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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032031 doi:10.1088/1757-899X/912/3/032031

Design optimization and development of an Automated

Storage and Retrieval System

T Ajay1, A Vinoth2 and J Daniel Glad Stephen2

1
PG Student, Department of Mechanical Engineering, SRM Institute of Science and
Technology, Kattankulathur, Chennai, India.
2
Assistant Professor, Department of Mechanical Engineering, SRM Institute of
Science and Technology, Kattankulathur, Chennai, India.

Email: ajay.dhuvya123@gmail.com

Abstract. This study aims about the planning and building up an framework for the automated
material handling system by diminishing the lead time in the transportation or development of
the item and furthermore concentrating on the development of the Automated Storage and
Retrieval System in the businesses for expanding generation rate and furthermore to improve
the material handling in warehouse. The objective of the study is to structure and manufacture
an Automated Storage and Retrieval system for a mechanical stockroom and upgrading,
reworking it dependent on the parameters like deals point, item prerequisite pitch or physical
parameters like tallness, width, weight and so forth by utilizing a streamlining procedures.

1. Introduction
Material handling requires short-movement inside a building's walls, or among a building and a
vehicle for transport. It uses a varied range of physical, semi-automated, and computerized apparatus
and includes consideration of material safety, storage, and control throughout its manufacturing,
warehousing, circulation, consumption, and clearance. Material handling can be used to establish time
and place utility by waste management, storage, and control as distinct from manufacturing, which
creates usefulness in the form by adjusting material type, and temperament of the components.
Material handling plays the significant part in fabrication and logistics. In manufacturing plants,
factories, and retail stores, almost every object of physical exchange was loaded onto a conveyor or lift
truck or other form of material handling equipment. Material handling is central to the strategy of most
production systems because the efficient material flow between a production system's activities
depends heavily on the procedure (or layout) of the activities [1, 2]. If two actions are contiguous, then
information may be easily furnished from one activity to another. Most existing material handling
systems are of rigging simply semi-motorized in light in fact that a human is required for endeavors
like tacking/exhausting and moving that are inconvenient just as too costly to totally automate [1, 2,
and 3]. If activities are separated, the transport requires more pricey industrial trucks or overhead
conveyors. The expensive cost of consuming an industrial truck for the transport of materials is due to
both the operator's labor cost and the negative influence on the performance of a fabrication when
multiple units of material are united into a single allocation batch to diminish the number of trips

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032031 doi:10.1088/1757-899X/912/3/032031

mandatory for transport. Regardless, nonstop progresses in identification, moving the material and
mechanical computerization have made it promising to totally automate a growing number of dealing
with assignments. Automated Storage and Retrieval System (AS/RS) is a blend of PC controlled
framework for persistently stacking and recouping loads from described limit regions [4, 5]. An
AS/RS be able to use with typical stacks similarly as custom-made loads, suggesting that each classic
weight can suitable in a reliably estimated volume. Standard weights unravel the treatment of a
requesting of a thing. Additionally, surveys of the exactness of the load of substance can be
constrained to the substance of a discrete metal box, instead of encountering a totally exploration of
the whole office, aimed at a singular thing [6-8]. The particle swarm intelligence (PSO) algorithm for
the optimization as it potentials good effect for compound tasks. Particle swarm optimization (PSO)
was used as the global optimization algorithm for concerning with complications in which the
improved result can be characterized by means of a fact or surface surrounded by an n-dimensional
space. Hypotheses are graphed within the area and planted with a primary pace, as well as statement
channel between the units [9-12]. The current existing system has constraints were the storage density
is considered as important factor because of space and no value is added in this process only storing
of the component and transport is carried out. The precision is critical because of potential expensive
indemnities to the load while handling. This study aims to design an Automated Storage and Retrieval
system and optimize the AS & RS using optimization technique for better performance and reduced
component handling time in warehouse.

2. Methodology
For the research a customized, unit-load AS/RS system is used. The unit-load system that is suitable
when large amount of components are stockpiled but the quantity of discrete standard types is
comparatively small [5, 7, 9, 12]. The loads can be kept to greater depths. Optimization of the system
is based on the handling of the products based on the FOI of physical dimension, Storage Space of the
component, Movement of the component and also the inquiry factor of the component based on the
dynamical changes when the machine was at working environment. The particles then pass through
the space of the solution, and will be evaluated after each time step permitting to more or less fitness
criterion. AS/RS frameworks are ordinarily used in applications where there is an extraordinarily great
capacity of weights existence moved into and out of limit. Storage thickness is huge for room goals
and no worth is incorporated this technique. Accuracy is fundamental because of possible expensive
recompenses to the pile. Based on the output of the algorithm the system will check for nearest storage
location for storing the product. If selected location is not empty then the system will again iterate to
lookup for next nearest location for storing the component. If the locations are completely occupied
then the system should send a wait signal so the component previously stored will be delivered for
creating an empty shelf for storing. Throughout the process the iteration will update the algorithm
phenomenon for next step of processing.

3. Design and Simulation

The storage parameter of the system was separated into two components with respect to its physical
dimensions, the inquiry factor [5, 13, 16, 17, and 18]. Product identification is the chief role for
repeatedly recognizing AS/RS. The scanners are located at the preliminary position, to scan the
identification code. The captured data is transmitted to the AS/RS system which, upon the
acknowledgement of load credentials, assigning and guides the load to the storage site [13, 14]. The
figure 1 and figure 2 discuss about the setup of the system with its components starting from source
which is the input of the system i.e. the material handling framework to the AS/RS framework where a
line of arrangement was utilized to stock the materials. If the framework was occupied in orchestrating
the processor will goes to the control framework of the S/R machine which sends and gets the input
from the framework to take choice for the assignment of capacity area for the segments and the R/S

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032031 doi:10.1088/1757-899X/912/3/032031

Machine will currently goes to the AS/RS framework by the yield of the processor. The Conveyor
framework and another Processor will be associated with the framework for the yield of the
framework for which the transportation of the material will be conveyed.

Figure 1. System Process flowchart.

A set data about the components was previously stored or uploaded in the system so that the AS/RS
system will read identification index and proceeds the optimization algorithm and then the ideal
storage area will be allotted based on the optimal path of the index factor of the product. Based on the
factor of inquiry the components will be ordered or sorted so that the components with the higher
order of FOI will be stored at the nearest location of the retrieval [4, 19, and 20]. So that the
components with less no. of FOI will be delivered later. The figure 1 and figure3 was discussed for the
algorithm which will run the system based on the inquiry factor for visual representation. The height
of a commodity is set at the point of entry to the storage. The height of the first loading level is set
after the calculation, and the product was put in the AS/RS. By the arrival of new components the first
level height is adjusted according to the highest product requirements. Distribution of products based
on FOI is conducted concurrently. Products with a superior FOI are guided nearer to the location of the
delivery. Since AS/RS is continuously loaded with products of varying heights and sizes, the particle
swarm algorithm has to identify the procedure for its distribution. [19] When the adjacent cell is
empty, each product can move in any direction, the products must first move in one position. Thus the
goods with superior FOI are continuously moved neared to the delivery location. The threshold rate for

3
3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032031 doi:10.1088/1757-899X/912/3/032031

storage space usage (SSU) can exceed if multiple items with height 3 have arrived the storage
consecutively. Then the optimisation algorithm in this case introduces a new amount of storage to the
AS/RS [19]. The conveyor system of inputs stops until the goods are distributed on both floors. When
the stacker is full the lift will move the loaded components to the second level [19]. On next level a
height dimension is executed and components are disperse created on their FOI. The optimization
cycle stops after the product inlet/output frequency deviation in AS/RS construction is fewer than 5%.
The loading location of slightly manufactured goods in the AR/RS may vary during system process
concerning a recently-entered components FOI level or a potential FOI level change of the product
itself.
The components used for optimization was listed below:
 CAR1- Component 1 RED
 CAB2- Component 2 BROWN
 CAG3- Component 3 GREEN
Height:
 Height1 – 150mm
 Height2 - 100mm
 Height3 - 60mm
Inquiry factor (IF) 1-5

Figure 2. Assembly Model of the System for simulation.

3.1. Initial Conditions

 Products with more FOI are positioned nearer to the delivery position
 Possibility of varying FOI during storage scheduling and storage operation
 Optimal circulation of products created on their heights and circulation of higher/weightier
products to lower points
 Number of vacant storage cells required by the delivery procedure would be 1/8 of the overall
number of storage cells

Figure 3. Sorting Algorithm Representation.

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032031 doi:10.1088/1757-899X/912/3/032031

4. Results and Discussion:

The FOI-swarm algorithm for product supply is integrated into the planning and operation of AS/RS
method. Table 1 is mentioned for the regularities of manufacturing and factors of inquiry (FOI) for
Table 1: Factor of Inquiry table for each components
CAR1 CAB2 CAG3
No. of Inquiry No. of Inquiry No. of Inquiry
Components Factor Components Factor Components Factor
Height1 15 5 25 3 20 1
Height2 25 2 15 5 5 3
Height3 12 1 5 2 10 4
discrete products.
As the simulation was started with load condition the system responds to various efficient working
conditions based on the usage of the lift the data’s are collected for analyzing the system output
performance [16]. From the figure 4 it is able to check the performance index based on the idle time
and travel loaded condition of the system with respect to loading and unloading of the components at
the rate of 10 components per minute from the starting location to storage rack and vice versa. The
figure 5 indicates the performance index based on the low load condition and travel loaded condition
of the system with respect to the loading and unloading of the component at the rate of 10 components
per minute from the starting location to storage rack and vice versa. From figure 6 is able to check the
performance index based on the medium load condition of the system that should handle and travel
loaded condition of the system with respect to loading and unloading of the components at the rate of
25 components per minute from the starting to ending of the process. From figure 7 it is able to check
the performance index based on the high load condition or maximum working condition of the system
that should be able to handle and travel at the loaded condition of the system with respect to the
loading and unloading of the components at the rate of 50 components per minute at the peak of its
operation. The starting condition was given considering the system preset position and calibration for
homing location as reference point. Then steadily increased the generation rate so that the idle time of
lift gets decreased but movement of the lift gets increased based on the movement of the component.

Figure 4. Starting condition (Idle to low). Figure 5. Working at low load condition (10
components).

Figure 6. Working at Medium Load condition Figure 7. Working at High load condition (50
(25 components). components).

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032031 doi:10.1088/1757-899X/912/3/032031

Figure 8. Efficiency of the system based on the utilization of elevator.

Figure 9. The average cycle time of the elevator.

The performance index of the system was created based on optimization results i.e. the utilization
of the lift and mean arrival time of the component. Previously, Fukunari [14] also propose that the
performance of the system will tends to increase when the system is working at its maximum operation
condition. From figure 8 the system will work efficiently at loading and unloading of the components
at its maximum generation point i.e. at the rate of 50 components/min. But the performance factor
depends on the no. of components generation i.e. transfer of components from loading and unloading
location. The average cycle time of the system can be determined by figure 9. The cycle time is
nothing but the time taken for the system to transfer the components from loading and unloading of the
components from its pick-up point and drop-off point. As the cycle time of system at idle time was
very low it wasn’t considered but when the transfer of the components was increased i.e. the
component movement was at 50 per minute, the cycle time was also increased to 80 percentage of the
working condition.
5. Conclusion
The findings from this study are listed as follows:

 The lead time of the system for transferring operation i.e. loading and unloading of the components
was reduced in comparison with the literature.

6
3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032031 doi:10.1088/1757-899X/912/3/032031

 The overall performance of the AS/RS system was increased by implementing Particle Swarm
Optimization algorithm in comparison with the literature.
 The results obtained from this simulation system will be compared with the results of the real time
system.

6. References
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[2] Baker P and Canessa M 2009 Warehouse design: A structured approach European journal of
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[3] Roodbergen KJ and Vis IF 2009 A survey of literature on automated storage and retrieval
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[4] Brezovnik S, Gotlih J, Balič J, Gotlih K and Brezočnik M 2015 Optimization of an automated
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[5] De Koster R, Le-Duc T and Roodbergen KJ 2007 Design and control of warehouse order
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[6] Yang P, Miao L, Xue Z and Qin L 2015 Optimal storage rack design for a multi-deep compact
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[7] De Koster RM, Le-Duc T and Yugang Y 2008 Optimal storage rack design for a 3-dimensional
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[8] Kuo PH, Krishnamurthy A and Malmborg CJ 2007 Design models for unit load storage and
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[9] Hrelja M, Klancnik S, Irgolic T, Paulic M, Jurkovic Z, Balic J and Brezocnik M 2014 Particle
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[10] Hrelja M, Klancnik S, Irgolic T, Paulic M, Jurkovic Z, Balic J and Brezocnik 2014 Turning
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[11] Hrelja M, Klancnik S, Balic J and Brezocnik M 2014 Modelling of a turning process using the
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[12] Manzini R, Gamberi M and Regattieri A 2006 Design and control of an AS/RS Int. J. Adv. anuf.
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[13] Fukunari M and Malmborg CJ 2009 A network queuing approach for evaluation of performance
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[14] Hur S and Nam J 2006 Performance analysis of automatic storage/retrieval systems by
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[15] Yin YL and Rau H 2006 Dynamic selection of sequencing rules for a class-based unit-load
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[16] Dooly DR and Lee HF 2008 A shift-based sequencing method for twin-shuttle automated
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[18] Nidhiry NM and Saravanan R 2014 Scheduling optimization of a flexible manufacturing system
using a modified NSGA-II algorithm Advances in Production Engineering & Management 9
139-51
[19] Adeyemo J and Olofintoye OO 2014 Evaluation of combined Pareto multiobjective differential
evolution on tuneable problems International journal of simulation modelling 276-287

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3rd International Conference on Advances in Mechanical Engineering (ICAME 2020) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 912 (2020) 032031 doi:10.1088/1757-899X/912/3/032031

[20] Das S Suganthan PN 2010 Differential evolution: A survey of the state-of-the-art IEEE
transactions on evolutionary computation 15 4-31