Design and implementation of automatic storange and classification systems

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS ELECTRONICS AND TELECOMMUNICATION ENGINEERING TECHNOLOGY DESIGN AND IMPLEMENTATION OF AUTOMATIC STORAGE AND CLASSIFICATION SYSTEMS LECTURER: Ph.D PHAN CONG BINH STUDENT: LE QUANG HUY TRAN CAO NGUYEN LE THANH TUAN SKL 1 Ho Chi Minh City, August, 2023 HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF MECHANICAL ENGINEERING MECHATRONICS GRADUATION THESIS Topic: “DESIGN AND IMPLEMENTATION OF AUTOMATIC STORAGE AND CLASSIFICATION SYSTEMS” Instructor: DR PHAN CÔNG BÌNH Members: LÊ QUANG HUY MSSV:19146124 TRẤN CAO NGUYÊN MSSV:19146002 LÊ THANH TUẤN MSSV:19146029 Class: 19146CLA Course: 2019-2023 Ho Chi Minh City, July 2023 TRƯỜNG ĐH SPKT TP HỒ CHÍ MINH CỘNG HÒA XÃ HỘI CHỦ NGHĨA VIỆT NAM KHOA CƠ KHÍ CHẾ TẠO MÁY Độc lập - Tự - Hạnh phúc Bộ môn CƠ ĐIỆN TỬ o0o TASKS OF GRADUATION THESIS Semester II / 2023 Instructor: Dr Phan Cơng Bình Members: Lê Quang Huy MSSV: 19146124 Phone number: 0774143136 Trần Cao Nguyên MSSV: 19146002 Phone number: 0896395830 Lê Thanh Tuấn MSSV: 19146029 Phone number: 0949554302 Topic code: 22223DT336 Topic: “Thiết kế thi công hệ thống phân loại lưu kho tự động” Early figures and documents: - The design model's frame size is 1200x1500x1000 (mm) - Estimated import and export capacity of 100 products/hour - Pallet size 150x75x85(mm), maximum weight 5kg Main content: - The system's mechanical component consists of a framework, a conveyor, motors, and chains - The Control interface has two operating modes: Manual and Auto - Design automatic storage and classification system controlled by PLC and monitored through Microsoft Visual Studio and WinCC interface - Product information and stock status are stored in the database Projected Products: - Technical drawings (Exported to PDF) - The report - Testing model Submission date: 21/07/2023 I Language: Written in English Presented in: English □ □ Vietnamese Vietnamese □ □ HEAD OF FACULTY HEAD OF INSTRUCTOR (Signature and full name) DEPARTMENT (Signature and full name) (Signature and full name) □ Allowed to defend a thesis (Instructor, signature and full name) II COMMITMENT Project: “Design and implementation of automatic storage and classification system” Instructor: Dr Phan Công Bình Student 1: Lê Quang Huy MSSV: 19146124 Class: 19146CLA1 Address: 182 Nguyễn Thị Định, P An Phú, TP Thủ Đức Phone number: 0774143136 Student 2: Trần Cao Nguyên Email: 19146124@student.hcmute.edu.vn MSSV: 19146002 Class: 19146CLA1 Address: Tổ 6, Khu phố 5, Uyên Hưng, Tân Uyên, Bình Dương Phone number: 0896395830 Student 3: Lê Thanh Tuấn Email: 19146002@student.hcmute.edu.vn MSSV:19146029 Class:19146CLA1 Address: Kp Định Thắng 1, Thị Trấn Phú Hoà, Phú Hoà, Phú Yên Phone number: 0949554302 Email: 19146029@student.hcmute.edu.vn Graduation thesis submission date: 21/07/2023 Commitment: “I hereby declare that this thesis is the work of my own research and implementation I not copy from any published article without citing the source I will take full responsibility for any fraud detected in my thesis” Ho Chi Minh City, 21st July 2023 Signature III ACKNOWLEDGMENT During the process of implementing the Graduation Thesis at Ho Chi Minh City University of Technology and Education, the team received a lot of attention and help from the teachers The team would like to express their deep gratitude to the teachers of the Faculty of Mechanical Engineering for creating favorable conditions for the team to carry out the project With deep gratitude, the implementation team would like to thank the instructor – Dr Phan Cong Binh has enthusiastically guided, imparted knowledge and created all favorable conditions for the group to carry out this topic Thank you to my family and friends who have always supported and encouraged me throughout the process of studying and implementing this project Despite their best efforts, the group will undoubtedly make mistakes despite their thorough research and implementation of the topic Consequently, the group anticipates hearing from you with comments and ideas to enhance the subject Sincerely thanks! Student Lê Quang Huy Trần Cao Nguyên IV Lê Thanh Tuấn ABSTRACT “Design and implementation of automatic storage and classification system” The Automatic Storage and Classification System provides an appropriate design for the warehouse and products handling The industry's objective is to convey the pallets as rapidly and inexpensively as feasible The reason for choosing this topic is because it can apply our knowledge from previous Mechatronic projects and subjects Additionally, there are few automated warehouse systems in Vietnam, the goal is to expand this system in Vietnam This system consists of Storage racks, Pallets, Movement Axes, Sensors, etc The PLC controls and coordinates the movement and performance of the system In this report, the design, operation and advantages of the new mechanism are presented Using conveyor chains to reduce investment costs and transport goods with larger loads The chain drive is used for the traveling mechanism to improve transportation efficiency as well as simple installation and easy maintenance The telescopic mechanism and the pallet shake slightly but the transmissions are still stable after three operation cycles in the automatic import and export mode This system’s implementation is simulated using SCADA The operating parameters of the system are accomplished through the design, calculation, and control processes The productivity of the model for import and export is approximated to 3800 items per day, with the time to import and export goods for each model around 23 seconds for pallets The fundamental system satisfies the beginning requirements, including operating in the proper sequence of an actual system, having a software interface full of fundamental features, identifying, and resolving faults, and recording, storing, and exporting data as necessary It enables the cargo to be moved within a warehouse swiftly, safely and precisely Instructor (Signature and full name) V TABLE OF CONTENTS TASKS OF GRADUATION THESIS i COMMITMENT iii ACKNOWLEDGMENT iv ABSTRACT v TABLE OF CONTENTS vi LIST OF PICTURES AND DIAGRAMS x LIST OF TABLES xiv LIST OF ABBREVIATIONS xv CHAPTER 1: OVERVIEW 1.1 The necessity of this subject 1.2 Scientific and practical significance of the topic 1.3 Research objectives of the topic 1.4 Object and range of the study 1.4.1 Research subjects 1.4.2 Research range 1.5 Research Methods 1.6 Structure of Graduation thesis CHAPTER 2: RESEARCH OVERVIEW 2.1 Introduction 2.2 Working principle 2.3 General structure of the system 2.4 Methods of product classification 2.5 Warehouse models are being used in practice 2.5.1 Stacked warehouse model VI 2.5.2 Automated warehouse model 2.5.3 Underground warehouse automation model 2.5.4 Model of a circular automatic goods storage warehouse 2.5.5 Criteria for evaluating the quality of the storage system CHAPTER 3: THEORETICAL BASIS 3.1 Mechanical Theory 3.1.1 Conveyor chain 3.1.2 Motor selection and Ratio distribution 10 3.1.3 Sequence of calculation and design the chain drive 11 3.1.4 Transmission gear 14 3.2 Configuration of the control system 19 3.2.1 Centralized Control System I/O 19 3.2.2 Distributed Control System I/O 19 3.3 Barcode reader device 20 3.4 Programmable Logic Controller (PLC) 22 3.4.1 Introduce PLC 22 3.4.2 PLC Siemens 22 3.5 Stepper motor 23 3.5.1 Introduce stepper motor 23 3.5.2 Stepper motor control method 24 3.6 Product detection sensors 25 3.6.1 Photoelectric sensors 25 3.6.2 Proximity Sensors 25 3.6.3 Capacitance level sensors 25 3.7 Barcode theory 26 3.7.1 Introduce 1D barcode 26 3.7.2 Types of popular barcodes today [2] 27 VII 3.7.3 Applications of barcodes in goods classification 30 3.8 SQL Database Software 30 3.9 Microsoft Visual Studio software and Windows forms App 32 CHAPTER 4: ORIENTATION AND SOLUTION 34 4.1 Request for a topic 34 4.1.1 Customer requirements 34 4.1.2 Technology Requirements 34 4.1.3 Design requirements of the model 34 4.1.4 Electrical design requirements 34 4.1.5 System configuration selection 34 4.1.6 Block diagram and function 35 4.2 Solutions to the requirements 35 4.2.1 Solutions for import-export system 35 4.2.2 Solutions on transmission mechanism 36 4.3 Selection of options 39 4.3.1 Proposing technological process 39 4.3.2 Model construction plan 40 4.3.3 Wiring Diagram 42 4.3.4 Electrical cabinet design 42 4.4 Design of control flowcharts 43 4.4.1 Control request 43 4.4.2 Drawing flowchart 43 4.5 Design the interface 44 4.5.1 Design requirements 44 4.5.2 Barcode reader interface design 45 4.5.3 Flowchart of bar code scanning program 46 CHAPTER 5: COMPUTATION AND DESIGN OF THE SYSTEM 48 VIII 4x 4 3,2 19 H7 F 50 F 50 115 ±0.1 82 E 222 E D D 20 82 ±0.1 240 C 10x C 65 8x R3 B B 57 120 57 20 50 41 50 GRADUATION THESIS TECNICAL REQUIREMENT: Distance tolerance between holes is ± 0.1 Dimension tolerance unmarked is 0.5 Remove bavia A 41 Student Le Quang Huy 24/7 Omega frame Instructor Dr.Phan C Binh HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION SS400 Scale: 1:2 03.1 A Rz 25 F F 222 E 102 E D C C D B B TECHNICAL REQUIREMENT: Dimension tolerance unmarked is ± 0.5 Remove bavia GRADUATION THESIS Student Le Quang Huy 24/7 C3-001 Instructor Dr.Phan C Binh A HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION SS400 Scale: 1:2 03.2 A 3.2 F F 19 H7 E 115 ±0.1 222 E D D 83 ±0.1 4x 22 ±0.1 240 C 89 44 ±0.1 A C 0.2 A B B 4xR3 234 26 ±0.1 98 ±0.1 GRADUATION THESIS TECHNICAL REQUIREMENT: Dimension tolerance unmarked is ± 0.5 Remove bavia A Student Le Quang Huy 24/7 U frame Instructor Dr.Phan C Binh HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION A SS400 Scale: 1:2 03.3 192 172 63 F 108 28 R15 F 60 30 E 240 760 700 50 E 24 135 D D 70 400 60 C C 170 170 186 240 ITEM NO PART NUMBER QTY Forklift Carriage Hydraulic Cylinder C4-001 B B GRADUATION THESIS Student A 20 46 24/7 Z-Axis Instructor Dr.Phan C Binh 50 Le Quang Huy HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION Scale: 1:6 04.0 A 50 50 Rz25 F E 252 E D D 17 ±0.1 146 67 ±0.1 12 C 27 6.4° 170 88 C 103 ±0.1 12 38 12x F 240 15 B B GRADUATION THESIS TECHNICAL REQUIREMENT Dimension tolerance unmarked is ± 0.5 Remove bavia Student Le Quang Huy 24/7 Forklift Carriage Instructor Dr.Phan C Binh A HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION A SS400 Scale: 1:3 04.1 F 70 Rz 25 ) H7/h6 ( E 16 H7/k6 40 A 25 E F 40 D D C 380 310 50 C TECHNICAL REQUIREMENT: Dimension tolerance unmarked is ± 0.1 Remove bavia At a hole of diameter 16, a surface roughness tolerance Rz = 3.2mm 70 B B GRADUATION THESIS A A SECTION A-A Student SCALE : Instructor Dr.Phan C Binh Le Quang Huy 24/7 HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION Hydraulic Cylinder A A5052 Scale: 1:3 04.2 3.2 F F 10 20 2x E E 61 ±0.1 50 ±0.1 D C D 35 ±0.1 15 ±0.1 50 4x C 30 ±0.1 112 ±0.1 4xR2 172 B B GRADUATION THESIS TECHNICAL REQUIREMENT: Dimension tolerance unmarked is ± 0.5 Remove bavia Student Le Quang Huy C4-001 Instructor Dr.Phan C Binh A 24/7 HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION A SS400 Scale: 1:1 04.3 F 10 F E 200 110 E D D C 270 C 30 220 B ITEM NO 170 PART NUMBER Rotation shaft Frame Sprocket Fixture Driven shaft QTY 1 B GRADUATION THESIS Student Le Quang Huy 24/7 Output conveyor Instructor Dr.Phan C Binh A HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION Scale: 1:5 05.0 A 3.2 F F E E D D 230 172 2.5 14.00 A 25 C H9 16 h8 C SECTION A-A 22.00 A 2xR2 SCALE : B B GRADUATION THESIS TECHNICAL REQUIREMENT: Remove bavia Dimension tolerance unmarked ± 0.1 A Student Le Quang Huy 24/7 Rotation shaft Instructor Dr.Phan C Binh HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION SS400 Scale: 1:1 05.1 A Rz 25 F E ( ) E Rz 20 18 F +0.04 +0.02 49.15 10 D 34 +0.09 9.35 0.00 D C C B B R8 H7 GRADUATION THESIS TECHNICAL REQUIREMENT: Dimension tolerance unmarked is ± 0.1 Remove bavia Paint anti-rust materials A Student Le Quang Huy 24/7 Sprocket Instructor Dr.Phan C Binh HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION Scale: 2:1 SS400 05.3 A Rz 25 F F 26 JS7 E 40 E D D R20 2x 15 ±0.1 10 ±0.1 70 C 10 C B B GRADUATION THESIS TECHNICAL REQUIREMENT Dimension tolerance unmarked is ± 0.5 Remove bavia Paint anti-rust materials A Student Le Quang Huy 24/7 Fixture Instructor Dr.Phan C Binh HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION A SS400 Scale: 2:1 05.4 3.2 F F E E D D 55 35 10 2.5 A H9 12 h8 C 10 h7 C 2xR2 A B SECTION A-A SCALE : B 22 GRADUATION THESIS Student TECHNICAL REQUIREMENT: Remove bavia Dimension tolerance unmarked is ± 0.1 Paint anti-rust materials A Le Quang Huy 24/7 Driven shaft Instructor Dr.Phan C Binh HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION Scale: 3:1 SS400 05.5 A Rz 25 580 F F 180 E E 120 10 30 120 D 920 10 D C 200 C TECHNICAL REQUIREMENT: Dimension tolerance unmarked is ± 0.5 Remove bavia 270 B B GRADUATION THESIS Student Le Quang Huy 24/7 Storehouse Instructor Dr.Phan C Binh A HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION MDF Scale:1:6 06.0 A Rz 25 68 F 20 45 45 20 D 13 D E 26 18 E F 50 C 75 C B 50 B 50 150 GRADUATION THESIS Student Le Quang Huy TECHNICAL REQUIREMENT: Dimension tolerance unmarked is ± 0.5 Remove bavia A 24/7 Pallet Instructor Dr.Phan C Binh HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION A MDF Scale: 1:1 07.0 S K L 0