International Journal of Advances in Electronics and Computer Science, ISSN: 2393-2835 Volume-4, Issue-3, Mar.

-2017
http://iraj.in
AUTOMATED STORAGE AND RETRIEVAL SYSTEM FOR
EDUCATIONAL PURPOSE- A REVIEW
1
JAINIL PRAJAPATI, 2HARSHAL GOYAL, 3JEEL PATEL, 4APURVA GANDHI, 5SAMARTH
BHADUWALA
1,2,3,4,5
Institute Of Technology & Management Universe, Vadodara, Gujarat-391510
Email: 1Jainilhp2011996@gmail.com, 2harshal.1806@gmail.com, 3jeelpatel16@gmail.com
4
apurvagandhi007@gmail.com,5samarth.bhaduwala@itmuniverse.ac.in

Abstract - The purpose of this review paper is to overview the design and working process of the automated storage and
retrieval system (AS/RS).For reducing the space used for storing and handling different materials like small spare Parts,
small inventories, fruits, vegetables, books etc. The facilitated warehouses and the retrieving systems are used. Utilization of
these types of warehouse and retrieving system, the handling of materials can be safer and efficient. The AS/RS system is
working on three dimensional solid modelling axes. The retrieval system is provided with requiring degrees of freedom
which is picking and placing the materials. Programming of this system is done with the help of computer software and the
system is controlled by microcontrollers and different kind of sensors .Different kind of warehouses like vertical and
horizontal are used for storing the materials on which this AS/RS system works. Further more different aspects and future
work are explained in this paper

Index terms - ASRS system, picking and placing systems, warehouse, sensors and microcontrollers.

I. INTRODUCTION system. Typically ASRS consists of series of storage

In large industries, for storing inventories like small
spare parts( nuts, bolts, needles, small components,
pallets etc) and in cold storages for storing food,
vegetables, medicines, foods and drugs, cold drinks,
chemicals and a considerable amount of space is
consumed in which handling of materials is difficult.
By using ASRS system, we can effectively manage
the space constraints if any and the overall floor
space area is reduced. Also, material handling will be
easier and efficient due to the fact that there will be
minimal requirement of manpower and also the route
sheets for a particular production system would be
very much simplified and linear.
In early days material handling was done using
animals and carts but later with the advancement of
science it was improved using forklifts and conveyor
belts. Storage and retrieval of materials was
introduced in 1940. Automated storage and retrieval
systems with automated guided vehicle (AGV) were
first introduced in the 1950s to eliminate the walking
that accounted for 70 % of manual retrieval time.
Automatic Storage and Retrieval System is an
important key part of model logistic system , along
with the consideration of limited space, requirement
of flexibility, expandability, quality, reliability,
management control, AS/RS application has
increased rapidly throughout the world in recent
years, especially in the US and China.[1]
ASRS system is very complex, it consists of lots of
mechanical equipments, automation control
equipment, computer systems. The initial cost of the
system is very huge. There are high risks associated
with implementation of such a complex costly
aisles each of which is served by a storage and
retrieval (S/R) machine or crane. Each aisle is
supported by a pickup and delivery (P&D) station
typically located at the end of the aisle and accessed
by the S/R machine and the external handling
system.[2]
In designing an AS/RS, many physical design and
control issues have to be addressed in the right way to
fully take advantage of all its pros. This paper intends
to present a critical overview of all important issues
concerning AS/RS design and control in production.
Previously, several overview papers have been
published that discuss part of the AS/RS literature. A
typical mode of application in S/R system pre
engineering is to use analytical modelling tools to
identify high potential system profiles based on
maximizing system performance within a budget
constraint.[3]
II.LITERATURE REVIEW FOR ASRS SYSTEM
A large number of system options exist for AS/RSs.
The most basic version of an AS/RS has in each aisle
one crane, which cannot leave its designated aisle
(aisle-captive) and which can transport only one unit-
load at a time. Product handling in this case is by
unit-load (e.g., full pallet quantities) only; no people
are involved to handle individual products. The racks
in the basic version are stationary and single-deep,
which means that every load is directly accessible by
the crane. This AS/RS type is referred to as a single
unit-load aisle-captive AS/RS .Numerous variations
exist of this basic AS/RS. An overview of the main
options is presented in Fig.1

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 International Journal of Advances in Electronics and Computer Science, ISSN: 2393-2835
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Figure-1: Classification of AS/RS system
One possible variation of the basic AS/RS is when
cranes are capable of changing aisles. In this case, it
is possible to have fewer cranes than aisles in the
system. This may be useful if the amount of requests
does not justify the purchase of a crane for each aisle.
To overcome the restriction of the crane’s unit-load
capacity, multi-shuttle cranes exist. Such a crane can
transport two or more loads at a time. Cranes which
can transport two loads are also referred to as dual-
shuttle cranes; cranes capable of transporting more
than two loads are still rarely seen.
Often an AS/RS is installed for handling unit-loads
only (typically, pallets). Unit-loads arrive at the I/O-
point of the AS/RS from other parts of the warehouse
by means of, for example, automated guided vehicles,
conveyors, or forklift trucks. The unit-loads are
stored in the AS/RS and after a period of time they
are retrieved again, for example, to be shipped to a
customer. Alternatively, the picking operation can be
integrated with the AS/RS. One option is to design
the crane such that a person can ride along (person-
onboard). Instead of retrieving a full pallet
automatically from the location, the person can pick
one item from the location. A more common option
to integrate item picking is when the AS/RS drops off
the retrieved unit loads at a workstation. A picker at
this workstation takes the required amount of
products from the unit-load after which the AS/RS
moves the remainder of the load back into the storage
rack. This system is often referred to as an end-of-
aisle system. If the unit-loads are bins, then the
system is generally called a miniload AS/RS.
Finally, worthy of mentioning is a special type of
AS/RSs called autonomous vehicle storage and
retrieval systems. This system separates horizontal
and vertical travel. Vehicles travel horizontally over
rails through aisles, while lifts are used to transfer
loads vertically. [4]
III. COMPONENTS OF ASRS SYSTEM
1) High Rise Storage Racks: For effective
utilization of vertical space, generally the materials
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Volume-4, Issue-3, Mar.-2017
are stored in high columns. The racks are designed in
these columns, where they are made up of steels and
can be installed quickly. Two rails for moving ASRS
over the racks, in bottom and top. Bottom fixed with
respect to storage racks and top rail for movement
between two rows. RFID tags are positioned in front
of every rack.
2) Crane: This is a twin column structure, handles
store/retrieval operations. The fork which extends
left/right side or for dropping material into bin. For
emergencies, in case the automation is failed operator
can manually operate from the cabin.
3) Storage Bins: Containers used for store/ retrieval
in ASRS. The material or raw products like bolts,
pipes etc will be dropped are taken out from these
bins. So the bins should be of dust free and correct
dimensions are used. RFID readers are fixed in the
front end of the bins.
4) Controllers: PLC and Microcontroller: Practically
to replace the human operator on the stacker crane
and the entire task the operator would do, is
automated by micro PLC. It is programmed to
execute commands received from system controller,
by moving the stacker crane for the desired
operations, and giving a feedback to the PC based
system controller. The stacker carne controller is
connected to several sensors and limit switches to get
the physical inputs. The output goes to the operator’s
panel for activation of limit switches. The sequencing
of operations like inputs from sensors and limit
switches are programmed in the PLC. And also the
driver and relay operations for rotate, elevate, stretch
of arm developed in ASRS also programmed in PLC.
According to the command from microcontroller the
PLC make arm for ASRS to respond. Microcontroller
is used as another support for ASRS.[6]
A. RFID: RFID module is connected with
microcontroller. It operates under low frequency of
125 kHz. RFID tags are fixed at the front end of the
rack. The product or part id is stored in the memory
of microcontroller. Once the operation of ASRS is
started the search for material begins. RFID reader
reads all the digit codes of tags and once it is
matched, it sends the identity for further processing to
microcontroller. When code is matched and product
is found, then according to the instruction from
operator the material is shifted. Here passive type of
RFID is used, when the reader is brought in contact
with the tag of 6 cm the coil is influenced by
magnetic field and becomes active.[5]
B. PC: PC along with memory, UPS, interface
modules and cards are provided with reliable
environment. The system software having menus for
operator interactions with number of selection
choices are displayed in windows screen e.g. bin
 International Journal of Advances in Electronics and Computer Science, ISSN: 2393-2835 Volume-4, Issue-3, Mar.-2017
http://iraj.in
number, column left/right, stop, store or retrieval. In b) It initiates and terminates the motion of
memory all the product id and their quantity are the individual components of the
stored. So the database is updated regularly. For user manipulator in a desired sequence and at
convenient software maintains the database of e-bin. the specified point,
A sample window representing various menus to
operate ASRS through computer.[5] c) It permits the robots to be interfaced to
the outside world via sensors

4. Sensors- The sensors are used to collect the

information about the status of the
manipulator and the end effectors. This can
be done continuously or at the end of a
desired motion. The sensors collect the
information like: instantaneous position,
velocity and acceleration of various links
and joints of the manipulator.

This information is send to the controller. Using the

Figure 2: Components of AS/RS
IV. DESIGN OF AS/RS SYSTEM
AS-RS design is based on structure and its controlling
scheme employed for this project. Layout for
programming is also designed to accomplish
successful implementation. Success and failure of any
system depends upon its design. Design consists of
structure, controlling scheme and programming
layout.
Structure: There are different components in AS/RS
system described below:
information, the controller determines the
configuration of the robot and controls the movement
of the manipulator. The information sent by the
sensors can be analogy, digital or combination of two.
The sensors used in robots can be divided into two
classes: - Non-Visual sensors, Visual sensors
Controlling scheme- Basic component behind
stepper motors is microcontroller. We have employed
it with master slave controlling scheme. One
microcontroller reserved for column selector motor is
set as master microcontroller while the other two are
slave ones. It gives command to slave
microcontrollers for rotation of row and column
selectors motors respectively. This controlling
scheme can be seen from fig.

1. Motors- 3 phase DC motors are used for

providing the movement to the system. They
are used as actuators in the system, also
provides linear and rotational degree of
freedom which enhances flexibility of the
system.

2. Manipulators- Manipulator is the

combination of mechanical linkages,
connected by joins to form an open-loop
kinematic chain. The manipulator is capable
of movement in various directions. The
manipulator gets the task performed through
the end effectors, which is connected to the
manipulator.

3. Controller- The controller receives the

instructions from the processor of a
computer and controls the motion of the
actuators. It takes feedback from the sensors.
It performs the following functions:
a) It stores the position and sequence date
of the manipulator,
Figure-3: Controlling scheme

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 International Journal of Advances in Electronics and Computer Science, ISSN: 2393-2835
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Programming logic
Figure 4: Programming logic
This system includes keypad as input device. The
input is translated in to motor rotations inside
microcontroller. Home position (pick and drop point)
is at one end of assembly and by default trolley
remains there when no user attempt is made. Coding
includes three digit address entered from the user.
Validity of address is defined by each digit. 1st digit
is associated with column address, 2nd digit with row
address and 3rd digit with rack address. Valid user
input is one that follows the limitation imposed on
each digit. Only correct input is processed for storage
and retrieval operation. Digits processing is executed
on first come first serve basis when input termination
indicator is submitted appropriately. Each address is
linked with distinct combination of three square
waves and direction outputs. These outputs guide
three motors in hardware to reach specific location
mentioned by user. After performing the requested
function, vehicle is guided in program to return to
home position.[1]
V. BENEFITS
 Reliable
 Specific storage/retrieving location of each
material does not require sorting out
 Provides reduction in labor cost
 Minimum errors
 Better space utilization
 Products are made more secure without
being damaged
 Better inventory control. [1]
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Volume-4, Issue-3, Mar.-2017
CONCLUSION
In this study we presented a simulation based
performance analysis of ASRS system based on
predefined rack configuration. In this reviewpaper all
the details of proposed system have been discussed.
The problem of handling spare parts and inventories
can be solved by this system. It also results in better
space utilization and saves time from sorting out
without damage of products. This system eradicates
manual work.
ACKNOWLEDGEMENT
This review paper was partially supported by ITM-
Universe. We thank our colleagues from ITM-
universe who provided insight and expertise that
greatly assisted the research, although they may not
agree with all of the interpretation of this paper
The completion of the review paper would not have
taken place without the contribution of key person.
The progress of the review paper for the project was
supervised by Prof. Samarth Bhaduwala from
Mechanical Engineering Department of Institute of
Technology and Management Universe for assistance
with his useful knowledge and experts for comments
that greatly improve the manuscript. A special thanks
to our Head of Department Prof. Minesh Patel. Their
guidance, advise and wisdom throughout this work
are also greatly appreciated.
Finally special thanks to my family and colleagues
who provided constant support and encouragement
during this work.
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[2] Warehouse Design under Class-Based Storage Policy of
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[4] Roodbergen, K.J. , Vis, I.F.A., A survey of literature on
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International Journal of Advances in Electronics and Computer Science, ISSN: 2393-2835 Volume-4, Issue-3, Mar.-2017
http://iraj.in
[5] INTELLIGENT BASED AUTOMATED STORE AND Technology and Education, Tianjin, China 2, International
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