1.

INTRODUCTION
This research evaluates the potential and working principle of the mini load ASRS design.
It is an automated system known as ASRS Automated Storage and Retrieval System, created
to manage the requests of small size storage. This system is designed to provide effective
material storage and getting back the products quickly. Increased storage capacity and
improved business process efficiency are more potential examples. Additionally, factors like
low expenses for operation and energy efficiency are taken into consideration.
Mini load ASRS has a wide range of uses in various industries and storage requests. These
are mainly; e-commerce and retail industry, automotive industry for correct storage of
components and parts, pharmaceutical and healthcare industry for storing and distributing
sensitive and limited shelf-life products, food and beverage industry for maintaining freshness
as well as correct product storage.
1.1.RESEARCH AND LITERATURE SURVEY
a) ASRS’s Configuration Types
ASRS (Automated Storage and Retrieval Systems) can have different types of installations.
Important components of automated storage and retrieval systems are included in these
subjects, which also exhibit various system designs based on the size of loads, aisle layouts,
and operator participation. Here are some common ASRS installation types:
1. Unit Load ASRS: Unit Load ASRS is a storage system that enables the automated
storage and retrieval of large-scale loads. This system typically handles unit loads such
as pallets, containers, or large-sized boxes. Unit loads are automatically transported to
the storage area and placed in storage locations using rail or conveyor systems.
2. Mini Load ASRS: A storage system called Mini Load ASRS is intended for the
automated storing and retrieval of small-sized boxes, cartons, or parts. Precision
positioning mechanisms and vertical transport systems are included with Mini Load
ASRS. These solutions are created to decrease material access times and are ideal for
smaller storage areas.
3. Deep-lane ASRS: Automated storage systems with lengthy or deep aisles are referred
to as deep-lane ASRS. These systems have the goal to offer high-density storage and
enhance storage use. Usually, they are made up of high rack systems with several
load-carrying devices.
4. Man-on-board ASRS: In a man-on-board automated storage system, an operator tends
to a carrier vehicle. With the help of these devices, the operator may move about the
storage space while collecting or arranging things. The operator normally supervises
the activities from a cabin or platform

b) Applicatıon Varieties And Development Researches

When the research are analyzed; in general, on the optimization of ASRS journey
times using various simulation programs. Various algorithms have been explored, and by
comparing the results using optimization approaches, the maximum design of a
warehouse-shelf system designed to optimize efficiency and business volume was carried
out. Jalal Ashayeri,R. Heuts, M. Valkenburg presented a model for an ODBS rack system
different products to designated suitable places single and double command loop
estimated cycle geometric-based analytics that calculate times. [1]
Each company's loading and retrieval of items into the warehouse is varied. This situation
necessitates the utilization of warehouses in various constructions. Fangyu Chen, Hongwei
Wang and Chao Qi work on the collector's workload density a route extraction approach to
test. They used a new routing algorithm for ant colony optimization based two collector. As a
result of their simulation studies, in many examples, the shortest collection times achieved
[2]
The structural features of the shelves in the storage system should be analyzed very well.
Ahmet Fenercioğlu and his work mate did a structural analysis of shelves in warehouse
systems with the finite element method and they found that maximum strain were in the bolts
slots. The analysis of the rack system should be done according to the loads to be carried,
otherwise weak places in the designs might cause to irreversible damage to the shelf system or
carrier robots. [3]

c) ASRS usage by companies

Service levels and consumer expectations have risen exponentially in recent years. At the
same time, the work force is decreasing, particularly in areas where Amazon has a physical
presence. The company can also use the Age of Inventory report to understand how long the
inventory has been in their logistics centers.
As a multinational logistics and freight company, DHL works with ASRS systems in
storage, collection and distribution activities. These systems enable automatic categorization,
storage and routing of packages to shipping locations.
As an automotive and industrial technology company, Bosch uses ASRS systems. Bosch
optimizes the flow of materials on the production line with automated storage and pickup
systems, enabling Bosch’s high-precision parts storage, and rapid pickup, thus making
production processes more efficient.
2.DESIGN REQUIREMENTS
Dimensions, movement capabilities, control system, performance, durability, assembly
convenience, and cost efficiency are all critical to ensuring the ASRS achieves the specified
criteria. Following these guidelines is critical for meeting project objectives and building an
efficient and successful ASRS design. These standards serve as guidance for the critical
elements that influence the performance and functioning of the components in question. These
criteria confirm the functionality of the design and its capacity to accomplish its intended
purpose by establishing the technical quality, size, and performance requirements of the
components.
 Dimensions:
The Mini Load ASRS design ought to dimension 45 cm width by 45 cm height.
Within its enough interior space, it should be able to house 9x9 boxes.
 Capabilities for movement:
The system should be able to move along the X and Y axes and place the boxes precisely.
For horizontal movement, a precise and smooth belt-pulley system should be employed.
For vertical movement, a suitable worm gear and connection system should be used.
  Automation and control:
For control, an Arduino Uno or a comparable microcontroller should be utilized.
Step motors must be controlled and managed correctly by motor drivers.
 Performance and power:
Step motors with a power rating of 1.7 Nm should provide excellent speed and accuracy.
The wheels should allow for smooth movement while achieving the requirements.
 Reliability and durability:
For long-term stability, the design should be built using solid materials.
It ought to make sure that the boxes are transported safely and properly.
 Ease of assembly and maintenance:
For simplicity in installation, the design should make use of appropriate screws and
connections.
Maintenance and repair access should be made easier.
 Effectiveness in terms of cost:
The design ought to aim to reduce expenses by including cost-effective components.
4.DESIGN DETAIL
4.1. Mechanical design
The materials used for the mechanical part of the system are respectively; sigma profil, worm
gear, 3D printed parts which made of PLA. When choosing these materials, it was taken into
account that the two critical strengths in the mechanical design should meet the desired
values. Also, the system should be as light and economical as possible.
The points to be considered while selecting the parts are as follows;
Forces and stresses acting on fasteners, bending and deflection on the carrier beam
4.1.1. 3D PLA Printed Fasteners ;
Calculations were made with the following formulations for each fastener separately.

∑ F y=0
∑ F x=0
∑ M Az=0
V ×Q 3 ×V
τ= =
I × t 2 ×b × d
M×c F
σ= +
I A
σ < σ yield
τ < τ yield
τ yield =0.5 × σ yield
σ yield =60 Mpa for PLA
As a result of the calculations made, it was decided to print the fasteners from PLA material
with a 3D printer, since the stresses and forces acting on the fasteners are not too much,
because the PLA material is both economical, easy to access and provides the desired
strength.
4.1.2. Carrier Beam
For Beam deflection
The bending, shear force and deflection on the beam were calculated with the following
formulations, taking into account the forces acting on the carrier beam and the beam's own
weight.

∑ F y =0
∑ F x=0
∑ M Az=0
Elastic modulus of Aluminum E=200Gpa
Cross sectional area of beam A=0.03 ×0.03
1 3
Moment of inertia = 12 ×b × h where b = 0.03m , h= 0.03 m

Figure-1: Shear, moment and deflection of beam formulas [4]

deflection on the shafts manually, the equations under table A-9 simple support intermediate
load can be used.
30mmx30mm and 450mm long sigma profiles made of aluminum material were used as
carrier beams. This material, chosen as a result of the calculations, provides the desired
strength and due to its economic, geometric structure, easy accessibility and light weight, it
was decided to make the carrier beam and the skeleton of the system from this material.
4.2. ELECTRONIC DESIGN
Arduino uno and motor drivers were used to control the electronic components in the system.
The reason for this is that the working algorithm of the system can be controlled with these
two electronic devices. In addition, 12 Volt 5 amp adapter is used as power source.
5.SOLID MODEL AND DRAWWING
6.PRODUCT SPECIFICATION
Size of profile:
4 sigma profiles with a length of 400 mm in size 30x30 mm
1 sigma profile with a length of 500 mm in size 30x30 mm
The motors: 2 step engines with 1.7 Nm power
The control unit: The Arduino Uno microcontroller
The motorists: 2 Compatible motor drivers
Horizontal movement: Belt and pulley arranged in suitable sizes
Vertical movement: 1 wormy gear with a diameter of 10 mm
The Assembly Elements: Metric in 2 sizes screw
The bolt nut: Metric 2.5 bolt nut
The wheels: 6 wheels appropriate
Kaplin: Suitable for connecting to the engine.
7.COST ANALYSIS
7.1 Sigma profile
sigma profiles were obtained from the school, but the average 30x30 sigma profiles in the
market are around 40 Turkish liras.
7.2 3D PLA parts
After the 3D printer parts were modeled, the PLA used for each part was learned in grams
with the cura program. Since PLA material is sold in grams, the cost in kilograms multiplied
by the weight of the material used is calculated.
7.3 Ardunio and motor driver
Arduino and motor drivers were obtained from electronic markets.
7.4 Step Motor
It was obtained from the robolink shop that sells stepper motor electronic equipment.
7.5 Total Cost
Quantity Unit Cost Total Cost
Sigma profile 5 30 ₺ 150 ₺
3D PLA parts 300 g 250 per kilogram ₺ 90 ₺
Ardunuio 1 pcs 120 ₺ 120 ₺
Motor driver 2 pcs 30 ₺ 60 ₺
Step Motor 2 pcs 120 ₺ 240 ₺
Total - - 660 ₺
Table-3: overall cost of system
[1] Ashayeri, J.,Heuts, R. M., Valkenburg, M.W.T., Veraart, H.C. & Wilhelm M.R., (2002). A
geometrical approach to computing expected cycle times for zone based storage layouts in
AS/RS, Int. Journal of Production Research.
[2] Chen, F., Wang, H., Qi, C., & Xie, Y.(2013). An ant colony optimization routing algorithm
for two order pickers with congestion consideration. Computers & Industrial Engineering,
66(1), 77-85.
[3] Közkurt, C., Fenercioğlu, A., & Soyaslan, M. (2012). Structural Analysis of Warehouse
Rack Construction for Heavy Loads. World Academy of Science, Engineering and
Technology, 6.
[4] Shigley, J. E., Mischke, C. R., & Budynas, R. G. (2020). Mechanical Engineering Design.
p. 1015. (Table A-9)