IMPLEMENTING WEIGHT DISTRIBUTION SYSTEM TO IMPROVE AN EXISTING AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS)

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IMPLEMENTING WEIGHT DISTRIBUTION SYSTEM TO IMPROVE AN EXISTING AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS)

By

Kennan Jonathan Sirait 11112063

BACHELOR’S DEGREE in

MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY EduTown BSD City

Tangerang 15339 Indonesia

August 2016

Revision after Thesis Defense on 20^th of July 2016

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Kennan Jonathan Sirait I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.

Kennan Jonathan Sirait

____________________________________________

Student

Date

Approved by:

Erikson Ferry S. Sinaga, ST, M.Kom

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Thesis Advisor

Date

Cepi Mohammad Hanafi, SS.T, MT

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Thesis Co-Advisor

Date

Dr. Ir. Gembong Baskoro, M.Sc

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Dean Date

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EXISTING AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS) Page 3 of 124

Kennan Jonathan Sirait ABSTRACT

IMPLEMENTING WEIGHT DISTRIBUTION SYSTEM TO IMPROVE AN EXISTING AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS)

By

Erikson Ferry S. Sinaga, ST, M.Kom, Advisor Cepi Mohammad Hanafi, SS.T, MT, Co-Advisor

SWISS GERMAN UNIVERISTY

The main purpose of this thesis is to implement weight distribution system in a miniature of Automated Storage and Retrieval System (AS/RS) which is able to store and retrieve a pallet from/to the rack. The storage will be depended on the weight of the pallet. The storing will also obtain an input from infrared proximity sensor to sense whether the destination rack is occupied or not. Load cell is used to weigh the pallet.

This thesis project is focusing on developing and improving the miniature Automated Storage and Retrieval System that can store and retrieve a pallet from or into the shelf by receiving an input from a microcontroller. This thesis also studies how to receive input signals from microcontroller and use the input signal to run the system. The objectives of this thesis is achieved.

Keywords: AS/RS, load cell, adc, weight distribution, infrared proximity

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Kennan Jonathan Sirait DEDICATION

I dedicate this thesis to God that always guide me and enlighten me with His blessing.

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Kennan Jonathan Sirait ACKNOWLEDGEMENTS

First I would like to thank God for his grace and guidance throughout this thesis time.

He has enlightened me and given me the strength to face all the problems.

Second I would like to thank my family for their supports and the wisdom. To my parents who always encourage me and help me with my problems.

Third I would like to thank my advisor, Erikson Sinaga, ST, M.Kom and Cepi Hanafi, SS.T, MT for the advice and the guidance to achieved the thesis objectives. I would also like to thank Mr. Fredy and Mr. Maskula for their assistance and direction whenever I faced a problem.

Colleagues and friends will forever not be forgotten. Especially to Ignasius Kevin, Jimmy Kurnia, Nur Rizza Muhammad, Ferdyanto Awandy, Muhammad Kemal, Bryan Aditya, Prastha Delta, and other Mechatronics batch 2012 fellow students. I thank them for unforgettable memories of college life. Also to my fellow high school friends that keep encourage me and help me, I thank them. I would like to give my special thanks for Keisha Vaniputri Kiswanto for her patience, presence and encouragement whenever I fell apart.

Last but not least, thanks to SGU for all the opportunities to study mechatronics, experiencing internship local and abroad, and also for this final assignment.

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Kennan Jonathan Sirait TABLE OF CONTENTS

Page

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF CONTENTS ... 7

LIST OF FIGURES ... 11

LIST OF TABLES ... 14

CHAPTER 1 - INTRODUCTION ... 15

1.1 Background ... 15

1.2 Thesis Purpose ... 15

1.3 Thesis Scope ... 15

1.4 Thesis Limitations ... 16

1.5 Problems Identification ... 16

1.6 Thesis Structure ... 16

CHAPTER 2 - LITERATURE REVIEW ... 17

2.1 Introduction ... 17

2.2 Application of AS/RS ... 18

2.3 AS/RS Types ... 18

2.3.1 Horizontal Carousels ... 18

2.3.2 Vertical Carousels ... 19

2.3.3 Vertical Lift Module (VLMs) ... 20

2.3.4 Fixed-Aisle (F/A) Storage Retrieval System ... 21

2.4 Control Strategies (O’Shea, 2007)... 22

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2.5 Load Cell ... 23

CHAPTER 3 – RESEARCH METHODS ... 26

3.1 Observation and Collecting Data and Information ... 26

3.2 System Overview ... 26

3.3 System Breakdown ... 27

3.4 Mechanical Improvements ... 28

3.4.1 Pulley Mounting Improvement ... 28

3.4.2 Bridge Addition ... 29

3.4.3 Bridge Mounting ... 30

3.4.4 Belt Tensioner ... 31

3.4.5 Foot Adjuster ... 31

3.4.6 Foot Adjuster Mounting ... 32

3.4.7 Pallet ... 32

3.5 Electrical Improvements and Parts ... 33

3.5.1 Load Cell ... 33

3.5.2 24-bit ADC HX711 ... 34

3.5.3 Infrared Proximity Sensor ... 35

3.5.4 Arduino Mega 2560 ... 35

3.5.5 Limit Switch ... 36

3.5.6 Motor Driver L298N ... 37

3.5.7 Control Box Layout ... 37

3.5.8 Rotary Encoder (Photoelectric Sensor Coupler) ... 38

3.5.9 Wiring Connection Diagram ... 40

3.5.10 Power Supply ... 40

3.6 Program ... 41

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3.6.1 Main Program ... 41

3.6.2 Initial Process ... 42

3.6.3 Retrieving Process ... 43

3.6.4 Storing Process ... 44

3.6.5 Weight Distribution System ... 45

CHAPTER 4 – RESULTS AND DISCUSSIONS ... 47

4.1 Mechanical Result ... 47

4.1.1 Aluminum Pulley Mounting ... 48

4.1.2 Bridge Addition ... 49

4.1.3 Belt Tensioner ... 50

4.1.4 Foot Adjuster Addition ... 51

4.1.5 Pallet ... 51

4.2 Electrical Result ... 52

4.2.1 Load Cell Test and Attachment ... 52

4.2.2 Encoder Testing ... 57

4.2.3 Motor Y and Z Testing ... 58

4.2.4 Motor Driver Testing ... 61

4.2.5 Infrared Proximity Sensor Testing ... 61

4.2.6 Control Box ... 62

4.2.7 Wiring Connection Outlook ... 63

4.3 Program Result ... 64

4.3.1 Main Process ... 65

4.3.2 Initialization ... 65

4.3.3 Storing Process ... 66

4.3.4 Retrieving Process ... 74

4.3.5 Storing and Retrieving Process Testing ... 79

4.3.6 Weight Distribution ... 80

4.3.7 Weight Distribution Testing ... 82

CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 84

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5.1 Conclusions ... 84

5.2 Recommendations ... 84

GLOSSARY ... 85

REFERENCES ... 86

APPENDIX A – TECHNICAL DRAWING ... 87

A.1. Tension Adjuster Plate ... 87

A.2. Pulley Mounting ... 88

A.3. Left Pulley Mounting ... 88

A.4. Right Pulley Mounting ... 89

A.5. Bridge Mounting ... 89

A.6. Foot Adjuster Mounting ... 90

A.7. Bridge Addition ... 90

A.8. Pallet ... 91

APPENDIX B – DATASHEET ... 92

B.1. Arduino Mega 2560 ... 92

B.2. Motor Driver L298N ... 98

B.3. HX711 ... 100

APPENDIX C – PROGRAM ... 107

APPENDIX D – BILL OF MATERIAL ... 123

CURRICULUM VITAE ... 124