Design and Development of Smart Automated Storage and Retrieval System

Abstract

In today’s fast-paced industrial and academic environments, efficient storage and retrieval of items is vital to save both time and space. This paper presents the design and development of a compact, smart Automated Storage and Retrieval System (ASRS) aimed specifically at small-scale environments such as academic laboratories, startups, workshops, and libraries where space and budget constraints often limit the adoption of automation technologies. The system is built on widely accessible open-source hardware components like Arduino Uno, CNC Shield, and stepper motors, making it cost-effective and easy to replicate.

The proposed ASRS automates the process of storing and retrieving items using programmable motion commands based on G-code and M-code standards commonly used in CNC machines. Its design is modular and scalable, enabling extension to larger storage racks if needed. User interaction is simplified through a keypad or wireless interface, making operation intuitive even for users without technical backgrounds.

This work highlights how compact, affordable automation can be integrated into small-scale setups to improve operational efficiency, reduce manual labor, and move towards the smart factory concepts promoted by Industry 4.0. The system also emphasizes energy efficiency and digital control, providing a practical solution that bridges the gap between expensive industrial ASRS units and manual storage methods.


1. Introduction

Automated Storage and Retrieval Systems (ASRS) have revolutionized how warehouses, factories, and large institutions manage their inventory, contributing to faster operations, enhanced safety, and optimized use of storage space. These systems typically rely on robotics, conveyors, and computerized control to automatically place and retrieve goods without human intervention, leading to significant improvements in productivity.

However, most commercial ASRS units are designed for large-scale applications and come with high costs and bulky infrastructure requirements. This limits their use in smaller environments such as educational laboratories, small manufacturing units, libraries, and startup workshops, where budget constraints and limited space make traditional ASRS infeasible.

The system leverages open-source electronics, particularly the Arduino Uno microcontroller platform, coupled with CNC Shield and stepper motors for precise motion control.

2. Literature Review

Automated Storage and Retrieval Systems have been the subject of extensive research and industrial development over the past decades. Traditional ASRS implementations typically focus on large-scale warehouses and distribution centers, where automation is justified by high throughput and cost savings. These conventional systems often include cranes, conveyors, and shuttles, controlled by proprietary software and complex hardware. While highly effective, their size, cost, and complexity prevent easy adoption by small-scale users.

In academic research, there have been attempts to design microcontroller-based ASRS prototypes to provide low-cost alternatives for educational purposes. Many of these systems incorporate basic stepper motor control, sensors, and manual operation interfaces. However, they often lack modular design and advanced control logic that can allow for efficient, scalable, and user-friendly operation.

Furthermore, existing microcontroller-based ASRS prototypes rarely support industry-standard G-code/M-code programming, which can greatly simplify the motion control logic and enable integration with CNC-based systems. Additionally, previous designs usually do not offer mobile platforms, limiting flexibility in deployment.

This project improves upon prior work by combining open-source hardware, programmable path logic, and mobility into a single system. The use of G-code and M-code allows complex motion sequences to be defined and modified easily. Moreover, the inclusion of wireless communication and user-friendly interfaces ensures the system is accessible to non-technical operators. This holistic approach addresses the common shortcomings found in earlier ASRS models designed for small-scale use.

3. System Architecture

The architecture of the proposed ASRS is designed to balance simplicity, functionality, and cost-efficiency, while ensuring adaptability for different applications.

Core Components:

  1. Arduino Uno: Acts as the central processing unit, interpreting user commands and controlling hardware components.
  2. CNC Shield: Serves as a motor driver interface, enabling the Arduino to precisely control stepper motors for accurate positioning.
  3. Stepper Motors: Provide controlled movement along storage racks, enabling automated storage and retrieval.
  4. Limit Switches: Installed at the boundaries of movement axes, these sensors provide essential feedback for position resetting and safety to prevent mechanical damage.
  5. Power Supply: Supplies stable voltage and current to all system components.
  6. PC Interface: A computer communicates with the Arduino via USB or wireless connection to upload motion commands written in G-code or M-code.


Mobile Platform Design:

Instead of a fixed system, the ASRS is built on a compact mobile platform that can navigate within the storage rack area. This design reduces installation complexity and increases flexibility, allowing the system to be used in multiple locations or rearranged easily.

Control Flow:

  1. Commands are input via a keypad or sent wirelessly from a PC.
  2. Arduino interprets the commands and translates them into motor movements.
  3. The CNC Shield drives the stepper motors accordingly.
  4. Limit switches monitor physical limits and provide real-time feedback.
  5. The system executes storage or retrieval sequences autonomously.

4. Working and Control Logic

The operational workflow of the ASRS is centered around programmable motion control through standardized G-code and M-code instructions, widely used in CNC machining and automation.

  • User Interaction:
    Users interact with the system through a simple keypad interface or remotely via Bluetooth or wireless connection. This flexibility ensures easy operation by users without specialized training.
  • Command Processing:
    Input commands are parsed by the Arduino Uno, which interprets the G-code/M-code commands that define movement paths, storage positions, and retrieval actions.
  • Motor Control: The CNC Shield converts interpreted commands into electrical signals to drive the stepper motors, allowing precise movement along X, Y, and Z axes (or other configurations depending on the rack design).
Safety and Calibration:
Limit switches positioned at the extremities of movement axes detect physical limits, preventing motor overrun or mechanical collisions. They also facilitate system homing, enabling the ASRS to reset its position after power cycles or interruptions.

5. Novelty Features

  1. Compact Mobile Design:
    Eliminates the need for fixed installations, allowing flexible deployment and saving valuable workspace.
  2. Dual Functionality:
    Enables both storing and retrieving objects with minimal user intervention.
  3. Scalable Rack System:
    The rack design supports vertical and horizontal expansions to increase storage capacity as needed.
  4. Cost-Effective:
    Built entirely from open-source hardware and low-cost components, making it affordable for small setups.
  5. User-Friendly Interface:
    Controlled via a simple keypad or Bluetooth connection, minimizing the learning curve.
  6. Custom Path Logic:
    Supports G-code and M-code programming for flexible and programmable motion control.
  7. Versatile Applications:
    Suitable for academic labs, warehouses, libraries, workshops, and home inventory management.

Table 1: Comparison with Conventional ASRS

Feature

Traditional ASRS

                  Proposed Compact ASRS

Cost

    High

                   Low

Size

    Large setup

                   Compact & mobile

Scalability

    Limited

                   Modular design

Interface

    Industrial HMI

                   Keypad / Wireless

Power Consumption

    High

                   Moderate

Custom Logic

    Limited

                   G-code / M-code Based

6. Results and Applications

The prototype was extensively tested in a controlled laboratory environment. The ASRS successfully performed automated storage and retrieval tasks, demonstrating precise movement and reliable operation.

Its compact form factor and affordable cost make it an excellent choice for various small-scale applications, including:

  • Academic and research laboratories requiring organized storage of components or samples.
  • Compact libraries or archives needing automated book retrieval.
  • Small warehouses and inventory systems in startups or workshops.
  • Home-based or mobile inventory management setups.

The mobile platform allowed easy repositioning, adding to the system's versatility.

7. Conclusion and Future Scope

The compact ASRS developed in this work effectively bridges the gap between industrial-grade automation systems and the needs of small-scale users. It enables affordable, reliable, and programmable automation, empowering educational institutions, small businesses, and hobbyists to adopt smart storage solutions.

Future enhancements could include:

  • Integration with IoT systems for real-time inventory tracking.
  • Implementation of camera-based object detection and recognition.
  • Use of AI algorithms for optimizing storage strategies and decision-making.
  • Expanding mobility features and wireless control capabilities.

These developments will further enhance usability, efficiency, and applicability of the ASRS in diverse settings.


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