Abstract:
Manual picking and sorting in warehouses were identified as slow, costly, and labor
intensive processes, with labor contributing to 65% of total operational costs, and
picking accounting for 55%. To address these inefficiencies, a robot was designed to
follow a multi-functional approach for efficient warehouse cargo handling, integrating
Radio Frequency Identification (RFID) scanning, line following, comparison, and pick
and-drop capabilities. The robot's QTR IR (Infrared Rays) sensor array was calibrated
upon activation for precise surface detection. RFID codes were used to identify
packages and their drop locations, enabling the correct items to be picked. Navigation
was managed through an IR sensor array, with two motors attached to wheels and a
balancing wheel for smooth movement between pickup and drop locations. Secure
package handling was achieved with an articulated robot arm powered by servo motors.
The robot was made fully programmable via Arduino, allowing customizable and
flexible control over operations. After receiving a command via a wireless signal or
push button, packages were picked up and delivered to specified locations. Initial testing
revealed issues with reflective surfaces affecting sensor accuracy, which were resolved
by using non-reflective material to ensure reliable line following. Significant benefits
in warehouse automation were achieved by reducing human error, lowering costs, and
improving efficiency, making it a valuable solution for logistics operations. The
prototype was tested in a controlled environment with designated pick-up and drop-off
locations. Future improvements included the addition of higher-torque motors,
expanded pick-up and drop-off points, and integration with a networked database. The
system could be upgraded for large-scale applications with a pneumatic or hydraulic
arm and a PLC-based control system.
