线性衬套利用滚珠特征的滚动运动。由于通过简单的机构即可实现线性运动，因此线性衬套可用于多种用途，包括托架，食品处理和半导体制造工具。线性滑动衬套使用圆形通道作为引导轴，从而节省了空间，从而可以实现紧凑的方案。低摩擦，通道表面是精密研磨的。由于滚珠特征与滚道表面之间的接触表面减少了，因此直线滑动衬套轴承提供了与其他直线运动工具相关的低摩擦力。在本模块中，我们使用两种尺寸的直线球衬套，分别是16mm和20mm的硬镀铬杆，以帮助组装运动 安装螺栓该项目使用的六角扳手和六角头螺栓的类型和尺寸不同。此外，它分为按钮头盖，插座头盖，沉没式和六角头盖。总共安装了43个按钮头盖，21个沉头头，16个内六角头和8个内六角双头螺栓以及4个六角头螺栓。因此，整个模块中总共固定了92个螺栓。有关使用的粗体的更多信息，请参见附录A。 找平底垫该模块配有四个调平垫，而调平脚几乎始终是固态金属。调平垫通常在底部有一个橡胶或聚氨酯垫，可提供抓地力以防止机器移动，并有助于稳定橱柜，搁板和机械等。当地板可能被钢脚划伤或划伤时，可以使用调平垫代替调平脚。 电气/电子外壳电气箱是一种用于电气或电子工具箱的柜子，用于安装控件，旋钮和显示器，并阻止电击波对工具箱用户的使用，并使对象远离周围环境；该外壳由25cm x 15cm的压克力板制成，通过12mm的长螺栓连接三个平行板，分别在8cm和12.5cm的内部留出空隙，从而形成了开放式搁板的设计。用于在限位开关和Arduino UNO板之间安装控制电机驱动器，Arduino UNO板和接口电路。在任何危险情况下，最上面的架子上都装有安全开关。 拖链电缆架，相应地称为拖链，驱动链或电缆链根据生产商的不同，计划设计指南以围绕并引导可弯曲的电缆以及连接到移动中的机器人设备的液压或气动软管。在此模块中，我们使用三种尺寸的拖链7 x 7 mm，10 x15毫米和15 x 30毫米。对于x轴，电缆使用长度为450 mm的7 x 7 mm尺寸的拖链，对于z轴，电缆被引导为长度为730 mm的10x15 mm拖链，而对于y轴，电缆电缆将软管插入15x30毫米的拖链中，长度为990毫米。 y轴承载着从x轴和z轴引出的所有电缆，这是主控制器外壳的瓶颈。有关使用的拖链的更多信息，请参见附录B。 耦合它是用于接合两个不同的杆/轴（由其开口端组成）以传导动力的组件。通常，尽管存在一些扭矩控制联轴器，当超过某个扭矩周长时，它会滑移或分离，因此通常不会通过操作断开轴的连接。在电机和丝杠之间只有一个联轴器安装在z轴上，联轴器是使用车削和铣床由直径25mm的不锈钢棒制成的。0 螺旋风管接线线槽的应用与拖链相同，不同之处仅在于它的柔韧性和可以以任何形式成形。通常，它是一种电缆管理产品，它允许用户以轻松而有条理的方式布线大体积的电缆。投影线的长度分别为700毫米和400毫米，直径分别为15毫米和8毫米。1 框架结构框架设计为3 x 3列和行。行和列的设计方式是实现对角线运动演示，再加上减少半直角三角形以减少成本并达到演示目的。但是，架子用10mm宽的不锈钢导轨固定在机架上，足以搬运重物。框架的底部由尺寸为50毫米x 240毫米的不锈钢矩形管503制成，底座尺寸为600毫米x 600毫米，在其顶部使用250尺寸的不锈钢矩形管503制作货架。毫米x 120毫米，每个架子的内部尺寸为（长x阔x高）200毫米x 180毫米x 150毫米= 5.4 x 106毫米3。将其乘以8个43.2 106mm3的货架容量，而第3列第2行的最后一个货架是Pick and Place货架，可以连接到传送带或人工装载。选择不锈钢作为车架的制造方法是要使其坚固到足以承受相当重的负载。由于存储和检索过程，与其他选项相比，这种材料的寿命更长。图1说明了框架结构设计的CAD模型。图1.使用CAD的框架结构设计1.2 组装运动模块组件的设计方式使机构的运动可以平稳无摩擦。机器具有三个装配运动，分别归类为x，y和z协调系统。 x轴坐标组件负责通过来回移动来从机架中存储和检索包装； c.f.图2.组件的最大移动区域为360mm。 x轴通过带有z轴的线性球衬套安装，以向上或向下抬起存储和检索机构。Z轴坐标组件负责通过遵循用户输入中的特定命令，将“存储和检索”机制上下移动到特定行。 c.f.图3.该轴的最大行进面积为640 mm。该组件安装到y轴组件。y轴是核心组件，它安装在框架基座上，以使其他两个组件沿指定方向移动； z轴通过线性滚珠衬套与y轴安装在一起。 c.f.图4.此轴具有650mm的最大允许移动区域，可将整个组件一起向左或向右移动以指定列号。1.3 设计与制作在设计这样的模块时，首先要注意的是列出所需的材料，切成所需的确切尺寸，然后通过焊接或螺栓连接的方式进行组装。其次，也是最重要的一点是，为了获得更高的惯性矩而设计框架的管子的方向，因为更高的惯性矩意味着更高的抗弯曲性。根据图4，与其他两个轴相比，预制管的方向表明Iz轴具有最大的惯性矩。下一节将提供有关模块设计和开发的简要信息。图2.在X轴上组装运动图3.在Z轴上组装运动图4.沿Y轴组装运动图5.矩形管惯性矩信息1.3.1 框架和底座设计框架由底座和架子列组成，即九个货架，底座的二维尺寸分别如图6所示。矩形框架包括一个尺寸为50mm x 240mm的矩形管，该管的每一侧均以长度为600mm的45度角切割，制作了四个等长的棒，并用累积长度为2400mm的钨炬线将其钎焊，从而提供了坚固的坚固性。整个框架。 备注：所有尺寸以毫米为单位图6.基本尺寸1.3.2 机架设计和3D尺寸在基础框架的顶部，搁板设计为尺寸为250 mm x 120 mm的矩形管，由三列组成，图7显示了每个列管的尺寸，即第一列高度为600mm，消耗了四个相等的长度。对于600mm的矩形管，第二根柱子是由两个与底座焊接的450mm高的矩形管组成，而第三根柱子的高度接近300mm，由从底座上连接的两个矩形管组成。机架的高度为150mm，长度为200mm。每列的宽度为180mm，可进行8个存储和取回存储，以及1个用于存放和取放托架的架子。在带有架子的情况下，将Y轴组件固定器焊接成其他组件的核心力矩。端板安装在底架的侧面，以用线性螺钉固定两活塞镀铬杆。在左板上连接驱动马达，以使组件向左或向右移动。如图。图8显示了带有架子和Y轴组件固定器的底座。按照与x组装相同的结构方法，它们通过Y，Z和X轴组装机构连接。对于z支架，一端支撑板与Yaxis组件连接，另一端由铝板支撑，铝板支撑不锈钢杆，包括线性螺丝和两个活塞镀铬杆。1.3.3 控制系统：电气工程 驱动电机：在该模块中，有3个步进电机，即NEMA 23，NEMA 23和NEMA 34，分别由X，Y和Z轴使用。电机安装在每个组件的末端，以指定的步数在特定方向上移动组件。对于NEMA 23和NEMA 34，电机分别以1.89 Nm和8.5 Nm的保持扭矩（两相）运行。有关电动机的详细信息，请参阅附录C。 限位开关：该模块包含六个限位开关。每个组件都装有两个不同的开关，它们是原位开关。原点位置开关是一种同步方式，每当系统复位时，所有相应的组件都将移至原点位置，即X轴原点，Y轴原点和Z轴原点，并在此处停止直到下一个命令被执行。由用户输入以执行操作。万一发生任何错误的移动，我们假设组件在不考虑其原始位置的情况下沿相反的方向移动，然后移动到组件的安全开关，即X轴安全，Y轴安全和Z轴安全，敲击它会返回相反的方向，以重新初始化其原始位置并保护组件免于磨损。 电源：此模块提供12伏和25安培的电流，三个输出提供给电机驱动器，其中NEMA 23电机驱动器消耗3安培，而NEMA 34电机驱动器消耗高达4.5安培。 安全开关：对于当前工作，安全开关用于紧急目的，出于安全目的立即关闭系统。安全开关连接在从电源到线性电源的交流输入带电电缆之间，以常开（NO）方式连接。备注：所有尺寸以毫米为单位 图7.带有Y轴组件的机架尺寸图8. ASRS机器的主要结构1.3.4 控制系统：电子工程 Arduino UNO：Arduino Uno是依赖于ATmega328P（数据表）的微控制器板。它具有14个计算机化的输入和输出引脚（其中6个可用作PWM输出），6个简单的信息基础，16 MHz的石英石英时钟速度，USB关联，电源保持器，ICSP接头连接器和复位控件。它包含了有助于微控制器的所有内容；基本上，通过USB链接将其与PC关联，或者通过AC至DC连接器或电池为其供电以启动。您可以对UNO进行修改，而不必过分强调完成错误的事情，可以想象到的最可怕的结果是，您可以交换筹码几美元，然后再次开始。 “ Uno”表示意大利语中的一个，并被选为Arduino软件（IDE）1.0版的发布标志。 Arduino软件的版本和开发板本身是Arduino的参考版本，目前已开发用于更新版本。 Uno板是该板上USB进程中的第一个，并且是Arduino索引阶段的参考显示屏。有关当前，过去或过时的电路板的简要说明，请参阅Arduino电路板列表。图9演示了Arduino UNO板17，该板的技术数据如表1所示。表2说明了所使用的Arduino UNO板的引脚配置。图9.使用的Arduino UNO板表1. Arduino UNO板的技术规格微控制器阿特梅加328P工作电压5V输入电压7-12V输入电压极限6-20V数字输入输出引脚14个（其中6个提供PWM输出）PWM数字输入输出引脚6模拟输入引脚6每个输入输出引脚的直流电流20毫安3.3V引脚的直流电流50毫安快闪记忆体32千字节框架2千字节吉普赛人1千字节水晶钟速度16兆赫内置LED引脚13板子的尺寸和重量L = 68.6毫米，宽度= 53.4毫米，重量= 25g表2. Arduino UNO板的输出引脚配置别针内容描述5VEN +，DIR +和PUL + GNDEN ，DIR 和PUL 2 Z踏脚（PUL +）3 Z直接引脚（DIR +）4 限位开关5 限位开关6 限位开关7 限位开关8 限位开关9 限位开关10 Y步进销（PUL +）11 Y直接引脚（DIR +）12 X踏脚（PUL +）13 X直接引脚（DIR +）A0启用X，Y和Z的引脚EN + 电机驱动器TB6600：TB6600 Arduino步进电机驱动器是一种易于使用且精通的步进电机驱动器，可以控制双相步进电机。与Arduino和可以输出5伏数字脉冲信号的各种微控制器完美搭配。 TB6600驱动器具有9至42伏直流电源的广泛控制输入。而且，它可以提供4的输出安培峰值电流，对于大多数步进电动机来说已经足够了。驾驶员是速度和路线控制的基础。您可以使用6 DIP开关设置其小步长和输出电流。有7个小尺度步长（1、2 / A，2 / B，4、8，16、32）和8种电流控制（0.5，1，1.5，2，2.5，2.8，3，3.5）整体安培。每个标志端子都断开快速拾取耦合器的连接，从而提高了其抗高频阻抗18,19。附录D中分别提供了有关电机驱动器的更多信息。如图。图10展示了一个带有Arduino，步进电机和电源的电机驱动器的连接图示例。接口电路黑白限位开关和arduino UNO：限位开关引脚通过一个1 K欧姆的电阻器分别接地到Arduino Pin，5伏电压通过一个电阻器提供给限位开关。该电路由6个电阻器，2个GND和5伏VCC输入引脚，6个6个开关的12个端子块和Arduino Pins的6个端子块组成。接口电路的示意图在图11中提供，而模块的整个控制单元分别在图12中显示。图10.连接图图11.接口电路示意图图12.模块的控制电路1.3.5 软件在编程过程中，选择Arduino用于合并和领导编码的逻辑控制活动。通用软件IDE用于编写用于控制模块的编码，所使用的语言是基本的C。理解与机器相关的笛卡尔辅助框架的一种简单方法是利用右手规则。伸出手掌，拇指和食指朝外，中指朝上。在组装之前发现您的转弯，使其与组装线段对齐，您会看到轴清晰对齐。系统沿坐标系的移动始终基于组件的移动方式，而不是货架本身。例如，增加Y坐标值会使组件向左移动，但是从架子的角度看，它沿组件向右移动。减小Z轴坐标将移动存储和向上增加检索机制，将其向下移至与架子相对的位置。每个三维系统都有自己的内部集中地，称为Assembly Home。最初启动模块时，通常不知道其在物理空间中的位置，因此需要进行校准才能使其回到原始位置。当此过程发生时，机器的所有三个轴都朝着其极限机械极限移动。触摸极限后，信号将被定向到控制器，该控制器会记录该特定装配轴的原始位置。通过针对其他装配体的轴完成此操作，该机器将被视为“已归位”。模块架的坐标系在图13中定义。每个单元的坐标为（z，y），以简化存储和检索活动期间的定位过程。包括的系统结构是组件线性运动的初始位置，堆放和接收的位置取自架子8，将来可能与输送机相连。架子1（3，0）架子2（2，0）架子5（2，1）层板3（1、0）6层（1，1）层板8（1、2）架子4（0，0）架子7（0，1）9层（0，2）起重机总成图13.货架坐标系1.3.6 流程图和编码说明该程序具有以下功能，这些功能相互连接以执行所需的任务。他们是：/将针脚编号分配给X-Y-Z轴的方向和脉冲：康斯特进一步针=12：康斯特伊特迪尔平克斯=13：康斯特内特步平=10：康斯特 伊特 迪尔平尼 = 11;康斯特内特步平Z=2：康斯特伊特迪尔平兹=3：康斯特恩平= A0;/设置分配了脉冲引脚号的全局变量：内步骤针：/将引脚号分配给交换机：康斯特Z_home=9：康斯特Y_home=8：康斯特X_home=7：康斯特X_safety=6康斯特Y_safety=5：康斯特Z_safety=4：/分配固定数量的步骤，代表：const int dist_col = 15500; /列之间的距离const int dist_row = 24000; /行之间的距离const int dist_x = 18000; / X轴移动的距离const int offset = 3000; /检索和存储操作的偏移量const int offset_z = 3800; / Z轴初始位置的偏移值/整数值代表Z和Y轴的坐标位置：intordinate_Z; intordinate_Y;/存储当前坐标位置的整数值：temp_coordinate_Z：temp_coordinate_Y：/整数值代表坐标之间的差异-一个架子在ZY平面中距另一个架子的距离：长result_Y：长result_Z：/用于计算轴步数的整数应从一个架子移动到另一个架子：长int step_Y; long int steps_Z;/用于计算while循环中Z和Y轴步长的整数：未签名的长入b：未签名的长入 c：/表示要执行的货架的整数，并执行操作（0检索； 1商店）以执行：内部货架内部操作/ for / while循环和if / else语句的整数：积分i=0，y=0，d=1，k=0；空隙设置，空隙循环，空隙自我移动，空隙检索，空隙存储，空隙运动，空隙运动_YZ，空隙操作_运动_YZ，字符串getValue和空隙初始化。有关程序的功能说明，请参阅附录E。图形用户界面对于此模块，使用Microsoft Visual Studio创建了图形用户界面（GUI）。该应用程序通过Arduino板以9600波特率与模块进行串行通信。图14显示了该应用程序的界面。该应用程序主要有三个面板，即端口属性，手动操作，重置，存储和检索。在“端口属性”中，COM端口被设计为下拉选择功能按钮，它在其中检测到PC的连接端口，在代码中将波特率分配为9600，在按下“打开端口”按钮后必须选择该波特率，因此该模块为与PC成功连接。手册操作包括从1到9的货架选择，通过输入“ 0”和“ 1”可以进行检索或存储操作，复位操作是将整个系统初始化为“原始位置”。 “移动”按钮用于命令机器执行给定的任务； “存储”是将当前数据保存在文本文件中的选项，以使机器和应用程序保持最新状态，从而不会在同一架子上重复执行两次操作。在“手动操作面板”中，它具有嵌套的“重置”面板，其中两个按钮“重置”的值为“ 1”，而“不”的值为“ 0”，通过按下每个按钮，它将值写入“重置”框中在手动操作中。 “存储面板”具有从1到9的所有货架，其中一个是用于存放物品的“拾放”货架。通过在“操作箱”下的“手动操作”面板中写入“ 1”和“ 1”作为存储，将其与“重置面板”相同，在用户按下文件架1后，将写入“ 1”中所述的值。 ”，然后将其颜色从绿色更改为红色，其中红色表示存储已存储或已满，绿色表示其空着，同时将“检索面板”中“层板1”按钮的颜色更改为绿色。因此，一旦按钮变成红色，它就被禁用。所有其他架子都执行相同的操作，从而在用户和机器之间建立了良好的通信方式。1.3.7 程序功能使用Microsoft Visual Studio构造的GUI通过以下方式发送适当的命令来控制排序机串口通讯。它以友好的方式构建，带有按钮和标签，可简化用户的操作过程。左侧是串行端口通信。这将打开和关闭与电路板连接的串行端口。如果用户希望通过计算机控制机器，则需要打开串行端口，并且还需要设置表示信息转换速度的波特率。 GUI包含两个主要部分，其中一个用于手动插入货架号和操作，另一个则通过单击相应的按钮来进行，这对用户来说更加方便。 GUI的第二部分提供了对存储和检索的控制。用户可以容易地按下“商店”部分下的相应架子的按钮以将容器存储在架子中，或者按下“取回”部分下的相应架子的按钮以从该架子检索容器。按下存储按钮后，它将变为红色，以通知用户该架子上已经存储了一个容器。同样，一旦检索到该物品，该按钮将变为绿色，以通知用户该货架已空并且可以存储。所有命令和操作都以以下形式组装：架子号：操作：复位状态；其中，架子编号表示要存储或检索的相应架子编号，并为其指定1到8的值。该操作表示是要存储还是检索，并分别用1或0表示以进行存储和检索。最后一个子命令是重置状态，如果设置为0，则机器将重置。因此，如果用户想存储在货架1上，请按“货架1”按钮图14.当前工作的拟议GUIa）前视图b）左视图c）右视图d）后视图e）顶视图f）底视图图15.组装好的ASRS机器的不同视图图16.装配好的ASRS机器的实际图像显示了其重要部分3.4. 拟议的未来工程将来可能会进行以下操作，以进一步增强已开发的ASRS机器。它们不限于： 通